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Engine Assembly: Installation

  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, install the temperature sensor.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 1: Identifying Temperature Sensor
      G04055986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.
      Fig 2: Applying Adhesive On Threads Of Oil Pressure Switch
      G04055987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: Part No.08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent. 

    2. Using a 24 mm deep socket wrench, install the oil pressure switch.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

      Fig 3: Identifying Oil Pressure Switch
      G04055988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not start the engine within 1 hour after installation for prevent oil leaks.
  3. INSTALL ENGINE OIL LEVEL SENSOR 
    1. Install the engine oil level sensor and a new gasket with the 4 bolts.

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

      Fig 4: Identifying Engine Oil Level Sensor With 4 Bolts
      G04055989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the 6 ignition coils with the 6 bolts.

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

  5. INSTALL V-BANK COVER BRACKET SUBASSEMBLY 
    1. Install the V-bank cover bracket with the bolt.

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

      Fig 5: Identifying V-Bank Cover Bracket Installing Bolt
      G04055990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE RADIO SETTING CONDENSER 
    1. Install the 2 bolts and 2 radio setting condensers.

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

      Fig 6: Identifying 2 Bolts And Radio Setting Condensers
      G04055991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL KNOCK SENSOR (See  INSTALLATION  ) 
  8. INSTALL FUEL INJECTOR ASSEMBLY 

    HINT:

    See INSTALLATION .

  9. INSTALL FUEL PUMP 

    HINT:

    See INSTALLATION .

  10. INSTALL FUEL TUBE SUB-ASSEMBLY 
    1. Install the 2 bolts and fuel tube sub-assembly.

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

      Fig 7: Identifying Fuel Tube Sub-Assembly Installing Bolts
      G04055992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL INTAKE MANIFOLD (See  INSTALLATION  ) 
  12. INSTALL WATER HOSE JOINT 
    1. Connect the 2 hoses, and install the bolt and water hose joint.

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

      Fig 8: Identifying Water Hose Joint
      G04055993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 SURGE TANK STAY 
    1. Install the bolt and No. 2 surge tank stay.

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

  14. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    HINT:

    See INSTALLATION

  15. INSTALL INJECTOR DRIVER 
    1. Install the injector driver with the bolt and 2 nuts.

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

      Fig 9: Identifying Injector Driver, Bolt And Nuts
      G04055976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly.
  17. INSTALL WATER PUMP PULLEY (See  INSTALLATION  ) 
  18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

      Each bolt length is as follows 

      BOLT LENGTH SPECIFICATIONS

      Mark Specified Length
      A 70 mm (2.76 in.)
      B 35 mm (1.38 in.)
      Fig 10: Identifying V-Ribbed Belt Tensioner With 5 Bolts
      G04055995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

    3. Tighten the other bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

  19. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the mounting bracket with the 4 bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

    2. Connect the 2 clamps.
      Fig 11: Identifying Engine Mounting Bracket LH
      G04055996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the mounting bracket with the 4 bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

  21. INSTALL COOLER COMPRESSOR ASSEMBLY (See  INSTALLATION  ) 
  22. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
    Fig 12: Identifying Engine Mounting Bracket RH
    G04055997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the plate and idler pulley with the bolt.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Fig 13: Identifying Idler Pulley Installing Bolt
      G04055998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover with the 3 clips.
      Fig 14: Identifying No.1 Engine Cover With 3 Clips
      G04055999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 2 ENGINE COVER 
    1. Install the No. 2 engine cover with the 3 clips.
    2. Connect the clamp.
      Fig 15: Identifying No.2 Engine Cover
      G04056000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL V-RIBBED BELT (See  INSTALLATION   ) 
  27. INSTALL ENGINE HANGERS 

    Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

  28. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY 
    1. Using SST, hold the crankshaft.

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

    2. Apply adhesive to 2 or 3 threads of the mounting bolts ends.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

    3. Install the front spacer, drive plate and rear spacer on the crankshaft.
      Fig 16: Holding Crankshaft Using SST
      G04056001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install and tighten the 8 mounting bolts uniformly in several steps.

      Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf) 

      Fig 17: Identifying Bolts Tightening Sequence
      G04056002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Do not start the engine for at least 1 hour after installing.
  29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember subassembly with the 2 bolts.

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

      Fig 18: Identifying Front Suspension Crossmember Subassembly
      G04056003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    HINT:

    See INSTALLATION .

