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Engine Assembly: Installation

WARNING: This page is about a different car, the 2008 Lexus IS F. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL FRONT ENGINE MOUNTING INSULATOR 
    1. Install the 2 engine mounting insulators with the 2 nuts

      Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

    2. Install the 2 engine mounting spacers
    Fig 1: Installing Front Engine Mounting Insulators
    G05749497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember sub-assembly with the 2 nuts

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

    Fig 2: Locating Front Suspension Crossmember Nuts
    G05749496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft

      SST 09213-38010,09330-00021 

    2. Clean the 10 bolt holes.
      Fig 3: Holding Crankshaft Using SST
      G05749494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the crankshaft angle sensor rotor.

      HINT

      Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft

      Fig 4: Aligning Pin Hole Of Crankshaft Angle Sensor Rotor With Pin Of Crankshaft
      G05749501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the drive plate and ring gear sub-assembly and drive plate spacer RR on to the crankshaft.
      Fig 5: Identifying Drive Plate And Ring Gear
      G05749502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      NOTE:
      • Do not reuse the drive plate and ring gear sub-assembly installation bolts.
      • Do not impact or damage the drive plate and ring gear sub-assembly installation bolts. Be sure to handle them carefully.
      Fig 6: Locating Tightening Sequence Of Drive Plate Bolts
      G05749503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Mark the upside of each drive plate and ring gear sub-assembly installation bolt with paint
    7. Retighten the drive plate and ring gear sub-assembly installation bolts 90° as shown in the illustration.
    8. Check that the painted marks are now at a 90° angle to the upside.
  4. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY  (See INSTALLATION )
    Fig 7: Identifying Retightening Angle Of Drive Plate Bolts
    G04943215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL REAR ENGINE MOUNTING MEMBER 
    1. Install the rear engine mounting member to the automatic transmission assembly with the 4 nuts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY  (See INSTALLATION )
    Fig 8: Locating Rear Engine Mounting Member Nuts
    G05749493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT  (See INSTALLATION )
  8. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  9. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  10. INSTALL COMPRESSOR AND PULLEY 
    1. Using an E8 "TORX" socket, install the compressor and pulley with the 2 stud bolts

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 9: Identifying Compressor Stud Bolts
      G05749492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the compressor and pulley with the 2 bolts and 2 nuts

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      HINT

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor

      Fig 10: Identifying Compressor Bolts And Nuts
      G05749507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL OIL COOLER TUBE 
    1. Install the oil cooler tube with the 2 bolts and nut

      Torque: Bolt 

      14 N*m (140 kgf*cm, 10 ft.*lbf) 

      Nut 

      5.5 N*m (56 kgf*cm, 49 in.*lbf) 

    2. Connect the wire harness clamp.
  12. CONNECT WIRE HARNESS AND CONNECTORS  (See INSTALLATION )
    Fig 11: Locating Oil Cooler Tube Bolts And Nut
    G05749508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT BREATHER PLUG HOSE  (See INSTALLATION )
  14. INSTALL V-RIBBED BELT  (See INSTALLATION )
  15. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH  (See INSTALLATION )
  17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH  (See INSTALLATION )
  19. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  20. INSTALL ENGINE MOUNTING DAMPER 
    1. Install the 2 engine mounting dampers with the 2 bolts

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

    Fig 12: Locating Engine Mounting Dampers Bolts
    G05749509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH 
    1. Install the engine under cover sub-assembly LH to the front suspension crossmember sub-assembly with the 2 clamps.
    Fig 13: Identifying Engine Under Cover Clamps
    G05749487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH 
    1. Install the engine under cover sub-assembly RH to the front suspension crossmember sub-assembly with the 2 clamps.
  23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE  (See INSTALLATION )
  24. INSTALL ENGINE OIL LEVEL DIPSTICK 
    Fig 14: Identifying Engine Under Cover Clamps
    G05749488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL ENGINE AND TRANSMISSION 
    1. Place the engine on an engine lifter.

      HINT:

      Place the engine on wooden blocks or equivalent so that the engine is level

    2. Remove the 2 bolts and 2 engine hangers
    3. Operate the engine lifter to install the engine into the vehicle.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
    4. Install the 10 bolts and 2 nuts

      Torque: Bolt A 

      204 N*m (2080 kgf*cm, 150 ft.*lbf) 

      Bolt B 

      50 N*m (510 kgf*cm, 37 ft.*lbf) 

      Bolt C 

      49 N*m (500 kgf*cm, 36 ft.*lbf) 

      Nut 

      167 N*m (1703 kgf*cm, 123 ft.*lbf) 

      Fig 15: Identifying Engine Bolts And Nuts
      G05749512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine rear mounting member to the body with the 4 bolts.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

  26. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY  (See INSTALLATION )
  27. INSTALL STEERING COLUMN ASSEMBLY 

