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Engine Mechanical: Engine: Installation

  1. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
  2. INSTALL KNOCK SENSOR  (See INSTALLATION )
  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR  (See INSTALLATION )
  4. INSTALL ENGINE OIL LEVEL SENSOR 
    1. Install the oil level sensor with the 4 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      Fig 1: Locating Oil Level Sensor & Bolts
      G05846922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY  (See INSTALLATION )
  6. INSTALL WATER INLET HOUSING  (See INSTALLATION  )
  7. INSTALL WATER PUMP PULLEY  (See INSTALLATION  )
  8. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the idler pulley with the bolt.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 2: Locating Idler Pulley With Bolt
      G05846923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the idler pulley with the bolt.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 3: Locating Idler Pulley Bolt
      G05846924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY 
    1. Install the engine cover.
      Fig 4: Identifying No. 4 Engine Cover Sub-Assembly
      G05846925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL ENGINE WIRE 
    1. Install the engine wire with the 2 bolts.

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

      Fig 5: Locating Knock Sensor Connectors & Bolts
      G05846926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 4 knock sensor connectors.
  12. INSTALL SEPARATOR CASE  (See INSTALLATION )
  13. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)  (See INSTALLATION )
  14. INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection)  (See INSTALLATION )
  15. INSTALL FUEL DELIVERY PIPE (for Direct Injection)  (See INSTALLATION )
  16. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY  (See INSTALLATION )
  17. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)  (See INSTALLATION )
  18. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY  (See INSTALLATION )
  19. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY  (See INSTALLATION )
  20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY  (See INSTALLATION )
  21. INSTALL ENGINE COVER SUB-ASSEMBLY  (See INSTALLATION )
  22. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)  (See INSTALLATION )
  23. INSTALL FUEL DELIVERY PIPE (for Port Injection)  (See INSTALLATION )
  24. INSTALL FUEL TUBE SUB-ASSEMBLY  (See INSTALLATION )
  25. INSTALL NO. 3 COVER SUB-ASSEMBLY  (See INSTALLATION )
  26. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY  (See INSTALLATION )
  27. INSTALL INTAKE MANIFOLD  (See INSTALLATION )
  28. INSTALL THROTTLE BODY ASSEMBLY  (See INSTALLATION )
  29. INSTALL VENTILATION HOSE 
  30. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY  (See INSTALLATION )
  31. INSTALL NO. 1 ENGINE COVER 
  32. INSTALL INJECTOR DRIVER  (See INSTALLATION )
  33. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH 
    1. Install the mounting bracket with the 6 bolts.

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

      Fig 6: Locating Front No. 1 Engine Mounting Bracket & Bolts (RH)
      G05846927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Install the mounting bracket with the 6 bolts.

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

      Fig 7: Locating Front No. 1 Engine Mounting Bracket & Bolts (LH)
      G05846928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL ENGINE MOUNTING DAMPER 
    1. Install the 2 mounting dampers with the 2 nuts.

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

      Fig 8: Locating Mounting Dampers & Nuts
      G05846929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  37. REMOVE ENGINE STAND 
    1. Install the 2 engine hangers with the 2 bolts as shown below.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 9: Locating Engine Hangers & Bolts
      G05846930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach an engine sling device and hang the engine with a chain block.
      NOTE: When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.
    3. Remove the bolts and engine assembly from the engine stand.
      Fig 10: Identifying Engine Hanger Locations
      G05846931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL ENGINE MOUNTING SPACER  (See INSTALLATION  )
  39. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the crossmember with the 2 nuts.

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

      Fig 11: Locating Crossmember & Nuts
      G05846932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.

      SST 09213-54015 (90119-08216), 09330-00021 

      Fig 12: Holding Crankshaft Using SST
      G05846933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the sensor rotor, ring gear and spacer plate on the crankshaft.
    3. Uniformly install and tighten 10 new bolts in the sequence shown below.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      NOTE:
      • Do not reuse the flywheel installation bolts.
      • Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
      Fig 13: Locating Tightening Sequence Of Bolts
      G05846934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the upside of each flywheel installation bolt with paint.
    5. Retighten the flywheel installation bolts by 90° as shown below.
    6. Check that the painted marks are now at a 90° angle to the upside.
      7. Fig 14: Identifying Paint Mark On Flywheel Installation Bolts
      G05846935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY  (See INSTALLATION )
  42. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  43. INSTALL ENGINE WIRE 
    1. Install the engine wire with the 4 nuts.

