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Engine Assembly: Installation: Installation

  1. INSTALL ENGINE HANGER  See step  74
  2. REMOVE ENGINE STAND 
    1. Attach an engine sling device and hang the engine with a chain block.
      Fig 1: Identifying Engine, Hanger & Sling Angle Diagram
      GTY264471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Hanger
      *2 Engine
      *a 50° or less
    2. Lift the engine and remove it from the engine stand.
    3. Place the engine onto a workbench.
  3. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Connect the 2 water hoses and install the No. 1 water by-pass pipe.
      Fig 2: Identifying Water Hoses, No. 1 Water By-Pass Pipe & Clip Paint Marks
      GTY277388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Paint Mark
      *a Upper Side
      *b RH Side

      HINT: 

      • When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
      • The direction of the hose clamp is indicated in the illustration.
  4. INSTALL ENGINE ASSEMBLY 
    1. Attach an engine sling device and hang the engine with a chain block.
    2. Slowly lower the engine into the engine compartment.
    3. Install the front engine mounting insulator LH and RH with the 2 nuts and 4 bolts.

      for nut 

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

      for bolt 

      Torque: 57 N*m (581 kgf*cm, 42 ft.*lbf) 

      Fig 3: Identifying Nuts, Bolts & Front Engine Mounting Insulators (LH & RH)
      GTY256870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Bolt
      Nut
    4. Remove the 2 bolts and 2 engine hangers.
  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.
      • SST: 09213-70011 
        1. 09213-70020
      • SST: 09330-00021 
    2. Install the crankshaft angle sensor rotor.
      Fig 4: Identifying Crankshaft Angle Sensor Rotor
      GTY287705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Engine Side

      HINT: 

      • Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.
      • As the crankshaft angle sensor rotor is not reversible, be sure to install it so that it is facing in the direction shown in the illustration.
    3. Install the drive plate and ring gear and the rear drive plate spacer to the crankshaft.
      Fig 5: Identifying Drive Plate And Ring Gear With Drive Plate Spacer
      GTY281788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Drive Plate and Ring Gear
      *2 Rear Drive Plate Spacer
      Transmission Side

      HINT: 

      As the rear drive plate spacer and the drive plate and ring gear are not reversible, be sure to install them so that they are facing in the directions shown in the illustration.

    4. Install the drive plate and ring gear and bolts.

      HINT: 

      The bolts are tightened in 2 progressive steps.

      1. Clean the bolts and bolt holes.
      2. Apply adhesive to 2 or 3 threads at the end of each of the 10 bolts.
        Fig 6: View Of Applying Adhesive To Bolts
        GTY224615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        TEXT IN ILLUSTRATION

        *1 Adhesive
      3. Step 1:

        Uniformly install and tighten the 10 new bolts in several steps in the sequence shown in the illustration.

        Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

        Fig 7: Identifying Bolt Tightening Sequence
        GTY285719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Mark the top of each drive plate installation bolt with paint.
      5. Step 2:

        Tighten the drive plate installation bolts 90°.

      6. Check that the painted marks are now at a 90° angle to the top.
        NOTE:

        Do not start the engine for at least an hour after installing the drive plate.

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator is necessary.

    1. Install the rear No. 1 engine mounting insulator to the transmission with the 4 bolts.

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

    2. Install the rear engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.

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

  7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 
    1. Install the automatic transmission assembly. Refer to INSTALLATION .
  8. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT  . Refer to INSTALLATION - Step 12
  9. INSTALL PROPELLER SHAFT ASSEMBLY 
    1. Install the propeller shaft assembly. Refer to INSTALLATION .
  10. INSTALL FRONT PROPELLER SHAFT ASSEMBLY 
    1. Install the front propeller shaft assembly. Refer to INSTALLATION .
  11. CONNECT OIL COOLER TUBE SUB-ASSEMBLY 
    1. Connect the oil cooler tube with the bolt.

      Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 

  12. CONNECT ENGINE WIRE 
    1. Connect the ECM connector.
      1. Attach the grommet to the wire harness support.
        Fig 8: View Of Grommet And Wire Harness Support
        GTY272533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Grommet
        *2 Wire Harness Support
      2. Pass the wire harness into the vehicle and install the wire harness support.
      3. Connect the 6 connectors and attach the clamp.
        Fig 9: Identifying ECM Connectors Location
        GTY220053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the lower instrument panel. Refer to INSTALLATION - Step 30 .
    3. for Engine Room RH Side:
      1. Attach the 3 wire harness clamps to connect the engine wire and connect the connector.
        Fig 10: Identifying No. 2 Engine Wire Harness & Ground Wire Bolt
        GTY261172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Engine Wire
        *2 Ground Wire
      2. Connect the ground wire with the bolt.