    See INSTALLATION

  28. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY  (See INSTALLATION )
  29. CONNECT HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY  (See INSTALLATION )
    Fig 16: Locating Mounting Member Bolts
    G05749483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. CONNECT STEERING KNUCKLE LH  (See INSTALLATION )
  31. CONNECT STEERING KNUCKLE RH 

    HINT

    Perform the same procedure for the LH side

  32. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH  (See INSTALLATION )
  33. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT

    Perform the same procedure for the LH side

  34. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY  (See INSTALLATION )
  35. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY  (See INSTALLATION )
  36. INSPECT AND ADJUST BOTH NO. 2 AND NO. 3 JOINT ANGLE  (See INSTALLATION )
  37. INSTALL OUTSIDE AIR GUIDE PLATE RH  (See INSTALLATION )
  38. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR  (See INSTALLATION )
  39. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  40. CONNECT HEATED OXYGEN SENSOR  (See INSTALLATION )
  41. INSTALL FRONT CENTER FLOOR BRACE  (See INSTALLATION )
  42. INSTALL REAR NO. 1 FLOOR PANEL BRACE  (See INSTALLATION )
  43. INSTALL TAIL EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  44. INSTALL NO. 2 FLOOR UNDER COVER  (See INSTALLATION )
  45. INSTALL NO. 1 FLOOR UNDER COVER  (See INSTALLATION )
  46. CONNECT WIRE HARNESS 
    1. Install the ground cable with the nut.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 17: Locating Ground Cable Bolt
      G05749482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the power steering wire harness.
      1. Connect wire harness connector (D) to the power steering link assembly and securely lock the connector
      2. Connect 2 wire harness connectors (B) and (C) to the power steering link assembly.
      3. Install the 2 wire harness clamps to the power steering link assembly
      4. Connect the earth wire to the bracket with bolt (A)

        Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 18: Connecting Power Steering Wire Harness
      G05753105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the ground cable with the bolt and clamp

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      Fig 19: Locating Ground Cable With Bolt And Clamp
      G05750434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the ground cable with the bolt

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 20: Locating Ground Cable Bolt
      G05750433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the wire to the engine room No. 1 junction block.
    6. Connect the clamp.
      Fig 21: Connecting Wire To Engine Room No 1 Junction Block
      G05749518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the nut and connect the wire harness.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

    8. Install the No 1 engine room relay block cover
      Fig 22: Locating Wire Harness Nut
      G05749477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the positive (+) battery cable with the nut and clamp.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 23: Locating Battery Positive Cable Nut
      G05749476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Connect the 5 connectors and grommet to the ECM box.
      Fig 24: Locating Connectors And Grommet
      G05749475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Connect the No. 4 connector holder
      Fig 25: Connecting No 4 Connector Holder
      G05750474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Connect the 3 connectors and connector clamp
  47. INSTALL ENGINE ROOM ECU COVER  (See INSTALLATION )
  48. INSTALL WIRE HARNESS CLAMP BRACKET  (See INSTALLATION )
  49. INSTALL BATTERY TRAY  (See INSTALLATION )
  50. INSTALL POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
    Fig 26: Locating Wire Harness Connectors And Connector Clamp
    G05750428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL NO. 1 BATTERY TRAY SUPPORT 
  52. INSTALL BATTERY  (See INSTALLATION )
  53. INSTALL DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  54. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE  (See INSTALLATION )
  55. CONNECT NO. 1 FUEL HOSE 
    1. Push in the fuel tube connector to the No. 1 fuel hose until the fuel tube connector makes a "click" sound
      NOTE:
      • Check that there is no damage or foreign objects on the fuel pipe connectors.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 27: Identifying Fuel Tube Connector
      G05749524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push in the fuel tube connector to the No. 1 fuel hose until the fuel tube connector makes a "click" sound.
    3. Push down on the retainer to lock it in place.
      NOTE:
      • Check that there is no damage or foreign objects on the fuel pipe connectors.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 28: Pushing In Fuel Tube Connector
      G05749525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 fuel pipe clamps.
      Fig 29: Locating Fuel Pipe Clamps
      G05749470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. CONNECT NO. 3 FUEL HOSE 
    1. Push in the fuel tube connector to the No. 3 fuel hose until the fuel tube connector makes a "click" sound.
      NOTE:
      • Check that there is no damage or foreign objects on the fuel pipe connectors.
      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
      Fig 30: Identifying Fuel Tube Connector
      G05749527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 fuel pipe clamps.
    Fig 31: Locating Fuel Pipe Clamps
    G05749468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL NO. 2 FUEL VAPOR FEED HOSE 
    1. Connect the No 2 fuel vapor feed hose.
    Fig 32: Locating Fuel Vapor Feed Hose
    G05749467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT VACUUM HOSE ASSEMBLY 
    1. Connect the vacuum hose assembly to the intake air surge tank assembly with the clamp.
    2. Connect the vacuum hose assembly to the hose clamp.
    NOTE: Align the vacuum hose matchmarks and the hose clamps as shown in the illustration.
    Fig 33: Aligning Vacuum Hose Matchmarks And Hose Clamps
    G05749530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL HEATER WATER OUTLET HOSE A 
    1. Connect the heater water outlet hose A.
  60. INSTALL HEATER WATER INLET HOSE A 
    1. Connect the heater water inlet hose A.
    Fig 34: Locating Heater Inlet Water Hose And Outlet Water Hose
    G05749465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. CONNECT NO. 2 OIL COOLER OUTLET HOSE 
    1. Connect the No. 2 oil cooler outlet hose with the clip.
  62. CONNECT NO. 2 OIL COOLER INLET HOSE 
    1. Connect the No 2 oil cooler inlet hose with the clip.
    Fig 35: Locating Oil Cooler Inlet Hose And Outlet Hose
    G05749464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose with the clamp
    Fig 36: Locating No 2 Radiator Hose
    G05749463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose with the clamp.
    Fig 37: Locating No 1 Radiator Hose
    G05749462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. CONNECT RESERVE TANK OUTLET HOSE 
    1. Connect the reserve tank outlet hose with the clamp.
    Fig 38: Locating Reserve Tank Outlet Hose
    G05749461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly with the 2 bolts