  31. INSTALL STARTER ASSEMBLY (See  INSTALLATION  ) 
  32. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Install a new gasket as shown in the illustration.
      Fig 19: Identifying Gasket
      G04056004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold with 6 new nuts.

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

      Fig 20: Identifying Exhaust Manifold With 6 Nuts
      G04056005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the stud bolt when installing the exhaust manifold.
      • Be sure to tighten either of nuts A first as shown in the illustration.
  33. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket as shown in the illustration.
      Fig 21: Identifying Gasket
      G04056006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold with 6 new nuts.

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

      Fig 22: Identifying Exhaust Manifold
      G04056007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the stud bolt when installing the exhaust manifold.
      • Be sure to tighten either of nuts A first as shown in the illustration.
  34. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY 
    1. Install a new O-ring to the oil dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Push in the oil dipstick guide end into the guide hole.
    4. Install the No. 1 oil dipstick guide with the bolt.

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

    5. Connect the clamp.
      Fig 23: Identifying Oil Dipstick Guide Sub-Assembly
      G04056008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the No. 2 oil dipstick guide with the bolt.

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

      Fig 24: Identifying No.2 Oil Dipstick Guide With Bolt
      G04056009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the oil dipstick.
  35. INSTALL ENGINE AND TRANSMISSION ASSEMBLY 
    1. Set the engine lifter.
    2. Operate the engine lifter, then install the engine to the vehicle.
    3. Install the engine and transmission assembly with crossmember with the 12 bolts.
      Fig 25: Identifying Engine And Transmission Assembly With Crossmember And 12 Bolts
      G04056010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      1. 167 N*m (1,700 kgf*cm, 123 ft.*lbf) for Nut 
      2. 204 N*m (2,080 kgf*cm, 150 ft.*lbf) for bolt A 
      3. 50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt B 
      4. 49 N*m (500 kgf*cm, 36 ft.*lbf) for bolt C 
    4. Install the engine rear mounting member with the 4 bolts.

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

      Fig 26: Identifying Engine Rear Mounting Member With 4 Bolts
      G04056011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (See  INSTALLATION  ) 
  37. CONNECT POWER STEERING LINK WIRE HARNESS 
    1. Install the power steering earth wire to the power steering link assembly with bolt (B).

      Torque: 13 N*m (130 kgf*cm, 10 ft.*lbf) 

    2. Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.
    3. Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.
    4. Install the 2 wire harness clamps to the power steering link assembly.
    5. Connect the earth wire to the bracket with bolt (A).

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

      Fig 27: Identifying Power Steering Link Wire Harness
      G04056012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH 
    1. Install the front lower ball joint with the 2 bolts.

      Torque: 120 N*m (1,224 kgf*cm, 89 ft.*lbf) 

      Fig 28: Identifying Lower Ball Joint To Steering Knuckle Bolts
      G04029203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH 

    HINT:

    Install the RH side following the same procedures as for the LH side.

  40. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH 
    1. Install the bolt on the lower side of the front shock absorber while holding the nut.
      Fig 29: Installing Bolt On Lower Side Of Front Shock Absorber
      G04056014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 157 N*m (1,600 kgf*cm, 116 ft.*lbf) 

  41. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT:

    Install the RH side following the same procedures as for the LH side.

  42. CONNECT HEIGHT CONTROL SENSOR LINK 
    1. Connect the height control sensor link and install it with the nut.

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

      Fig 30: Identifying Height Control Sensor Link Nut
      G04056015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (See  INSTALLATION  ) 
  44. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Install the protector with the 4 bolts.
      Fig 31: Identifying Protector With 4 Bolts
      G04056016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  45. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.

      HINT:

      • Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.
      • Check that the connector and fuel main pipe are securely connected by trying to pull them apart.
        Fig 32: Connecting Connector To Fuel Main Pipe
        G04056017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel pipe clamp.
      Fig 33: Identifying Fuel Pipe Clamp
      G04056018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. CONNECT NO. 3 FUEL HOSE 
    1. Connect the No. 3 fuel hose and clamp.
      Fig 34: Identifying No.3 Fuel Hose And Clamp
      G04056019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. CONNECT FUEL MAIN TUBE 

    HINT:

    See FUEL SYSTEM .

  48. CONNECT ENGINE WIRE 
    1. Install the bolt, clamp and engine wire No. 3.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    2. Connect the ground cable and install it with the bolt.

