ENGINE INSTALLATION

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

INSTALL IGNITION COIL

Perform a visual inspection on the spark plug tube gasket.

Standard

Inspection Area	Inspection Result
Upper surface	No scratches or deformation
Outer lip	No scratches or deformation
Inner lip	No scratches

Set each spark plug tube gasket on each ignition coil assembly.
After installing each spark plug tube gasket, securely insert each ignition coil assembly.
Install the 8 bolts.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }
Connect the 8 ignition coil ignition coil assembly connectors.

INSTALL KNOCK SENSOR
1. Install the 4 knock sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  The acceptable installation angle of the knock control sensors is between 10° upwards and downwards from the horizontal position.
2. Connect the 4 knock sensor connectors.
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
1. Install a new gasket to the engine coolant temperature sensor.
2. Install the engine coolant temperature sensor.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Connect the engine coolant temperature sensor connector.
INSTALL ENGINE OIL LEVEL SENSOR
1. Install a new gasket to the engine oil level sensor.
2. Insert the engine oil level sensor into the oil pan and rotate it 180°.
3. Install the engine oil level sensor with the 4 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
4. Connect the engine oil level sensor connector.
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Apply adhesive to 2 or 3 threads of the switch.
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
2. Using a 24 mm deep socket wrench, install the switch.
  
  Torque:
  
  15 N*m { 153 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Do not start the engine within 1 hour after installation.
3. Connect the switch connector.
INSTALL WATER INLET HOUSING
1. Install a new gasket to the water pump.
2. Install the water inlet housing with the 3 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL WATER PUMP PULLEY
1. Temporarily install the pulley with the 4 bolts.
2. Using SST, hold the pulley and tighten the 4 bolts.
  
  SST
  
  09960-10010 ( 09962-01000, 09963-01000 )
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
1. Install the bolt and No. 1 idler pulley sub-assembly.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  Tech Tips
  
  Install the No. 1 idler pulley sub-assembly in the direction shown in the illustration.
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the bolt and No. 2 idler pulley sub-assembly.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY
1. Install the No. 4 engine cover sub-assembly.
INSTALL ENGINE WIRE
1. Install the engine wire with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 4 knock sensor connectors.
INSTALL SEPARATOR CASE
1. Install the separator case with the 4 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL FUEL INJECTOR ASSEMBLY
1. Apply gasoline to a new O-ring and install it to the injector.
  
  Note
  
  Check that there is no damage or foreign material in the groove of the injector when installing the injector's O-ring.
2. Connect the connector to the injector.
3. Install the injector to the delivery pipe as shown in the illustration.
  Note
  
  Make sure that there are no scratches or foreign matter in or around the insertion hole of the delivery pipe.
  
  When inserting the injector, be careful not to damage the O-ring.
  
  Attach the part of the injector labeled B between the parts of the delivery pipe labeled A.
INSTALL FUEL DELIVERY PIPE
1. Connect the 4 wire harness clamps.
2. Install the 4 delivery pipe spacers and 8 insulators to the intake manifold.
3. Install the 2 delivery pipes (with injector) to the intake manifold.
4. Install the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Check that the part of the injector labeled B is between the parts of the delivery pipe labeled A.
5. Connect the 2 connectors.
INSTALL FUEL TUBE SUB-ASSEMBLY
1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
2. Push down on the retainer to lock it in place.
  Note
  - Check that there is no damage or foreign objects on the connected part of the fuel pipe.
  - After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH
INSTALL NO. 3 ENGINE COVER
INSTALL INTAKE MANIFOLD
1. Install 2 new gaskets to the intake manifold.
2. Temporarily install the intake manifold with the 2 nuts and 8 bolts. Then tighten the 2 nuts and 8 bolts uniformly in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Connect the No.1 ventilation hose to the intake manifold.
  
  Note
  
  Face the claws of the clips as shown in the illustration.
INSTALL THROTTLE BODY ASSEMBLY
1. Install a new gasket to the intake manifold.
2. Connect the No. 4 water by-pass hose and No. 5 water by-pass hose to the throttle body.
  
  Note
  
  Position the claws of the clamps as shown in the illustration.
3. Install the throttle body with the 4 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Connect the throttle motor connector.
INSTALL VENTILATION HOSE
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install the water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.
2. Connect the heater water inlet hose, heater water outlet hose, water inlet hose, and No. 3 water by-pass hose to the water by-pass pipe sub-assembly with the 4 clamps.
  
