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Engine Assembly: Installation

  1. REMOVE ENGINE STAND 
    1. Install 2 engine hangers with 2 bolts as shown in the illustration.

      Part No. 

      ENGINE HANGERS AND BOLTS REFERENCE

      Item Part No.
      Engine hanger 12281-38030
      Bolt 90119-14120

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

      Fig 1: Locating Engine Hangers
      G05151204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach an engine sling device and hang the engine with a chain block.
    3. Remove the bolts and engine assembly from the engine stand.
  2. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH 
    1. Install the engine mounting bracket LH with the bolt.

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Fig 2: Identifying Engine Mounting Bracket LH
      G05628430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL FRONT ENGINE MOUNTING INSULATOR RH 
    1. Install the mounting insulator with the nut.

      Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf) 

      Fig 3: Locating Mounting Insulator Nut RH
      G05628429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT ENGINE MOUNTING INSULATOR LH 
    1. Install the mounting insulator with the nut.

      Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf) 

      Fig 4: Locating Mounting Insulator Nut LH
      G05151407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL ENGINE ASSEMBLY 
    1. Slowly lower the engine assembly into the engine compartment.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
    2. Attach the engine mounting insulators to the vehicle.
    3. Install the 4 engine mounting insulator bolts.

      Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) 

    4. Remove the 2 bolts and 2 engine hangers.
      Fig 5: Identifying Engine Mounting Insulator Bolts
      G05628427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Connect the hose and install the water by-pass pipe with the 2 bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      Fig 6: Locating Water By-Pass Pipe Bolts
      G05759993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT OIL COOLER PIPE ASSEMBLY  (See INSTALLATION )
  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.

      SST 09213-70011 (09213-70020), 09330-00021 

    2. Install the crankshaft position sensor rotor, drive plate and rear drive plate spacer to the crankshaft.
      Fig 7: Holding Crankshaft
      G05628437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install and uniformly 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 flywheel installation bolts.
      • Do not strike or damage the flywheel installation bolts. Be sure to handle them carefully.
        Fig 8: Identifying Flywheel Bolts Tightening Sequence
        G05151210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the upside of each flywheel installation bolt with paint.
    5. Tighten the flywheel installation bolts 90° as shown in the illustration.
    6. Check that the painted marks are now at a 90° angle to the upside.
      Fig 9: Tightening Flywheel Installation Bolts 90°
      G04943215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR 
    1. Install the rear engine mounting insulator to the transmission with the 4 bolts.

      Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf) 

    2. Install the engine mounting heat insulator with the 2 bolts.

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

      Fig 10: Locating Rear Engine Mounting Insulator Bolts
      G05760008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 
    1. Install the automatic transmission (See INSTALLATION ).
  11. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  12. INSTALL STARTER COVER  (See INSTALLATION )
  13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH  (See INSTALLATION )
  14. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  15. INSTALL NO. 1 MANIFOLD STAY  (See INSTALLATION )
  16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH  (See INSTALLATION )
  17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  18. INSTALL NO. 2 MANIFOLD STAY  (See INSTALLATION )
  19. INSTALL PROPELLER SHAFT HEAT INSULATOR  (See INSTALLATION )
  20. INSTALL REAR PROPELLER SHAFT ASSEMBLY 
    1. Install the rear propeller shaft (See INSTALLATION ).
  21. INSTALL FRONT PROPELLER SHAFT ASSEMBLY 
    1. Install the front propeller shaft (See INSTALLATION ).
  22. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  23. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  24. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  25. INSTALL TAILPIPE ASSEMBLY  (See INSTALLATION )
  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE  (See INSTALLATION )
  27. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  28. CONNECT VANE PUMP ASSEMBLY  (See INSTALLATION )
  29. CONNECT COOLER COMPRESSOR ASSEMBLY  (See INSTALLATION )
  30. CONNECT WIRE HARNESS AND HOSE 
    1. Connect the 2 clamps and 2 connectors.
      Fig 11: Locating Clamps And Connectors
      G05759989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 connectors and 2 clips to the engine room junction block.
      3. Fig 12: Locating Air Injection Control Driver Connectors
      G05759988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine wire with the nut. Then connect the 2 clips.

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

    4. Connect the 4 air injection control driver connectors.
    5. Install the ground wire to the air injection control bracket with the bolt.

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

    6. Install the ground wire to the body with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    7. Connect the cable to the positive (+) battery terminal.
    8. Install the wire to the positive (+) battery cable with the nut.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    9. Connect the 2 air injection system hoses.
      10. Fig 13: Locating Clamps And Air Pump Connectors
      G05628419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the ground wire with the bolt.