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

    2. Connect the clamp and 2 clamp brackets with the 2 bolts.

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

    3. Connect the intake air control valve actuator connector.
    4. Connect the purge VSV connector.
      Fig 15: Locating Purge VSV Connector, Clamp Brackets & Clamp
      G05846936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 4 injector driver connectors as shown below.
      Fig 16: Locating Injector Driver Connectors
      G05846937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. for Engine RH Side:
      1. Connect the 2 clamps and install the 3 clamp brackets with the 3 bolts.

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

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

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

        Fig 17: Locating Ignition Coil Connectors, VVT Sensor Connectors & Engine Wire Connector
        G05846938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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).
      9. Connect the fuel pump connector (for high pressure).
      10. Connect the 2 VVT sensor connectors.
      11. Connect the 4 ignition coil connectors.
      12. Connect the camshaft timing control valve connector.
    7. for Engine LH Side:
      1. Install the clamp bracket with the bolt.

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

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

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

      3. Connect the 2 camshaft timing control motor connectors (for Bank 1).
      4. Connect the oil pressure sensor connector.
      5. Connect the engine coolant temperature sensor connector.
        Fig 18: Locating Clamp Bracket & Bolt With Camshaft Timing Control Motor Connectors
        G05846939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Connect the clamp and install the 2 clamp brackets with the 2 bolts.

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

        Fig 19: Locating Clamp, Bracket & Bolts
        G05846940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Connect the No. 8 engine wire connector.
      8. Connect the fuel pump connector (for high pressure).
      9. Connect the 2 VVT sensor connectors.
      10. Connect the 4 ignition coil connectors.
      11. Connect the camshaft timing control valve connector.
    8. Connect the throttle body connectors.
  44. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  45. INSTALL OIL COOLER TUBE  (See INSTALLATION )
  46. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 2)  (See INSTALLATION )
  47. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  48. INSTALL OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the new O-ring to the guide.
    3. Install the dipstick guide with the 2 bolts.

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

    4. Install the dipstick.
  49. INSTALL ENGINE AND TRANSMISSION 
    1. Place the engine on an engine lifter.

      HINT:

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

    2. Remove the 2 bolts and 2 engine hangers.
      Fig 20: Locating Engine Hangers & Bolts
      G05846941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Operate the engine lifter, then install the engine to the vehicle.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
    4. Align the crossmember to the marks on the vehicle, and temporarily install the engine and transmission with crossmember with the 4 bolts.
      NOTE: Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.
      Fig 21: Placing Mark Over Front Right Vehicle Side Attachment Area Of Crossmember
      G05846942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the 4 bolts.

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

      Fig 22: Locating Engine Lifter Bolts
      G05846943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 4 engine rear mounting member's bolts.

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

      Fig 23: Locating Engine Rear Mounting Member's Bolts
      G05846944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY  (See INSTALLATION )
  51. CONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY 
    1. Connect the front No. 2 lower suspension arm (see INSTALLATION ).
  52. CONNECT COOLER COMPRESSOR ASSEMBLY 
    1. Connect the cooler compressor with the 2 stud bolts, 2 nuts and 2 bolts.

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

      25 N*m (255 kgf*cm, 18 ft.*lbf) for nuts 

      25 N*m (255 kgf*cm, 18 ft.*lbf) for bolts 

      Fig 24: Identifying Cooler Compressor Assembly Bolts, Nuts & Stud Bolts
      G05846945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)  (See INSTALLATION )
  54. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  55. INSTALL POWER STEERING LINK ASSEMBLY (w/ VGRS)  (See INSTALLATION )
  56. INSTALL POWER STEERING LINK ASSEMBLY (w/o VGRS)  (See REASSEMBLY )
  57. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/ VGRS)  (See INSTALLATION )
  58. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS)  (See INSTALLATION )
  59. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS)  (See INSTALLATION )
  60. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)  (See INSTALLATION )
  61. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH  (See INSTALLATION )
  62. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH  (See INSTALLATION )
  63. INSTALL FRONT STABILIZER BAR 
    1. Install the stabilizer bar (see INSTALLATION ).
  64. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 
    1. Install the propeller shaft (see INSTALLATION ).
  65. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY  (See INSTALLATION )
  66. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Install the front exhaust pipe (see INSTALLATION ).
  67. CONNECT HOSES AND CONNECTORS 
    1. Connect the purge line hose.
      Fig 25: Locating Purge Line Hose
      G05846946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 heater hoses.
      Fig 26: Locating Heater Hoses
      G05846947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the wires with No. 1 engine room junction block with the 2 nuts.

