Installation (To 12/2010): Installation

WARNING: This page is about a different car, the 2011 Toyota Avalon. However, it is still accessible from the selected car via links, so may be relevant.

INSTALL ENGINE COOLANT TEMPERATURE SENSOR
1. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.
  
  Fig 1: Removing/Installing Engine Coolant Temperature Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
INSTALL KNOCK CONTROL SENSOR . Refer to INSTALLATION - Step 1
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.
  
  Fig 2: Applying Adhesive On Threads Of Oil Pressure Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
2. Using a 24 mm deep socket wrench, install the oil pressure switch.
  
  Fig 3: Removing/Installing Oil Pressure Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
1. Install the No. 1 vacuum switching valve with the bolt.
  
  Fig 4: Locating Bolt And No. 1 Vacuum Switching Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL RADIO SETTING CONDENSER
1. Install the 2 radio setting condensers with the 2 bolts.
  
  Fig 5: Locating Bolts And Radio Setting Condensers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
1. Install the front No. 1 engine mounting bracket LH with the 6 bolts.
  
  Fig 6: Locating Engine Mounting Bracket Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
INSTALL WATER PUMP PULLEY . Refer to INSTALLATION - Step 1
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the No. 2 idler pulley sub-assembly and 2 plates with the bolt.
  
  Fig 7: Identifying No. 2 Idler Pulley Sub-Assembly Bolt And 2 Plates
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf)
  
  HINT:
  
  Plate diameter:
  
  Idler pulley cover plate: 33.6 mm (1.32 in.)
  
  No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
INSTALL NO. 2 TIMING GEAR COVER
1. Install the No. 2 timing gear cover with the 2 bolts.
  
  Fig 8: Locating No. 2 Timing Gear Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
  
  Fig 9: Identifying V-Ribbed Belt Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Each bolt length is as follows:
  
  A: 70 mm (2.76 in.)
  
  B: 33 mm (1.30 in.)
2. Install the V-ribbed belt tensioner by tightening bolt 1 and bolt 2 in the order shown in the illustration.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
3. Tighten the other bolts.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSTALL DRIVE SHAFT BEARING BRACKET
1. Install the drive shaft bearing bracket with the 3 bolts.
  
  Fig 10: Identifying Drive Shaft Bearing Bracket And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf)
INSTALL ENGINE MOUNTING BRACKET RH
1. Install the engine mounting bracket RH with the 3 bolts.
  
  Fig 11: Locating Engine Mounting Bracket RH With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Install a new gasket as shown in the illustration.
  
  Fig 12: Identifying Exhaust Manifold Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold sub-assembly LH with the 6 nuts.
  
  Fig 13: Locating Exhaust Manifold Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
  
  Fig 14: Identifying No. 2 Exhaust Manifold Heat Insulator And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay with the bolt and nut.
  
  Fig 15: Locating No. 2 Manifold Stay With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY
1. Install 2 new O-rings to the oil level dipstick guides.
  
  Fig 16: Locating No. 1 Oil Level Gauge Guide And No. 2 Oil Level Gauge Guide Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply a light coat of engine oil to the O-rings.
3. Push in the oil level dipstick guide end into the guide hole.
4. Install the No. 1 oil level dipstick guide with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
5. Install the No. 2 oil level dipstick guide with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
6. Install the oil level dipstick.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Install a new gasket as shown in the illustration.
  
  Fig 17: Identifying Exhaust Manifold Sub-Assembly RH Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold sub-assembly RH with the 6 nuts.
  
  Fig 18: Identifying Exhaust Manifold Sub-Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

INSTALL INTAKE MANIFOLD

NOTE:

DO NOT APPLY OIL TO THE BOLTS LISTED BELOW:

Tightening Parts
Intake Manifold and Cylinder Head Sub-assembly RH
Intake Manifold and Cylinder Head Sub-assembly LH

Set a new gasket on each cylinder head.
NOTE:
- Align the port holes of the gaskets and cylinder heads.
- Make sure that the gaskets are installed in the correct direction.
Set the intake manifold on the cylinder heads.