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

    4. for Engine Room LH Side:
      1. Attach the wire harness clamp.
        Fig 11: Identifying No. 2 Engine Wire Harness & Ground Wire Bolt
        GTY273319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Engine Wire
        *2 Ground Wire
      2. Connect the No. 2 engine wire and ground wire with the 2 bolts.

        for bolt A 

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

        for bolt B 

        Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      3. Attach the 2 claws and connect the engine wire to the engine room relay block.
        Fig 12: Locating Engine Wire Connector & Engine Room Relay Block
        GTY258257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Engine Wire
        *2 Engine Room Relay Block
      4. Install the nut to the engine room relay block.

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

      5. Connect the connector.
      6. Connect the ground wire with the bolt.

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

        Fig 13: Identifying Ground Wire Bolt
        GTY274587Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT FUEL HOSE AND NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel hose and No. 2 fuel tube. Refer to PRECAUTION .
    2. Install the 2 fuel pipe clamps to the fuel tube connector.
  14. INSTALL FLYWHEEL HOUSING SIDE COVER 
  15. INSTALL STARTER ASSEMBLY  . Refer to INSTALLATION - Step 2
  16. INSTALL STARTER COVER  . Refer to INSTALLATION - Step 3
  17. INSTALL EXHAUST MANIFOLD ASSEMBLY RH  . Refer to INSTALLATION - Step 3
  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  . Refer to INSTALLATION - Step 4
  19. INSTALL EXHAUST MANIFOLD ASSEMBLY LH  . Refer to INSTALLATION - Step 5
  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  . Refer to INSTALLATION - Step 7
  21. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 6
  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE  . Refer to INSTALLATION - Step 15
  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY  . Refer to INSTALLATION - Step 10
  24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY  . Refer to INSTALLATION - Step 11
  25. INSTALL EXHAUST PIPE STOPPER BRACKET  . Refer to INSTALLATION - Step 12
  26. INSTALL COOLER COMPRESSOR ASSEMBLY  . Refer to INSTALLATION - Step 2
  27. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the suction hose.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the suction hose.
    4. Install the suction hose with the 2 bolts and nut.

      for bolt A 

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      for bolt B and nut 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 14: Identifying Suction Hose, Bolts And Nut
      GTY268166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the discharge hose.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the discharge hose.
    4. Install the discharge hose with the 3 bolts.

      for bolt A 

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

      for bolt B 

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      for bolt C 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 15: Identifying Discharge Hose, Bolts And Nut
      GTY281415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL GENERATOR ASSEMBLY  . Refer to INSTALLATION - Step 1
  30. INSTALL VANE PUMP ASSEMBLY  . Refer to INSTALLATION - Step 1
  31. CONNECT PRESSURE FEED TUBE  . Refer to INSTALLATION - Step 2
  32. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE  . Refer to INSTALLATION - Step 4
  33. INSTALL INTAKE MANIFOLD  . Refer to INSTALLATION - Step 9
  34. INSTALL AIR TUBE SUB-ASSEMBLY  . Refer to INSTALLATION - Step 10
  35. INSTALL VENTILATION HOSE ASSEMBLY  . Refer to INSTALLATION - Step 12
  36. CONNECT NO. 4 WATER BY-PASS PIPE  . Refer to INSTALLATION - Step 13
  37. INSTALL EGR VALVE BRACKET  . Refer to INSTALLATION - Step 1
  38. INSTALL EGR VALVE ASSEMBLY  . Refer to INSTALLATION - Step 4
  39. CONNECT NO. 13 WATER BY-PASS HOSE  . Refer to INSTALLATION - Step 5
  40. CONNECT NO. 12 WATER BY-PASS HOSE  . Refer to INSTALLATION - Step 6
  41. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Single Air Conditioning System) 
    Fig 16: Identifying Water Pipe And Hose Sub-Assembly (Single A/C System)
    GTY274422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *1 Paint Mark - -
    *a Upper Side *b LH Side
    *c Rear - -
    1. Install the water pipe and hose with the 2 nuts.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. Connect the 4 water hoses.

      HINT: 

      • When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
      • The direction of each hose clamp is indicated in the illustration.
  42. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Dual Air Conditioning System) 
    Fig 17: Identifying Water Pipe And Hose Sub-Assembly (Dual A/C System)
    GTY258474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *1 Paint Mark - -
    *a Upper Side *b LH Side
    *c Rear - -
    1. Install the water pipe and hose with the 2 nuts.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. Connect the 6 water hoses.

      HINT: 

      • When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
      • The direction of each hose clamp is indicated in the illustration.
  43. INSTALL RADIATOR ASSEMBLY  . Refer to INSTALLATION - Step 7
  44. CONNECT OIL COOLER ACCESSORY ASSEMBLY  . Refer to INSTALLATION - Step 8
  45. INSTALL NO. 2 RADIATOR HOSE  . Refer to INSTALLATION - Step 9
  46. INSTALL FAN SHROUD  . Refer to INSTALLATION - Step 10
  47. INSTALL NO. 1 RADIATOR HOSE  . Refer to INSTALLATION - Step 11
  48. INSTALL RADIATOR RESERVOIR ASSEMBLY  . Refer to INSTALLATION - Step 12
  49. INSTALL RADIATOR SIDE DEFLECTOR RH  . Refer to INSTALLATION - Step 13
  50. INSTALL RADIATOR SIDE DEFLECTOR LH  . Refer to INSTALLATION - Step 14
  51. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case with the 3 bolts.

