Engine Assembly: Installation: Installation

Fig 1: Identifying Mounting Bracket With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the mounting bracket with the 4 bolts.

   Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf) 

   HINT: 

   The LH mounting bracket is marked with an "L".

Fig 2: Identifying Mounting Bracket With Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the mounting bracket with the 4 bolts.

   Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf) 

   HINT: 

   The RH mounting bracket is marked with an "R".

Fig 3: Identifying White Mark Of Exhaust Manifold Sub-Assembly LH

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1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
   NOTE:

   Be careful of the installation direction.

Fig 4: Locating Exhaust Manifold Sub-Assembly LH And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

   Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

1. Install the heat insulator with the 4 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

Fig 5: Identifying White Mark Of Exhaust Manifold Sub-Assembly LH

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
   NOTE:

   Be careful of the installation direction.

Fig 6: Identifying Nuts, Exhaust Manifold And Gasket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

   Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

1. Install the heat insulator with the 4 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install the 8 ignition coils with the 8 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install the engine hanger with the 2 bolts.

   Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

1. Install the engine hanger with the 2 bolts.

   Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

1. Install the 2 sensors with the 2 bolts.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install the sensor with the bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

1. Install a new O-ring to the oil control valve.
2. Install the oil control valve with the bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

3. Connect the oil control valve connector.

1. Install a new O-ring to the oil control valve.
2. Install the oil control valve with the bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

3. Connect the oil control valve connector.

Fig 7: Identifying Knock Sensor Angle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.

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

2. Connect the 2 knock sensor connectors.

1. Install a new O-ring to the water by-pass pipe.
2. Apply soapy water to the O-ring.
3. Push in the water by-pass pipe end into the pipe hole of the water pump.
4. Install the water by-pass pipe with the bolt.

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

5. Install the wire clamp to the bracket of the water by-pass pipe.

Fig 8: Identifying Gaskets And Water By-Pass Joint With 4 Nuts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

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

Fig 9: Identifying Front Water Bypass Joint Bolts And Nuts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

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

2. Connect the ECT sensor connector.

Fig 10: Identifying White Mark Of Intake Manifold

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
   NOTE:

   Be careful of the installation direction.

Fig 11: Identifying Intake Manifold Assembly Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the intake manifold assembly with the 6 bolts and 4 nuts.

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

3. Connect the 8 injector connectors.
Fig 12: Identifying Engine Wire Protector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the engine wire protector (rear side) with the 2 bolts.
5. Install the engine wire protector (LH side) with the 4 bolts.
6. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
Fig 13: Identifying ACIS VSV Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the No. 4 V-bank cover with the bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

8. Install the No. 1 V-bank cover bracket with the bolt.

   Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

9. Connect the VSV connector for ACIS.
Fig 14: Identifying Purge VSV Connector Bolts Location
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the No. 3 V-bank cover bracket with the bolt.

    Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

11. Install the No. 2 V-bank cover bracket with the bolt.

    Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

12. Install the purge VSV to the intake manifold with the bolt.

    Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

13. Connect the purge hose to the purge VSV.
14. Connect the purge VSV connector.

1. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.

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

2. Connect the water by-pass hoses.

HINT: 

If any one of the mounting bolts is broken or deformed, replace it.

Fig 15: Applying Adhesive To 2 Or 3 Threads Of Mounting Bolt End
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Fig 16: Identifying Mounting Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front spacer, drive plate and rear spacer on the crankshaft.
3. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.

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

   If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.

Fig 17: Marking Mounting Bolts With Paint
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the mounting bolt with paint.
5. Retighten the mounting bolt by 90° in the numerical order shown.
6. Check that the painted mark is now at a 90° angle.

Fig 18: Identifying Automatic Transmission Assembly To Engine
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Check the torque converter clutch installation. Refer to INSTALLATION - Step 2 .
2. Install the automatic transmission to the engine with the 9 bolts.

   Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

   for bolt A

   Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

   for bolt B

   HINT: 

   • Make sure that the mark is positioned as shown in the illustration.
   • Bolt head size:

     14 mm for bolt A

     17 mm for bolt B

   • Bolt (B) will be tightened with the wire harness clamp.
3. Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch mounting bolts.

   Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) 

   HINT: 

   First install the black colored bolt and then the remaining 5 bolts.

Fig 19: Locating Flywheel Housing Under Cover Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the flywheel housing under cover with the 2 bolts.

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

1. Temporarily install the oil cooler outlet tube.
2. Temporarily install the oil cooler inlet tube.
3. Install the 3 clamps with the 3 bolts.

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

   Fig 20: Identifying Shift Lock Control Unit Assembly Connector Terminals

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Fig 21: Locating Oil Cooler Outlet Tube Union Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a union nut wrench, tighten the oil cooler outlet tube.

   Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

   for use without union nut wrench

   Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

   for use with union nut wrench

   HINT: 

   • Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
   • Make sure a union nut wrench and a wrench are connected in a straight line.
Fig 22: Locating Oil Cooler Outlet Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a union nut wrench, tighten the oil cooler inlet tube.

   Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) 

   for use without union nut wrench

   Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

   for use with union nut wrench

   HINT: 

   • Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
   • Make sure a union nut wrench and a wrench are connected in a straight line.