Fig 19: Locating Intake Manifold Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

INSTALL NO. 2 ENGINE MOUNTING STAY RH
1. Install the No. 2 engine mounting stay RH with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL IGNITION COIL ASSEMBLY
1. Install the 6 ignition coil assemblies with the 6 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
REMOVE ENGINE STAND
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Refer to step 2
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY . Refer to INSTALLATION - Step 10
CONNECT CONNECTOR . Refer to INSTALLATION - Step 11
INSTALL WIRE HARNESS . Refer to INSTALLATION - Step 12
INSTALL ENGINE WIRE
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH . Refer to INSTALLATION - Step 2
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH . Refer to INSTALLATION - Step 1
INSTALL FRONT FRAME ASSEMBLY
1. Install the engine mounting insulators RH and LH with the 2 nuts.
  
  Fig 20: Locating Engine Mounting Insulators Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
2. Install the front engine mounting insulator with the bolt.
  
  Fig 21: Locating Front Engine Mounting Insulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)
3. Connect the 2 clamps.
  
  Fig 22: Locating Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the connector and clamp.
  
  Fig 23: Identifying Connector And Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP ASSEMBLY
1. Install the vane pump with the 2 bolts.
  
  Fig 24: Locating Frame Side Rail Plates RH And LH Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
2. Install the pressure feed tube clamp bolt.
  Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine assembly with transaxle on the engine lifter.
  
  Fig 25: Installing Front Suspension Member Brace Rears
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the engine assembly to the vehicle.
3. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.
  A
  
  Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
  
  B
  
  Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf)
4. Install the front suspension member brace rears RH and LH with the 4 bolts and 2 nuts.
  C
  
  Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
  
  D
  
  Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf)
INSTALL COOLER COMPRESSOR ASSEMBLY
1. Temporarily install the cooler compressor with the 4 bolts.
  
  Fig 26: Locating Compressor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.
  Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
3. Install the 2 connector clamps.
INSTALL GENERATOR ASSEMBLY . Refer to INSTALLATION - Step 1
INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to INSTALLATION - Step 9
INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT . Refer to INSTALLATION - Step 22
INSTALL FLYWHEEL HOUSING UNDER COVER . Refer to INSTALLATION - Step 23
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
1. Install the No. 1 exhaust pipe support bracket with the nut.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL FRONT AXLE ASSEMBLY LH . Refer to INSTALLATION - Step 3
INSTALL FRONT AXLE ASSEMBLY RH
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH . Refer to INSTALLATION - Step 4
INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT:

Use the same procedure described for the LH side.
INSTALL TIE ROD ASSEMBLY LH . Refer to INSTALLATION - Step 7
INSTALL TIE ROD ASSEMBLY RH
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT SPEED SENSOR LH . Refer to INSTALLATION - Step 6
INSTALL FRONT SPEED SENSOR RH
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT AXLE SHAFT LH NUT . Refer to INSTALLATION - Step 8
INSTALL FRONT AXLE SHAFT RH NUT
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT STABILIZER LINK ASSEMBLY LH . Refer to INSTALLATION - Step 2
INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:

Use the same procedure described for the LH side.
INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to INSTALLATION - Step 4
INSTALL FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET . Refer to INSTALLATION - Step 6
CONNECT STEERING GEAR OUTLET RETURN TUBE
1. Connect the steering gear outlet return tube.
  
  Fig 27: Locating Steering Gear Outlet Return Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
1. Connect the No. 1 oil reservoir to pump hose.
  
  Fig 28: Identifying No. 1 Oil Reservoir To Pump Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY . Refer to INSTALLATION - Step 41
CONNECT ENGINE WIRE
1. Install the ground cable to the cylinder head with the 2 bolts.
  Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
2. Connect the engine wire clamp.
  
  Fig 29: Locating Ground Cable Bracket Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the ground cable with the bolt to the wire bracket.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
4. Install the 2 ground cables with the 2 bolts.
  
  Fig 30: Locating Ground Cables With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Bolt A
  
  Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
  
  Bolt B
  
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
5. Connect the engine wire connector and 3 clamps.
6. Connect the wire to the engine room junction block. Then, install it with the nut and 2 connectors.
  
  Fig 31: Locating Engine Room Junction Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
INSTALL UPPER RELAY BLOCK COVER
INSTALL STARTER ASSEMBLY . Refer to INSTALLATION - Step 1
INSTALL ECM . Refer to INSTALLATION - Step 1
CONNECT HEATER WATER OUTLET HOSE A
1. Connect the heater water outlet hose.
  
  Fig 32: Locating Heater Outlet Water Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT HEATER WATER HOSE INLET A
1. Connect the heater water hose inlet.
CONNECT NO. 1 OIL COOLER OUTLET HOSE . Refer to INSTALLATION - Step 6
CONNECT NO. 1 OIL COOLER INLET HOSE . Refer to INSTALLATION - Step 7
INSTALL RADIATOR HOSE OUTLET
1. Install the clamp and connect the radiator hose outlet.
  