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

  52. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  53. INSTALL AIR CLEANER CAP AND HOSE 
    1. Attach the 4 clamps to install the air cleaner cap and hose.
      Fig 18: Identifying Clamps To Air Cleaner Cap & Hose
      GTY254662Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Air Cleaner Hose
      *2 Throttle Body
      *3 Groove
      *4 Protrusion
      *a Upper Side
      *b Front

      HINT: 

      When installing the air cleaner hose, align its groove with the protrusion of the throttle body as shown in the illustration.

    2. Tighten the hose clamp.

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

      HINT: 

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the mass air flow meter connector, No. 1 air hose and No. 2 ventilation hose and attach the wire harness clamp.
  54. INSTALL FRONT BUMPER COVER 
    1. Install the front bumper cover. Refer to INSTALLATION - Step 15 .
  55. INSTALL BATTERY TRAY 
  56. INSTALL BATTERY 
    1. Install the battery.
    2. Install the battery hold down clamp with the 2 nuts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

    3. Install the No. 2 engine wire with the nut.

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

  57. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
    1. Install the cowl top ventilator louver sub-assembly. Refer to INSTALLATION - Step 4 .
  58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .

  59. ADD ENGINE OIL  . Refer to REPLACEMENT - Step 6
  60. ADD ENGINE COOLANT  . Refer to REPLACEMENT - Step 6
  61. ADD POWER STEERING FLUID 
  62. BLEED POWER STEERING FLUID  . Refer to ON-VEHICLE INSPECTION - Step 2
  63. INSPECT FOR OIL LEAK  . Refer to REPLACEMENT - Step 7
  64. INSPECT FOR COOLANT LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  65. INSPECT FOR FUEL LEAK  . Refer to INSTALLATION - Step 18
  66. INSPECT ENGINE OIL LEVEL  . Refer to ON-VEHICLE INSPECTION - Step 2
  67. INSPECT FOR POWER STEERING FLUID LEAK 
  68. INSPECT FOR EXHAUST GAS LEAK  . Refer to INSTALLATION - Step 17
  69. PERFORM RESET MEMORY 
    1. Perform the Reset Memory procedures. Refer to INITIALIZATION .
  70. INSPECT IGNITION TIMING  See step  1
  71. INSPECT ENGINE IDLE SPEED  See step  2
  72. INSPECT CO/HC  See step  4
  73. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood with the 8 bolts.

      for bolt A 

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

      for bolt B 

      Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) 

      Fig 19: Locating Hood Sub-Assembly
      GTY254126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the washer hose.
  74. ADJUST HOOD SUB-ASSEMBLY  . Refer to ADJUSTMENT - Step 5
  75. CHARGE REFRIGERANT  . Refer to REPLACEMENT - Step 2
  76. WARM UP ENGINE  . Refer to REPLACEMENT - Step 3
  77. CHECK FOR REFRIGERANT GAS LEAK  . Refer to REPLACEMENT - Step 4
  78. INSTALL ENGINE ROOM SIDE COVER 
    1. Install the engine room side cover with the 4 clips.
  79. INSTALL ENGINE ROOM SIDE COVER LH 
    1. Install the engine room side cover LH with the 4 clips.
  80. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Attach the 2 V-bank cover hooks to the No. 1 V-bank cover bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.
      Fig 20: Identifying V-Bank Pins & Hooks
      GTY272572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin
      *2 Grommet
      *3 Hook
      *4 No. 1 V-bank Cover Bracket
  81. INSTALL UPPER RADIATOR SUPPORT SEAL 
    1. Install the upper radiator support seal with the 13 clips.
  82. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH 
    1. Install the front No. 1 fender apron to frame seal RH with the 5 clips.
  83. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH 
    1. Install the front No. 1 fender apron to frame seal LH with the 5 clips.
  84. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 4 clips.
  85. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 7 clips.
  86. INSTALL REAR ENGINE UNDER COVER ASSEMBLY 
    1. Install the rear engine under cover with the 4 bolts.

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

  87. INSTALL TRANSMISSION UNDER COVER 
    1. Install the transmission under cover with the 2 bolts.

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

  88. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 
    1. Hook the No. 1 engine under cover to the vehicle body as shown in the illustration.
      Fig 21: Identifying No. 1 Engine Under Cover Sub-Assembly And Hook Location
      GTY228995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 bolts.

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

  89. INSTALL LOWER FRONT BUMPER COVER 
    1. Install the lower front bumper cover with the 5 bolts and clip.

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

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