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

    11. Connect the 3 clamps and 2 air pump connectors.
    12. Install the connector bracket with the nut.

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

    13. Connect the clamp and 4 connectors to the connector holder block.
      Fig 14: Locating Clamp And Connectors
      G05759986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    14. Connect the ECM connector and clamp.

      HINT:

      Refer to the following procedures to connect the ECM connector (See INSTALLATION ).

      Fig 15: Locating ECM Connector And Clamp
      G05759985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. Connect the purge line hose.
      Fig 16: Locating Purge Line Hose
      G05628416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. CONNECT FUEL MAIN AND RETURN HOSE 
    1. Connect the fuel main and return hoses (See FUEL SYSTEM ).
    2. Install the fuel pipe clamp.
      Fig 17: Identifying Fuel Pipe Clamp
      G05760015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL WATER HOSE SUB-ASSEMBLY 
    33. Fig 18: Locating Water Hose Sub-Assembly
    G05759982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL RADIATOR ASSEMBLY  (See INSTALLATION )
  34. INSTALL FAN SHROUD  (See INSTALLATION )
  35. INSTALL NO. 2 RADIATOR HOSE 
  36. INSTALL NO. 1 RADIATOR HOSE 
  37. INSTALL AIR CLEANER ASSEMBLY 
    1. Install the air cleaner with the 3 bolts.

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

      Fig 19: Locating Air Cleaner Bolts
      G05628414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL AIR CLEANER HOSE ASSEMBLY  (See INSTALLATION )
  39. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood with the 4 bolts.

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

    2. Connect the 2 hood supports with the 2 hood support bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.lbf) 

      CAUTION: Install the hood support while supporting the hood by hand.
      NOTE: Check that the hood support is engaged in the ball joint and that it cannot be pulled out.
      Fig 20: Locating Hood Support Bolts
      G05759980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. ADJUST HOOD SUB-ASSEMBLY  (See HOOD )
  41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  42. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
  43. INSTALL FRONT FENDER MAIN SEAL LH  (See INSTALLATION )
  44. INSTALL FRONT FENDER MAIN SEAL RH  (See INSTALLATION )
  45. INSTALL FRONT WIPER ARM LH  (See INSTALLATION )
  46. INSTALL FRONT WIPER ARM RH  (See INSTALLATION )
  47. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)  (See INSTALLATION )
  48. INSTALL RADIATOR SIDE DEFLECTOR LH  (See INSTALLATION )
  49. INSTALL RADIATOR GRILLE  (See INSTALLATION )
  50. INSTALL FRONT FENDER APRON SEAL REAR RH  (See INSTALLATION )
  51. INSTALL FRONT FENDER APRON SEAL FRONT RH  (See INSTALLATION )
  52. INSTALL FRONT FENDER APRON SEAL REAR LH  (See INSTALLATION )
  53. INSTALL FRONT FENDER APRON SEAL FRONT LH  (See INSTALLATION )
  54. INSTALL OIL PAN PROTECTOR ASSEMBLY  (See INSTALLATION )
  55. INSTALL NO. 2 ENGINE UNDER COVER  (See INSTALLATION )
  56. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY  (See INSTALLATION )
  57. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH  (See INSTALLATION )
  58. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH  (See INSTALLATION )
  59. ADD ENGINE OIL  (See REPLACEMENT )
  60. ADD ENGINE COOLANT  (See REPLACEMENT )
  61. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  62. INSPECT FOR OIL LEAK  (See REPLACEMENT )
  63. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  64. INSPECT FOR EXHAUST GAS LEAK 
  65. INSPECT FOR FUEL LEAK  (See INSTALLATION )
  66. INSPECT SHIFT LEVER POSITION  (See ON-VEHICLE INSPECTION )
  67. INSPECT IGNITION TIMING  (See ON-VEHICLE INSPECTION  )
  68. INSPECT ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION  )
  69. INSPECT CO/HC  (See ON-VEHICLE INSPECTION  )
  70. INSPECT ENGINE OIL LEVEL  (See LUBRICATION SYSTEM )
  71. INSPECT ENGINE COOLANT LEVEL  (See COOLING SYSTEM )
  72. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.
      Fig 21: Identifying V-Bank Cover Hooks
      G05628449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL UPPER RADIATOR SUPPORT SEAL  (See INSTALLATION )
  74. INSTALL ENGINE ROOM SIDE COVER RH  (See INSTALLATION )
  75. INSTALL ENGINE ROOM SIDE COVER LH  (See INSTALLATION )
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