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Partial Engine ASSY: Replacement

  1. INSTALL ENGINE STAND 
  2. REMOVE THROTTLE BODY ASSY (See  REMOVAL (GS430, LS430 & SC430)  ) 
  3. REMOVE INTAKE MANIFOLD ASSY 
    1. Disconnect the VSV connector for EVAP.
    2. Disconnect the EVAP hose from the VSV for EVAP.
    3. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
    4. Remove the bolt and V-bank cover bracket No. 2.
    5. Remove the bolt and V-bank cover bracket No. 3.
    6. Disconnect the VSV connector for ACIS.
    7. Remove the bolt and V-bank cover bracket No. 1.
    8. Remove the bolt and V-bank cover fastener.
    9. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from upper intake manifold and camshaft bearing cap.
    10. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
    11. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water bypass joint and RH cylinder head.
    12. Disconnect the 8 injector connectors.
    13. Remove the 6 bolts, 4 nuts, the intake manifold assy and 2 gaskets.
  4. REMOVE STARTER ASSY (See  STARTER  ) 
  5. REMOVE GENERATOR ASSY  GENERATORS & REGULATORS  .) 
  6. REMOVE TIMING BELT COVER SUB-ASSY NO. 3 LH 
    1. Remove the cap nut and disconnect the water by-pass pipe No. 3 from the timing belt cover.
    2. Disconnect the 2 water by-pass hoses from the water by-pass pipe No. 3.
    3. Disconnect the engine wire from the 2 wire clamps.
    4. Disconnect the camshaft position sensor connector.
    5. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
    6. Remove the wire grommet from the timing belt cover.
    7. Remove the 4 bolts.
    8. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
    9. Disconnect the wire clamp for the sensor from the timing belt cover.
    10. Remove the connector holder from the sensor connector.
    11. Remove the timing belt cover.
  7. REMOVE TIMING CHAIN OR BELT COVER NO. 2 
    1. Disconnect the 2 PS air hoses from the clamp on the timing belt cover No. 2.
    2. Remove the cap nut, 3 bolts, timing belt cover No. 2 and gasket.
  8. REMOVE WATER INLET HOUSING (See WATER INLET HOUSING in  WATER PUMP ASSY  ) 
  9. REMOVE WATER BY-PASS JOINT FR 
    1. Disconnect the ECT sensor connector.
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  10. REMOVE WATER BY-PASS JOINT RR 
    1. Disconnect the heater inlet hose from the water by-pass joint.
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  11. REMOVE WATER BY-PASS PIPE SUB-ASSY 
    1. Disconnect the heater outlet hose from the water by-pass pipe.
    2. Disconnect the wire clamp (for knock sensor 1, 2) from bracket of the water by-pass pipe.
    3. Remove the bolt.
    4. Pull out the water by-pass pipe from the water pump.
    5. Remove the O-ring from the water by-pass pipe.
  12. REMOVE OIL LEVEL GAGE GUIDE 
  13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (RH BANK) 
  14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (LH BANK) 
  15. REMOVE CAMSHAFT POSITION SENSOR 
  16. REMOVE VVT SENSOR 
  17. REMOVE KNOCK SENSOR 
  18. REMOVE ENGINE HANGER NO. 1 
  19. REMOVE ENGINE HANGER NO. 2 
  20. REMOVE IGNITION COIL ASSY 
  21. REMOVE OIL FILTER BRACKET SUB-ASSY 
    1. Disconnect the oil pressure switch connector.
    2. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.
  22. REMOVE CRANKSHAFT POSITION SENSOR 
  23. REMOVE ENGINE OIL LEVEL SENSOR 
  24. REMOVE ENGINE WIRE 
  25. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
  26. REMOVE EXHAUST MANIFOLD SUB-ASSY RH 
  27. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2 
  28. REMOVE EXHAUST MANIFOLD SUB-ASSY LH 
  29. REMOVE WIRING HARNESS HEAT INSULATOR NO. 2 
  30. REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 RH 
  31. REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 LH 
  32. INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 LH 
    1. Install the mounting bracket with the 4 bolts

    Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

    HINT:

    The LH mounting bracket is marked with "L".

    Fig 1: Installing Front Engine Mounting Bracket (No. 1)
    G01321471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 RH 
    1. Install the mounting bracket with the 4 bolts

    Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

    HINT:

    The RH mounting bracket is marked with "R".