  Note
  
  Face the No. 3 water by-pass hose clip as shown in the illustration.
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
1. Install the front No. 1 engine mounting bracket RH with the 6 bolts.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
1. Install the front No. 1 engine mounting bracket LH with the 6 bolts.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL ENGINE MOUNTING DAMPER
1. Install the 2 engine mounting dampers with the 2 nuts.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
INSTALL GENERATOR ASSEMBLY
1. Using an E8 "TORX" socket wrench, set the generator with the 2 stud bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install the generator with the 2 bolts and 2 nuts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
3. Connect the generator connector.
4. Connect the harness to the +B terminal with the nut.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL FRONT ENGINE MOUNTING INSULATOR

Tech Tips

Perform this procedure only when replacement of the front engine mounting insulator is necessary.
1. Install the 2 front engine mounting insulators with the 2 nuts.
  
  Torque:
  
  70 N*m { 714 kgf*cm, 52 ft.*lbf }
INSTALL ENGINE MOUNTING SPACER
1. Install the 2 engine mounting spacers to the engine mounting insulator.
INSTALL NO. 1 ENGINE HANGER
1. Install the 2 No. 1 engine hangers with the 2 bolts as shown in the illustration.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  Tech Tips
  
  No. 1 engine hanger 12281-38150
  
  Bolt 90129-14120
2. Attach an engine sling device and hang the engine with a chain block.
  
  Note
  
  When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.
REMOVE ENGINE STAND
1. Lift the engine and remove it from the engine stand.
  
  Note
  
  With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
2. Place the engine onto a work bench.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Install the front suspension crossmember sub-assembly with the 2 nuts.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
1. Using SST, hold the crankshaft.
  
  SST
  
  09213-54015 ( 90119-08216 )
  
  09330-00021
2. Install the crankshaft angle sensor rotor.
  Tech Tips
  
  Align the pin of the crankshaft with the pin hole of the crankshaft angle sensor rotor.
  
  As the crankshaft angle sensor rotor are not reversible, be sure to install it in the direction shown in the illustration.
3. Install the drive plate and ring gear sub-assembly and spacer plate on to the crankshaft.
  
  Tech Tips
  
  As the drive plate and ring gear sub-assembly and spacer plate are not reversible, be sure to install it in the direction shown in the illustration.
4. Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  Note
  
  Do not reuse the drive plate installation bolts.
  
  Do not impact or damage the drive plate installation bolts. Be sure to handle them carefully.
5. Mark the upside of each drive plate installation bolt with paint.
6. Retighten the drive plate installation bolts by 90°.
7. Check that the painted marks are now at a 90° angle to the upside.

Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

Text in Illustration
*1	Crankshaft
*2	Torque Converter Centerpiece

Apply clutch spline grease to the circumference of the crankshaft contact surface with the torque converter centerpiece.

Clutch spline grease
Toyota Genuine Clutch Spline Grease or equivalent
Maximum spread
About 1 g (0.0353 oz.)

Confirm that 2 knock pins are on the transmission contact surface of the engine block before transmission installation.

Torque:

for Bolt A (17 mm head bolt)

71 N*m { 724 kgf*cm, 52 ft.*lbf }

for Bolt B (14 mm head bolt)

37 N*m { 377 kgf*cm, 27 ft.*lbf }
Note
- Make sure that the mark is positioned as shown in the illustration.
- Do not use excess force to pry on the automatic transmission assembly.

INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT
1. Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.
  
  Torque:
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
  
  Note
  
  First install the black colored bolt, and then the remaining 5 silver colored bolts.
INSTALL STARTER ASSEMBLY
1. Connect the starter connector.
2. Connect the starter wire with the 2 nuts.
  
  Torque:
  
  for nut A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  for nut B
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
3. Close the terminal cap.
4. Install the starter assembly with the 2 bolts.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
  
  Note
  
  Make sure the flywheel housing side cover is as shown in the illustration.
INSTALL ENGINE WIRE
1. Install the engine wire with the 4 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the clamp and 2 clamp brackets with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the intake air control valve actuator connector.
4. Connect the No. 1 vacuum switching valve connector.
5. Connect the throttle body connectors.
6. for Engine RH Side:
  1. Connect the 2 clamps and install the 3 clamp brackets with the 3 bolts.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  2. Connect the engine oil level sensor connector.
  3. Connect the crankshaft position sensor connector.
  4. Connect the starter connector and starter wire with the nut.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  5. Connect the generator connector and generator wire with the nut.
    