  Fig 33: Locating Radiator Hose Outlet Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR HOSE INLET
1. Install the clamp and connect the radiator hose inlet.
  
  Fig 34: Locating Radiator Hose Inlet Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TUBE SUB-ASSEMBLY
1. Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
  
  Fig 35: Identifying Fuel Tube Connector To Fuel Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check for damage or contamination on the connected part of the pipe.
  - Check if the pipe and the connector are securely connected by trying to pull them apart.
2. Engage the claw and install the No. 1 fuel pipe clamp.
  
  Fig 36: Locating No. 1 Fuel Pipe Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE AIR SURGE TANK ASSEMBLY . Refer to INSTALLATION - Step 3
INSTALL NO. 1 FUEL VAPOR FEED HOSE
1. Install the clamp and connect the No. 1 fuel vapor feed hose.
  
  Fig 37: Locating No. 1 Fuel Vapor Feed Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
1. Install the intake air resonator with the bolt and clip.
  
  Fig 38: Locating Intake Air Resonator Clip And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Connect the wire harness clamp.
INSTALL NO. 1 AIR CLEANER INLET
1. Install the No. 1 air cleaner inlet with the bolt.
  
  Fig 39: Locating No. 1 Air Cleaner Inlet With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
INSTALL AIR CLEANER CASE
1. Install the air cleaner case with the 3 bolts.
  
  Fig 40: Locating Air Cleaner Case Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Connect the connector, vacuum hose, and hose clamp.
3. Install the air cleaner filter element to the air cleaner case.
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE . Refer to INSTALLATION - Step 4
INSTALL NO. 2 AIR CLEANER INLET
1. Install the No. 2 air cleaner inlet with the 2 bolts.
  
  Fig 41: Locating Air Cleaner Filter Element From Air Cleaner Case And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
2. Connect the clamp and 2 vacuum hoses.
INSTALL ENGINE MOVING CONTROL ROD
1. Temporarily install the engine moving control rod with the 4 bolts.
  
  Fig 43: Locating Engine Moving Control Rod With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. First install the bolts A, and then the remaining bolt B.
  Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf)
INSTALL NO. 2 ENGINE MOUNTING STAY RH
1. Temporarily install the No. 2 engine mounting stay RH with the bolt.
  
  Fig 44: Locating No. 2 Mounting Stay RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf)
2. Tighten the 2 nuts.
  Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
INSTALL RADIATOR RESERVE TANK ASSEMBLY
INSTALL V-RIBBED BELT Refer to step 1
INSTALL BATTERY
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
INSTALL COWL TOP PANEL OUTER . Refer to INSTALLATION - Step 19
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to INSTALLATION - Step 2
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH . Refer to INSTALLATION - Step 3
INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH . Refer to INSTALLATION - Step 4
INSTALL FRONT WHEELS
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
ADD ENGINE OIL . Refer to REPLACEMENT - Step 3
ADD ENGINE COOLANT . Refer to REPLACEMENT - Step 2
ADD AUTOMATIC TRANSAXLE FLUID . Refer to INSTALLATION - Step 75
ADD POWER STEERING FLUID
BLEED POWER STEERING SYSTEM . Refer to ON-VEHICLE INSPECTION - Step 2
INSPECT FOR FUEL LEAK . Refer to ON-VEHICLE INSPECTION - Step 1
INSPECT FOR OIL LEAK
INSPECT FOR ENGINE COOLANT LEAK . Refer to REPLACEMENT - Step 3
INSPECT FOR EXHAUST GAS LEAK
INSPECT SHIFT LEVER POSITION . Refer to ADJUSTMENT - Step 1
ADJUST SHIFT LEVER POSITION . Refer to ADJUSTMENT - Step 2
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:

Adjust the front wheel alignment. Refer to ADJUSTMENT .
INSPECT IGNITION TIMING Refer to step 2
INSPECT ENGINE IDLE SPEED Refer to step 3
INSPECT CO/HC Refer to step 5
INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to INSTALLATION - Step 14
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the intake duct seal with the 6 clips.
  
  Fig 45: Locating Intake Duct Seal Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK SPEED SENSOR SIGNAL
1. Check the speed sensor signal. Refer to TEST MODE PROCEDURE .