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    2. Connect the vacuum switching valve connector and clamp
      Fig 39: Locating Air Cleaner Case Bolts
      G05749460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the vacuum hose and 2 clamps.
  67. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
  68. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL  (See INSTALLATION )
  69. ADD ENGINE OIL  (See REPLACEMENT )
  70. ADD ENGINE COOLANT  (See REPLACEMENT )
  71. ADD AUTOMATIC TRANSMISSION FLUID 

    AUTOMATIC TRANSMISSION FLUID

    Fig 40: Identifying Vacuum Hose Clamps
    G05749459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. CHARGE REFRIGERANT  (See REPLACEMENT )
  73. INSPECT FOR OIL LEAK 
  74. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  75. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  76. INSPECT FOR EXHAUST GAS LEAK 
  77. INSTALL FRONT WHEEL 
  78. STABILIZE SUSPENSION  (See INSTALLATION )
  79. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH  (See DISPOSAL )
  80. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT

    Perform the same procedure for the LH side.

  81. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  82. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 

    See FRONT WHEEL ALIGNMENT

  83. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT )
  84. INSPECT SHIFT LEVER POSITION  (See ON-VEHICLE INSPECTION )
  85. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET 
    1. Install the engine under cover air guide bracket with the 2 bolts

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

  86. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR  (See INSTALLATION )
  87. INSTALL NO. 2 ENGINE UNDER COVER 
    Fig 41: Locating Engine Under Cover Air Guide Bracket Bolts
    G05749457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL REAR ENGINE UNDER COVER RH 
  89. INSTALL REAR ENGINE UNDER COVER LH 
  90. INSTALL ENGINE UNDER COVER 
  91. INSTALL NO. 1 AIR CLEANER INLET 
    1. Install the No. 1 air cleaner inlet with the bolt and clip

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    Fig 42: Locating Air Cleaner Inlet Bolt
    G05749458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. INSTALL ENGINE ROOM SIDE COVER RH 
    1. Install the engine room side cover RH with the 3 clips.
    Fig 43: Identifying Engine Room Side Cover RH Clips
    G05749540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. INSTALL ENGINE ROOM SIDE COVER LH 
    1. Install the engine room side cover LH with the 5 clips
    Fig 44: Identifying Engine Room Side Cover LH Clips
    G05749455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the cool air intake duct seal with the 9 clips
    Fig 45: Identifying Cool Air Intake Duct Seal Clips
    G05749454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 4 clips to install the V-bank cover sub-assembly
      NOTE:
      • Be sure to engage the clips securely.
      • Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
      Fig 46: Identifying V-Bank Cover Clips
      G05749453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. INSPECT IGNITION TIMING  (See ENGINE )
  97. INSPECT ENGINE IDLE SPEED  (See ENGINE )
  98. INSPECT CO/HC  (See ENGINE )
  99. CHECK AUTOMATIC TRANSMISSION SYSTEM PRECAUTION 

    See PRECAUTION

  100. VEHICLE PREPARATION FOR HEADLIGHT AIMING ADJUSTMENT  (See ADJUSTMENT )
  101. PREPARATION FOR HEADLIGHT AIMING (Using a headlight aim test machine)  (See ADJUSTMENT )
  102. PREPARATION FOR HEADLIGHT AIMING (Using a screen)  (See ADJUSTMENT )
  103. INSPECT HEADLIGHT AIMING  (See ADJUSTMENT )
  104. ADJUST HEADLIGHT AIMING  (See ADJUSTMENT )
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