    Torque:
    
    12 N*m { 122 kgf*cm, 9 ft.*lbf }
  6. Connect the camshaft position sensor connector.
  7. Connect the engine wire connector.
  8. Connect the 2 camshaft timing control motor connectors. (for Bank 2)
  9. Connect the 2 VVT sensor connectors.
  10. Connect the 4 ignition coil connectors.
  11. Connect the camshaft timing control valve connector.
7. for Engine LH Side:
  1. Install the clamp bracket with the bolt.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  2. Connect the 3 clamps and 3 ground wires with the 3 bolts.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  3. Connect the 2 camshaft timing control motor connectors. (for Bank 1)
  4. Connect the oil pressure switch connector.
  5. Connect the engine coolant temperature sensor connector.
  6. Connect the clamp and install the 2 clamp brackets with the 2 bolts.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  7. Connect the No. 8 engine wire connector.
  8. Connect the 2 VVT sensor connectors.
  9. Connect the 4 ignition coil connectors.
  10. Connect the camshaft timing control valve connector.
INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 3 exhaust manifold heat insulator with the 3 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL OIL COOLER TUBE
1. Temporarily install the oil cooler tube inlet and oil cooler tube outlet.
2. Install the 2 clamps with the 2 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
3. Using a union nut wrench, tighten the union nuts of the oil cooler tube inlet and oil cooler tube outlet.
  
  Torque:
  
  44 N*m { 450 kgf*cm, 33 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 2)
1. Install a new gasket as shown in the illustration.
  
  Text in Illustration
  
  Front
2. Install the exhaust manifold to the cylinder head with the new 8 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Text in Illustration
  
  Front
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 3 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the sensor connector.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the new O-ring to the engine oil level dipstick guide.
3. Install the engine oil level dipstick guide with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Install the engine oil level dipstick.
INSTALL ENGINE AND TRANSMISSION
1. Place the engine on an engine lifter.
  Note
  - Place wooden blocks or plate lift attachments so that the engine is level.
  - With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
  - Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
2. Remove the 2 bolts and 2 engine hangers.
3. Operate the engine lifter, then install the engine to the vehicle.
  
  Note
  
  Make sure that the engine is clear of all wiring and hoses.
4. Align the crossmember to the marks on the vehicle, and temporarily install the engine and transmission with crossmember with the 4 bolts.
  
  Note
  
  Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.
5. Tighten the 4 bolts.
  
  Torque:
  
  165 N*m { 1683 kgf*cm, 122 ft.*lbf }
6. Install the 6 engine rear mounting member's bolts.
  
  Torque:
  
  35 N*m { 354 kgf*cm, 26 ft.*lbf }
CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
1. Temporarily connect the floor shift gear sifting rod sub-assembly to the connecting rod swivel with the nut.
  
  Tech Tips
  
  The nut will be tightened to a torque specification during the shift lever position adjustment procedure.
CONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY

Click here
CONNECT COOLER COMPRESSOR ASSEMBLY
1. Connect the cooler compressor assembly with the 2 stud bolts, 2 nuts and 2 bolts.
  
  Torque:
  
  for stud bolts
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  for nuts
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  for bolts
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)
1. Install a new gasket as shown in the illustration.
  
  Text in Illustration
  
  Front
2. Install the exhaust manifold to the cylinder head with the new 8 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Text in Illustration
  
  Front
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the heat insulator with the 3 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the sensor connector.
INSTALL POWER STEERING LINK ASSEMBLY (w/ VGRS)
1. Install the power steering link and rack housing bracket to the front frame with the 4 bolts and 4 nuts.
  
  Torque:
  
  70 N*m { 714 kgf*cm, 52 ft.*lbf }
  
  Text in Illustration
  
  *A for LHD *B for RHD
2. for LHD:
  
  Connect the 5 connectors and attach the 3 clips.
3. for RHD:
  
  Connect the 5 connectors and attach the 5 clips.
INSTALL POWER STEERING LINK ASSEMBLY (w/o VGRS)
1. Install the power steering link and rack housing bracket to the front frame with the 4 bolts and 4 nuts.
  