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

      Fig 27: Locating No. 1 Engine Room Junction Block Wires & Nuts
      G05846948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the ground wire with the bolt.

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

      Fig 28: Locating Ground Wire & Bolt
      G05846949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 3 connectors with front controller with the clamp.
      Fig 29: Locating Connectors With Front Controller Clamp
      G05846950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Attach the clamp and connect the cooler compressor connector.
      Fig 30: Locating Cooler Compressor Connector With Clamp
      G05846951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the 3 ECT connectors and 4 ECM connectors.
    8. Install the ECM box cover (upper).
      9. Fig 31: Locating ECT Connectors & ECM Connectors From ECM Box
      G05846952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY  (See INSTALLATION )
  69. CONNECT NO. 3 FUEL HOSE  (See INSTALLATION )
  70. INSTALL ENGINE ROOM ECU OUTLET DUCT 
    1. Install the outlet duct.
      2. Fig 32: Identifying Outlet Duct
      G05846953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. CONNECT NO. 2 RADIATOR HOSE 
  72. CONNECT NO. 1 RADIATOR HOSE 
  73. INSTALL AIR CLEANER ASSEMBLY RH  (See INSTALLATION )
  74. INSTALL AIR CLEANER ASSEMBLY LH  (See INSTALLATION )
  75. INSTALL V-RIBBED BELT  (See INSTALLATION  )
  76. INSTALL INTAKE AIR CONNECTOR PIPE  (See INSTALLATION )
  77. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  78. INSTALL FRONT SUSPENSION CROSSMEMBER LOWER 
    1. Install the suspension crossmember lower with the 6 bolts and 4 nuts.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 33: Locating Suspension Crossmember Lower Bolts & Nuts
      G05846954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL FRONT BUMPER COVER 
    1. Install the front bumper cover (see INSTALLATION ).
  80. CONNECT NO. 1 OIL COOLER OUTLET HOSE 
    1. Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.
      2. Fig 34: Locating No. 1 Oil Cooler Outlet Hose Claws Of Clip
      G05846955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. CONNECT NO. 1 OIL COOLER INLET HOSE 
    1. Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.
  82. ADD ENGINE OIL  (See REPLACEMENT )
  83. ADD ENGINE COOLANT  (See REPLACEMENT )
  84. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  85. PERFORM INITIALIZATION 
    1. Perform INITIALIZATION
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  86. INSPECT FOR OIL LEAK 
    1. Inspect for engine oil leak (see INSTALLATION ).
  87. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  88. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  89. INSPECT FOR EXHAUST GAS LEAK  (See INSTALLATION )
  90. INSTALL FRONT WHEEL 
  91. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  92. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Check and adjust the front wheel alignment (see ADJUSTMENT ).
  93. CHECK SHIFT LEVER POSITION  (See INSTALLATION )
  94. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER 
    1. Install the suspension member protector with the 8 bolts.

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

      Fig 35: Locating Suspension Member Protector Bolts
      G05846956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the under cover with the 8 bolts.

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

      27 N*m (275 kgf*cm, 20 ft.*lbf) for bolt B 

      Fig 36: Locating No. 2 Engine Under Cover Bolts
      G05846957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. INSTALL NO. 1 ENGINE UNDER COVER  (See REPLACEMENT )
  97. CHECK IGNITION TIMING  (See ON-VEHICLE INSPECTION  )
  98. CHECK IDLE SPEED  (See ON-VEHICLE INSPECTION  )
  99. CHECK CO/HC  (See ON-VEHICLE INSPECTION  )
  100. CHECK ENGINE OIL LEVEL  (See ON-VEHICLE INSPECTION )
  101. INSTALL ENGINE ROOM SIDE COVER RH 
    1. Install the side cover with the 4 clips.
      Fig 37: Locating Engine Room Side Cover Clips (RH)
      G05846958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. INSTALL ENGINE ROOM SIDE COVER LH 
    1. Install the side cover with the 4 clips.
      2. Fig 38: Locating Engine Room Side Cover Clips (LH)
      G05846959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY  (See INSTALLATION )
  104. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
  105. INSTALL COWL TOP VENTILATOR LOUVER RH  (See INSTALLATION )
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