1. Connect the 2 speed sensor connectors.
2. Connect the transmission wire connector.
3. Connect the park/neutral position switch connector.
Fig 23: Locating Wire Harness Clamps And Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the wire harness clamps with the 5 bolts.

   Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

   for bolt A

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

   for bolt B

   HINT: 

   Bolt (A) is tightened to the transmission housing.

1. Connect the engine wire to the transmission.
   1. Connect the VSV connector.
   2. Connect the engine wire to the 3 wire clamps.
   3. Connect the oil level sensor connector.

Fig 24: Attaching Engine Chain Hoist To Engine Hangers

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Attach the engine chain hoist to the engine hangers.
2. Slowly lower the engine and transmission assembly into the engine compartment.
3. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
Fig 25: Attaching Engine Chain Hoist To Engine Hangers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Keep the engine level.
Fig 26: Identifying Engine Rear Mounting Member With Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:

Be careful of installation direction.

5. Install the engine rear mounting member with the 4 bolts and 4 nuts.

   Torque: 25.5 N*m (260 kgf*cm, 19 ft.*lbf) 

   for bolts

   Torque: 13.5 N*m (137 kgf*cm, 10 ft.*lbf) 

   for nuts

Fig 27: Identifying Engine Mounting Insulator Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.

   Torque: 68 N*m (693 kgf*cm, 50 ft.*lbf) 

7. Install the 2 hole plugs.
8. Remove the engine chain hoist.
9. Install the No. 1 V-bank cover bracket to the No. 2 engine hanger with the nut.

Fig 28: Identifying Power Steering Gear Housing Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the sliding yoke to the PS gear housing and intermediate shaft.
2. Install the PS gear housing with the 4 bolts.

   Torque: 65 N*m (662 kgf*cm, 48 ft.*lbf) 

3. Install the 2 PS oil tube with the bolt.

Fig 29: Identifying Sliding Yoke Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Tighten the 2 bolts for sliding yoke.

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

Fig 30: Locating Floor Shift Gear Shifting Rod Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the floor shift gear shifting rod with the nut.

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

Fig 31: Identifying Parking Brake Cable Heat Insulator Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the insulator with the 4 bolts.

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

Fig 32: Identifying No. 1 Front Floor Heat Insulator Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the insulator with the 4 bolts.

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

Fig 33: Identifying Bolts, Nuts And Front Suspension Member Brace
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install 2 new gaskets and 2 converters with 6 new nuts.

   Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf) 

Fig 34: Identifying No. 1 Exhaust Pipe Support Bracket Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the bracket with the 2 bolts.

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

1. Install the front suspension member brace with the 2 nuts and 4 bolts.

   Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

   for bolt

   Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

   for nut

Fig 35: Identifying Nuts, Bolts, Rings, Exhaust Pipe And Gaskets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install a new 2 gaskets and the exhaust pipe with the 4 nuts, 4 bolts and 2 rings.

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

Fig 36: Identifying Nuts, Bolts, Exhaust Pipe And Gaskets
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install 3 new gaskets and the exhaust pipe with the 6 nuts and 6 bolts.

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

Fig 37: Identifying Brace Center Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the floor brace with the 4 bolts.

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

Fig 38: Identifying Cooler Compressor Assembly Bolts And Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.

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

   for bolts

   Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

   for nut

2. Connect the compressor connector.
3. Install the wire clamp.

Fig 39: Identifying Vane Pump Bolts And Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the vane pump with the 2 bolts and nut. Alternately tighten the bolts and nut.

   Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf) 

   for bolts

   Torque: 43.1 N*m (439 kgf*cm, 32 ft.*lbf) 

   for nut

2. Connect the PS oil pressure switch connector.
3. Install the RH engine under cover with the 2 screws.
4. Connect the 2 PS air hoses to the vane pump.

1. Connect the engine wire from the ECM box.
2. Install the nut, and connect the generator wire to the generator.
3. Connect the wire for generator wire to the wire clamp on generator.
4. Connect the ground cable to the stay on generator with the bolt.
5. Connect the PS oil hose to the No. 1 oil pan with the 2 bolts.
6. Connect the ground strap to the body with the 2 bolts.

Fig 40: Installing Fuel Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Using a union nut wrench, install the fuel pipe.

   Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

   for use with union nut wrench

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

   for use without union nut wrench

   HINT: 

   • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   • Make sure a union nut wrench and a wrench are connected in a straight line.

Fig 41: Locating ECM Box Cover With Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the cover with the 3 bolts.

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

Fig 42: Identifying Air Cleaner Assembly Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the air cleaner assembly with the 3 bolts.

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

2. Connect the MAF meter connector and clamp to the air cleaner.

Fig 43: Locating Connector Pipe With Bolt And Hose Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install the connector pipe with the bolt and hose clamp.

   Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf) 

   for hose clamp

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

   for bolt

Fig 44: Locating Air Hose And No. 1 Ventilation Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the air hose and No. 1 ventilation hose.

1. Install the V-bank cover with the 2 nuts.

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

   NOTE:

   Make sure that the wire harness does not get caught between parts.

1. Temporarily tighten the 4 bolts.