  Torque:
  
  70 N*m { 714 kgf*cm, 52 ft.*lbf }
  
  Text in Illustration
  
  *A for LHD *B for RHD
2. for LHD:
  
  Connect the 3 connectors and attach the 3 clips.
3. for RHD:
  
  Connect the 3 connectors and attach the 2 clips.
INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
1. Install the clamp to the steering column hole shield.
2. Text in Illustration
  
  *a Matchmark
  
  Align the matchmarks on the No. 2 steering intermediate shaft and steering column.
3. Install the bolt.
  
  Torque:
  
  35 N*m { 360 kgf*cm, 26 ft.*lbf }
INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS)
1. Text in Illustration
  
  *a Matchmark
  
  Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering sliding with shaft yoke.
2. Align the matchmarks on the steering sliding with shaft yoke and power steering link.
3. Temporarily install bolt B.
  
  Note
  
  Do not tighten the bolt.
4. Text in Illustration
  
  *a Front of the vehicle
  
  Install bolt A and tighten bolt B.
  
  Torque:
  
  35 N*m { 360 kgf*cm, 26 ft.*lbf }
INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)
1. Text in Illustration
  
  *a Matchmark
  
  Align the matchmarks on the No. 2 steering intermediate shaft and steering sliding with shaft yoke.
2. Align the matchmarks on the steering sliding with shaft yoke and steering intermediate shaft.
3. Temporarily install bolt B.
  
  Note
  
  Do not tighten the bolt.
4. Text in Illustration
  
  *a Front of the vehicle
  
  Install bolt A and tighten bolt B.
  
  Torque:
  
  35 N*m { 360 kgf*cm, 26 ft.*lbf }
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
1. Install the front suspension member reinforcement LH to the vehicle with the 4 bolts.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

Tech Tips

Install the RH side following the same procedures as the LH side.
INSTALL FRONT STABILIZER BAR

Click here
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here
CONNECT HOSES AND CONNECTORS
1. Connect the purge line hose.
2. Connect the 2 heater hoses.
3. Connect the wires with No. 1 engine room junction block with the 2 nuts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
4. Connect the ground wire with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
5. Connect the 3 connectors with front controller with the clamp.
6. Attach the clamp and connect the cooler compressor connector.
7. Connect the 3 TCM connectors and 4 ECM connectors.
8. Install the ECM box cover (upper).
CONNECT NO. 3 FUEL HOSE
1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.
2. Install the fuel pipe clamp.
  Note
  - Check that there is no damage or foreign objects on the connected part of the fuel pipe.
  - After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
INSTALL ENGINE ROOM ECU OUTLET DUCT
1. Install the engine room ECU outlet duct.
CONNECT NO. 2 RADIATOR HOSE
CONNECT NO. 1 RADIATOR HOSE
INSTALL AIR CLEANER ASSEMBLY RH
1. Install the air cleaner case RH with the 2 nuts and clip.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Install the air cleaner element to the air cleaner case RH.
3. Install the air cleaner cap RH with the 2 clamps.
4. Connect the mass air flow meter connector.
INSTALL AIR CLEANER ASSEMBLY LH
1. Install the air cleaner case LH with the 2 nuts and clip.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Install the air cleaner element to the air cleaner case LH.
3. Install the air cleaner cap LH with the 2 clamps.
4. Connect the mass air flow meter connector.
INSTALL V-RIBBED BELT
1. Install the V belt as shown in the illustration.
  
  Note
  
  Check that the drive belt is properly set to each pulley.
  1. Rotate the tensioner pulley counterclockwise, and then remove the fix bar.
INSTALL INTAKE AIR CONNECTOR PIPE
1. Align the protrusion of the intake air resonator with the cutout of the bracket and insert the protrusion.
2. Install the intake air connector pipe with the 3 hose clamps.
  