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

      Fig 35: Locating Bolt And Clamp
      G04056020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector and install the 4 clamps to the body.
    4. Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.

      Torque: 12 N*m (124 kgf*cm, 9 ft.*lbf) 

    5. Install the engine room No. 1 relay block cover.
    6. Connect the battery positive (+) cable and install it with the nut.

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

    7. Connect the ECM connectors.
      Fig 36: Identifying 4 Clamps
      G04056021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the connector holder.
      Fig 37: Identifying Connector Holder
      G04056022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL ECM COVER (See  INSTALLATION  ) 
  50. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (See  INSTALLATION  ) 
  51. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (See  INSTALLATION  ) 
  52. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose.
      Fig 38: Identifying Inlet Heater Water Hose
      G04056023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose.
      Fig 39: Identifying Outlet Heater Water Hose
      G04056024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. CONNECT INLET RADIATOR HOSE 
    1. Install the clamp and connect the inlet radiator hose.
  55. CONNECT OUTLET RADIATOR HOSE 
    1. Install the clamp and connect the outlet radiator hose.
  56. CONNECT RADIATOR RESERVOIR TANK HOSE 
    1. Install the clamp and connect the reservoir tank hose.
      Fig 40: Connecting Radiator Reservoir Tank Hose
      G04056025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. CONNECT NO. 2 FUEL VAPOR FEED HOSE 
    1. Install the clamp and connect the No. 2 fuel vapor feed hose.
      Fig 41: Identifying No.2 Fuel Vapor Feed Hose Installing Clamp
      G04056026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the hose to the surge tank.
  59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case, clamp and 2 bolts.

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

      Fig 42: Identifying Air Cleaner Case Sub-Assembly
      G04056027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See  INSTALLATION  ) 
  61. INSTALL NO. 1 INLET AIR CLEANER 
    1. Install the inlet air cleaner with the bolt.

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

      Fig 43: Identifying No.1 Inlet Air Cleaner
      G04056028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING 

    HINT:

    See INSTALLATION .

  63. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See INSTALLATION .

  64. ADD ENGINE OIL (See  REPLACEMENT  ) 
  65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

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

  66. ADD ENGINE COOLANT (See  COOLANT  ) 
  67. CHARGE REFRIGERANT (See  REPLACEMENT  ) 
  68. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  69. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  70. CHECK FOR ENGINE OIL LEAKS 
  71. CHECK FOR EXHAUST GAS LEAKS 
  72. CHECK FOR LEAKAGE OF REFRIGERANT (See  REPLACEMENT  ) 
  73. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  74. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  75. ADJUST SHIFT LEVER POSITION (See  ADJUSTMENT  ) 
  76. CHECK SHIFT LEVER POSITION (See  ON-VEHICLE INSPECTION  ) 
  77. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 

    HINT:

    See ADJUSTMENT .

  78. CHECK IGNITION TIMING (See  ON-VEHICLE INSPECTION   ) 
  79. CHECK ENGINE IDLE SPEED (See  ON-VEHICLE INSPECTION   ) 
  80. CHECK CO / HC (See  ON-VEHICLE INSPECTION   ) 
  81. CHECK ENGINE OIL LEVEL (See  ON-VEHICLE INSPECTION  ) 
  82. INSTALL ENGINE UNDER COVER REAR LH 
    1. Install the engine under cover rear LH with the bolt.
  83. INSTALL ENGINE UNDER COVER REAR RH 

    HINT:

    Install the RH side following the same procedures as for the LH side.

  84. INSTALL NO. 2 ENGINE UNDER COVER 
  85. INSTALL ENGINE UNDER COVER 
    Fig 44: Identifying No.2 Engine Under Cover
    G04056029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 3 clips to install the V-bank cover.
      NOTE:
      • Be sure to engage the clips securely.
      • Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
        Fig 45: Engaging 3 Clips To Installing V-Bank Cover
        G04056030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL ENGINE ROOM SIDE COVER LH 
    1. Install the side cover with the 5 clips.
      Fig 46: Identifying Side Cover With 5 Clips
      G04056031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL ENGINE ROOM SIDE COVER RH 
    1. Install the side cover with the 2 clips.
      Fig 47: Locating Clips On Engine Room Side Cover RH
      G04056032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the intake duct seal with the 11 clips.
      Fig 48: Identifying Intake Duct Seal With 11 Clips
      G04056033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
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