    Fig 2: Installing Front Engine Mounting Bracket (No. 1 RH)
    G01321472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL WIRING HARNESS HEAT INSULATOR NO. 2 
  35. INSTALL EXHAUST MANIFOLD SUB-ASSY LH 
    1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
      NOTE: Be careful of the installation direction.
    2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

    Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

    Fig 3: Identifying White Mark Position On Cylinder Head (LH) Gasket
    G01321473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2 
  37. INSTALL EXHAUST MANIFOLD SUB-ASSY RH 
    1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
      NOTE: Be careful of the installation direction.
    2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

    Fig 4: Identifying White Mark Position On Cylinder Head (RH) Gasket
    G01321474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
  39. INSTALL ENGINE WIRE 
  40. INSTALL ENGINE OIL LEVEL SENSOR 
  41. INSTALL CRANKSHAFT POSITION SENSOR (See  CRANKSHAFT POSITION SENSOR  ) 
  42. INSTALL OIL FILTER BRACKET SUB-ASSY 

    Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

  43. INSTALL IGNITION COIL ASSY 

    Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) 

  44. INSTALL ENGINE HANGER NO. 2 

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  45. INSTALL ENGINE HANGER NO. 1 

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  46. INSTALL KNOCK SENSOR 

    Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) 

  47. INSTALL VVT SENSOR 
  48. INSTALL CAMSHAFT POSITION SENSOR 

    Torque: 7.5 N.m (80 kgf.cm, 66 in..lbf) 

  49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (RH BANK) (See  CAMSHAFT TIMING OIL CONTROL VALVE  ) 
  50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (LH BANK) (See  CAMSHAFT TIMING OIL CONTROL VALVE  ) 
  51. INSTALL OIL LEVEL GAGE GUIDE 
  52. INSTALL WATER BY-PASS PIPE SUB-ASSY 
    1. Install a new O-ring to the water by-pass pipe.
    2. Apply soapy water to the O-ring.
    3. Push in the water by-pass pipe end into the pipe hole of the water pump.
    4. Install the water by-pass pipe with the bolt.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    5. Install the wire clamp to the bracket of the water by-pass pipe.
  53. INSTALL WATER BY-PASS JOINT RR 
    1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

  54. INSTALL WATER BY-PASS JOINT FR 
    1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    2. Connect the ECT sensor connector.
  55. INSTALL WATER INLET HOUSING (See  WATER PUMP  ) 
  56. INSTALL TIMING CHAIN OR BELT COVER NO. 2 
    1. Install the gasket to the timing belt cover.
    2. Install the timing belt cover with the cap nut and 3 bolts.
    3. Connect the 2 PS air hoses to the clamp on the timing belt cover.
  57. INSTALL TIMING BELT COVER SUB-ASSY NO. 3 LH 
    1. Install the gasket to the timing belt cover.
    2. Run the camshaft position sensor wire through the timing belt cover hole.
    3. Install the timing belt cover with the 4 bolts.
    4. Install the wire grommet to the timing belt cover.
    5. Install the sensor connector to the sensor holder.
    6. Connect the sensor connector.
    7. Install the sensor wire to the wire clamp on the timing belt cover.
    8. Install the engine wire to the 2 wire clamps on the timing belt cover.
    9. Connect the 2 water by-pass hoses to the water by-pass pipe No. 3.
    10. Install the No. 3 water by-pass pipe to the timing belt cover No. 3 LH with the cap nut.
  58. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
    Fig 5: Installing Timing Belt Cover Sub-Assembly No. 3 LH
    G01321475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL STARTER ASSY (See  STARTER  ) 
  60. INSTALL INTAKE MANIFOLD ASSY 
    1. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
      NOTE: Be careful of the installation direction.
      Fig 6: Identifying White Mark Position On Cylinder Head Gasket (Intake Manifold)
      G01321476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the intake manifold assy with the 6 bolts and 4 nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    3. Connect the 8 injector connectors.
      Fig 7: Installing Intake Manifold Assembly
      G01321477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire protector (rear side) with the 2 bolts.
    5. Install the engine wire protector (LH side) with the 4 bolts.
    6. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
      Fig 8: Installing Engine Wire Protector & Wire Clamps
      G01321478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the V-bank cover fastener with bolt.
    8. Install the V-bank cover bracket No. 1 with bolt.
    9. Connect the VSV connector for ACIS.
      Fig 9: Connecting VSV Connector For ACIS
      G01321479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the V-bank cover bracket No. 3 with bolt.
    11. Install the V-bank cover bracket No. 2 with bolt.
    12. Connect the VSV for EVAP to the intake manifold with the bolt.
    13. Connect the EVAP hose to the VSV for EVAP.
    14. Connect the VSV connector for EVAP.
    Fig 10: Installing The V-Bank Cover Bracket
    G01321480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL THROTTLE BODY ASSY 
  62. REMOVE ENGINE STAND 
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