  Torque:
  
  for intake air connector pipe and throttle body
  
  4.8 N*m { 49 kgf*cm, 42 in.*lbf }
  
  for intake air connector pipe and air cleaner cap
  
  3.8 N*m { 39 kgf*cm, 34 in.*lbf }
  Tech Tips
  - Insert the protrusion of the intake air connector pipe into the hole of the hose clamp.
  - The intake air connector pipe and throttle body clamp can be tightened within the range of 4.0 N*m (41 kgf*cm, 35 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf), and the intake air connector pipe and air cleaner cap clamp can be tightened within the range of 2.0 N*m (20 kgf*cm, 18 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf).
3. Attach the 2 wire harness clamps.
4. Connect the No. 1 and No. 2 ventilation hoses to the intake air connector pipe.
  Tech Tips
  
  Position the claws of the clamps as shown in the illustration.
  
  Install the clamps so that they are within the hose's paint marks.
INSTALL NO. 1 AIR CLEANER INLET
1. Align the holes with the connection areas labeled A, and attach the No. 1 air cleaner inlet.
2. Install the No. 1 air cleaner inlet with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL REAR FRAME SIDE RAIL
1. Install the 2 rear frame side rails with the 6 bolts and 4 nuts.
  
  Torque:
  
  for bolt A
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  for nut B
  
  44 N*m { 453 kgf*cm, 33 ft.*lbf }
INSTALL FRONT SUSPENSION LOWER CROSSMEMBER
1. Install the front suspension lower crossmember with the 4 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
2. Install the 2 clips.
INSTALL FRONT BUMPER COVER

Click here
CONNECT NO. 1 OIL COOLER OUTLET HOSE
1. Connect the No. 1 oil cooler outlet hose to the radiator.
CONNECT NO. 1 OIL COOLER INLET HOSE
1. Connect the No. 1 oil cooler inlet hose to the radiator.

Text in Illustration
	Front

Text in Illustration
	Front

Text in Illustration
	Front

Text in Illustration
	Front

Text in Illustration
*A	for LHD	*B	for RHD

Text in Illustration
*A	for LHD	*B	for RHD

Text in Illustration
*a	Matchmark

Text in Illustration
*a	Matchmark

Text in Illustration
*a	Front of the vehicle

Text in Illustration
*a	Matchmark

Text in Illustration
*a	Front of the vehicle

ADD ENGINE OIL

Add fresh oil.

Standard engine oil

Oil grade

Oil Viscosity (SAE)

API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil

0W-20

5W-20

5W-30

10W-30

API grade SL, SM or SN multigrade engine oil

15W-40

20W-50

Standard capacity

Item	Specified Condition
Drain and refill without oil filter change	8.4 liters (8.9 US qts, 7.4 Imp. qts)
Drain and refill with oil filter change	8.6 liters (9.1 US qts, 7.6 Imp. qts)
Dry fill	10.2 liters (10.8 US qts, 9.0 Imp. qts)

Install the oil filler cap.
Close the oil filler cap service hole cover.

ADD ENGINE COOLANT
Total capacity

11.8 liters (12.5 US qts, 10.4 Imp. qts)

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot coolant and steam may be released and cause serious burns.

Note

Before adding coolant, turn the A/C switch off.
1. Tighten the radiator drain cock plug.
2. Tighten the 2 cylinder block drain cock plugs.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
3. Add TOYOTA Super Long Life Coolant (SLLC) into the radiator reservoir.
  
  Capacity
  
  Approximately 5.0 liters (5.3 US qts, 4.4 Imp. qts)
  Tech Tips
  - TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
  - Please contact any authorized Toyota dealer, or repairer or another duly qualified and equipped professional for further details.
  - The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the coolant starts to flow inside the hose.
4. Further add coolant into the radiator reservoir until it reaches the FULL line.
5. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level.
  
  If the coolant level is low, add coolant.
6. Using a 6 mm hexagon wrench, install the vent plug.
  
  Torque:
  
  1.5 N*m { 15 kgf*cm, 13 in.*lbf }
7. Bleed air from the cooling system.
  
  Note
  
  Before starting the engine to warm up the engine, turn the A/C switch off.
  1. While idling the engine for approximately 10 minutes, make sure the coolant remains at the FULL line by adding coolant as necessary.
  2. After idling the engine for 10 minutes, add coolant until it reaches the B line.
    
    Capacity
    
    Approximately 2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp. qts)
    
    Text in Illustration
    
    B Line
    
    Tech Tips
    
    The B line is the lower edge of the inner wall of the filler neck.
  3. Close the radiator reservoir cap, and run the engine at 1500 to 2000 rpm for 5 minutes.
    
    CAUTION:
    
    Wear protective gloves.
    
