Installation

1UR-FSE LUBRICATION: OIL PUMP (for 2WD): INSTALLATION

1. INSTALL WATER INLET PIPE

(a) Apply soapy water to 2 new O-rings and install them to the inlet pipe.

(b) Install the inlet pipe to the No. 1 heat exchanger cover.

2. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

(a) Install a new oil pump gasket.

(b) Install a new O-ring.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

*
Apply seal packing as follows:

NOTICE:
* When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
* Install the chain cover within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

(d) Align the spline of the oil pump's drive rotor and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

(e) Temporarily install the 30 bolts and nut.

Bolt length:

NOTICE:
Make sure that there is no oil on the bolt threads.

(f) Tighten the 11 bolts in several steps, in the sequence shown in the illustration.

Torque : 47 Nm (479 kgf-cm, 35 ft-lbf)

(g) Temporarily install the belt tensioner with the standard bolt and 6 mm hexagon wrench bolt.

(h) Tighten the 21 bolts and nut in several steps, in the sequence shown in the illustration.

Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

NOTICE:
After the installation, if the seal packing has seeped out at the areas labeled A shown in the illustration, wipe it off.

(i) Install 2 new gaskets and 2 plugs.

Torque : 46 Nm (469 kgf-cm, 34 ft-lbf)

3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps (No. 2, No. 3, No. 7).

(b) Install a new gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

NOTICE:
* Remove any oil from the contact surface.
* Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after the installation.

(d) Install the cylinder head cover with 2 new seal washers and the 15 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolt A

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) for except bolt A

4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Install 4 new gaskets and 2 new O-rings to the camshaft bearing caps. (No. 1, No. 3, No. 6).

(b) Install a new gasket to the cylinder head cover.

NOTICE:
Remove any oil from the contact surface.

(c) Apply seal packing as shown in the illustration.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf) for bolt A

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) for except bolt A

5. INSTALL IGNITION COIL ASSEMBLY Installation

6. INSTALL CRANKSHAFT PULLEY

(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.

(b) Using SST, install the pulley bolt.

SST : 09213-54015

90119-08216

SST : 09330-00021

Torque : 300 Nm (3059 kgf-cm, 221 ft-lbf)

7. INSTALL RESONATOR BRACKET SUB-ASSEMBLY Replacement

8. INSTALL OIL FILTER BRACKET

(a) Install 2 new gaskets and the filter bracket with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

9. INSTALL OIL FILTER ELEMENT Replacement

10. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY (for Bank 1) Installation

11. INSTALL CAMSHAFT TIMING CONTROL MOTOR ASSEMBLY (for Bank 2) Installation

12. INSTALL FRONT WATER BY-PASS JOINT Reassembly

13. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY Installation

14. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation

15. INSTALL WATER PUMP PULLEY Installation

16. INSTALL WATER INLET HOUSING

(a) Install the inlet housing and a new gasket with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) Using needle-nose pliers, grip the claws of the clips and slide the clips to connect the water by-pass hoses and water inlet hose.

17. INSTALL FUEL PUMP ASSEMBLY (for High Pressure) Installation

18. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

19. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Installation

20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Installation

21. INSTALL ENGINE COVER SUB-ASSEMBLY Installation

22. INSTALL NO. 3 ENGINE COVER Installation

23. INSTALL INTAKE MANIFOLD Installation

24. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY Installation

25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

26. INSTALL INJECTOR DRIVER Installation

27. INSTALL GENERATOR ASSEMBLY Installation

28. INSTALL OIL LEVEL DIPSTICK GUIDE Installation

29. CONNECT COOLER COMPRESSOR ASSEMBLY Installation

30. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1) Installation

31. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

32. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/ VGRS) Installation

33. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS) Installation

34. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS) Installation

35. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS) Installation

36. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH Installation

37. CONNECT FRONT STABILIZER BAR Installation

38. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install the front exhaust pipe Installation.

39. CONNECT ENGINE WIRE

(a) Connect the engine wire with the 4 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Connect the clamp and install the 2 clamp brackets with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(c) Connect the intake air control valve actuator connector.

(d) Connect the purge VSV connector.

(e) Connect the 4 injector driver connectors as shown in the illustration.

(f) Connect the ground wire with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(g) for Engine Room RH Side:

(1) Connect the 2 clamps and Install the 3 clamp brackets with the 3 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(2) Connect the engine oil level sensor connector.

(3) Connect the crankshaft position sensor connector.

(4) Connect the starter connector and starter wire with the nut.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(5) Connect the generator connector and generator wire with the nut.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(6) Connect the camshaft position sensor connector.

(7) Connect the engine wire connector.

(8) Connect the 2 camshaft timing control motor connectors (for Bank 2).

Connect the fuel pump connector (for high pressure).

Connect the 2 VVT sensor connectors.

(11) Connect the 4 ignition coil connectors.

(12) Connect the camshaft timing control valve connector.

(13) Connect the wires with No. 1 engine room junction block with the 2 nuts.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(14) Connect the 3 connectors with front controller with the clamp.

(h) for Engine Room LH Side:

(1) Install the clamp bracket with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(2) Connect the 3 clamps and 3 ground wires with the 3 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(3) Attach the clamp and connect the cooler compressor connector.

(4) Connect the 2 camshaft timing control motor connectors (for Bank 1).

(5) Connect the engine oil pressure sensor connector.

(6) Connect the engine coolant temperature sensor connector.

(7) Connect the clamp and install the 2 clamp brackets with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(8) Connect the No. 8 engine wire connector.

Connect the fuel pump connector (for high pressure).

Connect the 2 VVT sensor connectors.

(11) Connect the 4 ignition coil connectors.

(12) Connect the camshaft timing control valve connector.

(13) Connect the 3 ECT connectors and 4 ECM connectors.

(14) Install the ECM box cover (upper).

40. INSTALL ENGINE ROOM ECU OUTLET DUCT Installation

41. INSTALL SKID CONTROL ECU BRACKET Installation

42. INSTALL SKID CONTROL ECU Installation

43. CONNECT NO. 2 RADIATOR HOSE

44. CONNECT NO. 1 RADIATOR HOSE

45. INSTALL V-RIBBED BELT Installation

46. INSTALL RADIATOR RESERVOIR ASSEMBLY Installation

47. INSTALL AIR CLEANER ASSEMBLY LH Installation

48. INSTALL AIR CLEANER ASSEMBLY RH Installation

49. INSTALL INTAKE AIR CONNECTOR PIPE Installation

50. INSTALL NO. 1 AIR CLEANER INLET Installation

51. INSTALL ENGINE UNDER COVER REAR LH Installation

52. INSTALL ENGINE UNDER COVER REAR RH Installation

53. INSTALL BATTERY TRAY

(a) Install the battery tray with the 3 bolts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(b) Install the battery and battery insulator.

54. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp and 2 clamp bolts with the nut.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

55. ADD ENGINE OIL Replacement

56. ADD ENGINE COOLANT Service and Repair

57. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

58. PERFORM INITIALIZATION

(a) Perform initialization Repair Instruction - Initialization.

NOTICE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

59. INSPECT FOR OIL LEAK

(a) Inspect for engine oil leak Installation.

60. INSPECT FOR COOLANT LEAK Component Tests and General Diagnostics

61. INSPECT FOR FUEL LEAK Fuel System

62. INSPECT FOR EXHAUST GAS LEAK Installation

63. CHECK ENGINE OIL LEVEL Testing and Inspection

64. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER Installation

65. INSTALL NO. 2 ENGINE UNDER COVER Installation

66. INSTALL NO. 1 ENGINE UNDER COVER Service and Repair

67. INSTALL ENGINE ROOM SIDE COVER RH Installation

68. INSTALL ENGINE ROOM SIDE COVER LH Installation

69. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY Installation

70. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

71. INSTALL COWL TOP VENTILATOR LOUVER RH Installation