    Be careful as the radiator hose are hot.
    
    Keep your hands away from the radiator fans.
    
    Tech Tips
    
    The thermostat open timing can be confirmed by pressing the No. 1 radiator hose by hand, and checking when the SLLC starts to flow inside the hose.
8. Stop the engine and wait until the coolant cools down to ambient temperature.
9. Check the coolant level.
  
  If the coolant level is below the FULL line, add coolant until it reaches the FULL line.
ADD AUTOMATIC TRANSMISSION FLUID

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the area that was worked on.
INSPECT FOR COOLANT LEAK

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Note

Before each inspection, turn the A/C switch OFF.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.
INSPECT FOR FUEL LEAK
1. Connect the intelligent tester to the DLC3.
2. Turn the engine switch on (IG).
  
  Note
  
  Do not start the engine.
3. Turn the intelligent tester on.
4. Select the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.
5. Check the fuel pump operation.
  1. Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard.
    
    If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.
6. Check for fuel leaks.
  1. Check that there are no fuel leaks anywhere on the system after performing maintenance.
    
    If there is a fuel leak, repair or replace parts as necessary.
INSPECT FOR EXHAUST GAS LEAK
1. If gas is leaking, tighten the areas necessary to stop the leak. Replace the damaged parts as necessary.
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
CHECK AND ADJUST FRONT WHEEL ALIGNMENT

Click here
CHECK SHIFT LEVER POSITION

Click here
INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
1. Install the front suspension member protector lower with the 8 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the 8 bolts.
  
  Torque:
  
  for Bolt A
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  for Bolt B
  
  27 N*m { 275 kgf*cm, 20 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER
1. Install the No. 1 engine under cover with the 13 screws and 7 clips.
CHECK IGNITION TIMING
1. Warm up and stop the engine.
  
  Tech Tips
  
  A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
2. When using the intelligent tester:
  1. Connect the intelligent tester to the DLC3.
  2. Start the engine and idle it.
  3. Push the intelligent tester main switch on.
  4. Enter the following items: Powertrain / Engine and ECT / Data List / Primary / IGN Advance /
    
    Standard ignition timing
    
    8 to 18° BTDC @ idle
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further details.
3. When not using the intelligent tester:
  1. Remove the V-bank cover.
  2. Remove the 5 clips and air cleaner inlet cover.
  3. Remove the 5 clips and engine room side cover LH.
  4. Remove the 2 bolts and No. 1 air cleaner inlet.
  5. Disconnect the air cleaner cap LH.
  6. Remove the 2 nuts and air cleaner case LH.
  7. Connect the tester probe of a timing light to the wire of the ignition connector for No. 1 cylinder.
    
    Note
    
    Use a timing light that detects primary signals.
  8. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
    
    SST
    
    09843-18040
    
    Note
    
    Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
    
    When checking the ignition timing, the transmission should be in neutral.
  9. Using a timing light, check the ignition timing.
    
    Standard ignition timing
    
    8 to 12° BTDC @ idle
  10. Remove SST from the DLC3.
  11. Check the ignition timing.
    
    Standard ignition timing
    
    8 to 18° BTDC @ idle
  12. Check that the ignition timing advances immediately when the engine speed is increased.
  13. Disconnect the timing light from the engine.
  14. Install the air cleaner case LH with the 2 nuts.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  15. Connect the air cleaner cap LH.
  16. Install the No. 1 air cleaner inlet with the 2 bolts.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  17. Install the engine room side cover LH with the 5 clips.
  18. Install the air cleaner inlet cover with the 5 clips.
  19. Install the V-bank cover.
CHECK IDLE SPEED
1. Warm up and stop the engine.
  
  Tech Tips
  
  A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
2. When using the intelligent tester:
  1. Connect the intelligent tester to the DLC3.
    
    Note
    
    Switch off all accessories and the A/C before connecting the intelligent tester.
  2. Race the engine speed at 2500 rpm for approximately 90 seconds.
  3. Push the intelligent tester main switch on.
  4. Enter the following items: Powertrain / Engine and ECT / Data List / Primary / Engine Speed /
    
    Standard idle speed
    
    700 to 800 rpm
    
    Note
    
    When checking the idle speed, the transmission should be in neutral.
    
    Tech Tips
    
    Refer to the intelligent tester operator's manual for further details.
    
    If the idle speed is not as specified, check the air intake system.
  5. Disconnect the intelligent tester from the DLC3.
3. When not using the intelligent tester:
  1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.
    
    SST
    
    09843-18030
    
    Note
    
    Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
  2. Race the engine speed at 2500 rpm for approximately 90 seconds.
  3. Check the idle speed.
    
    Idle speed (Transmission neutral position)
    
    700 to 800 rpm
    
    If the speed is not as specified, check the air intake system.
  4. Disconnect the tachometer from the DLC3.

Total capacity
11.8 liters (12.5 US qts, 10.4 Imp. qts)

Capacity
Approximately 5.0 liters (5.3 US qts, 4.4 Imp. qts)

Capacity
Approximately 2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp. qts)

Text in Illustration
	B Line

Standard ignition timing
8 to 18° BTDC @ idle

Standard ignition timing
8 to 12° BTDC @ idle

Standard ignition timing
8 to 18° BTDC @ idle

Standard idle speed
700 to 800 rpm

Idle speed (Transmission neutral position)
700 to 800 rpm

CHECK CO/HC

Tech Tips

This check determines whether or not the idle CO/HC complies with regulations.

Start the engine.
Keep the engine speed at 2500 rpm for approximately 180 seconds.
Insert the CO/HC meter testing probe at least 40 cm (1.31 ft) into the tailpipe during idling.

Immediately check CO/HC concentration at idle and 2500 rpm.

Tech Tips

When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

Check the heated oxygen sensor (for Sensor 1) Click here and heated oxygen sensor (for Sensor 2) Click here operation.

See the table below for possible causes, then inspect and correct the applicable causes if necessary.

CO	HC	Symptom	Causes
Normal	High	Rough idle	1. Faulty ignitions Incorrect timing Plugs are contaminated, shorted, or gaps are defective. 2. Leaky intake and exhaust valves 3. Leaky cylinder
Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks PCV hose Intake manifold Throttle body 2. Lean mixture causing misfire
High	High	Rough idle (Black smoke from exhaust)	1. Restricted air filter 2. Faulty SFI system Faulty pressure Defective engine coolant temperature sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty mass air flow meter

Symptom

Causes

Normal

High

Rough idle

1. Faulty ignitions

Incorrect timing
Plugs are contaminated, shorted, or gaps are defective.

2. Leaky intake and exhaust valves
3. Leaky cylinder

Low

High

Rough idle

(Fluctuating HC reading)

1. Vacuum leaks

PCV hose
Intake manifold
Throttle body

2. Lean mixture causing misfire

High

Rough idle

(Black smoke from exhaust)

1. Restricted air filter
2. Faulty SFI system

Faulty pressure
Defective engine coolant temperature sensor
Faulty ECM
Faulty injector
Faulty throttle position sensor
Faulty mass air flow meter

CHECK ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low level mark and full level mark.
  
  If low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.
  Tech Tips
  
  A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.
  - When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
  - If low quality oil or oil of an inappropriate viscosity is used.
  - When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.
  - When leaving the idling for a long time, or when driving frequently through heavy traffic.
  When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.
INSTALL ENGINE ROOM SIDE COVER RH
1. Install the engine room side cover RH with the 5 clips.
INSTALL ENGINE ROOM SIDE COVER LH
1. Install the engine room side cover LH with the 5 clips.
INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY
1. Attach the 4 clips B.
  Note
  - Make sure the clips are attached securely.
  - Attaching the clips forcefully or hitting the top of the clips may damage them.
2. Install the air cleaner inlet cover sub-assembly with the 5 clips labeled A.
INSTALL V-BANK COVER SUB-ASSEMBLY
1. After sliding the cover from the vehicle front to the rear to attaching the 2 clips labeled A, attach the 4 clips labeled B and install the V-bank cover sub-assembly.
  Note
  - Make sure the clips are attached securely.
  - Attaching the clips forcefully or hitting the top of the clips may damage them.
INSTALL COWL TOP VENTILATOR LOUVER RH
1. Install the 6 clips and cowl top ventilator louver RH.
  
  Note
  
  If the cowl top ventilator louver RH is not properly installed, water may leak into the engine room and cause malfunctions. Therefore, make sure the cowl top ventilator louver RH is installed properly.

No. 1 engine hanger	12281-38150
Bolt	90129-14120