ENGINE(for 2WD) INSTALLATION

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

    Click here

  2. INSTALL KNOCK SENSOR

    Click here

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  4. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  6. INSTALL WATER INLET HOUSING

    Click here

  7. INSTALL WATER PUMP PULLEY

    Click here

  8. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 1 idler pulley sub-assembly with the bolt.

      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.

      A001BIHE01
      *1 Front

  9. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 2 idler pulley sub-assembly with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  10. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. Install the No. 4 engine cover sub-assembly.

  11. INSTALL ENGINE WIRE


    1. Install the engine wire with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the 4 knock sensor connectors.

  12. INSTALL SEPARATOR CASE

    Click here

  13. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)

    Click here

  14. INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection)

    Click here

  15. INSTALL FUEL DELIVERY PIPE (for Direct Injection)

    Click here

  16. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  17. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

    Click here

  18. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here

  21. INSTALL ENGINE COVER SUB-ASSEMBLY

    Click here

  22. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

    Click here

  23. INSTALL FUEL DELIVERY PIPE (for Port Injection)

    Click here

  24. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

  25. INSTALL NO. 3 COVER SUB-ASSEMBLY

    Click here

  26. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH

  27. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY

  28. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

  29. INSTALL INTAKE MANIFOLD

    Click here

  30. INSTALL THROTTLE BODY ASSEMBLY

    Click here

  31. INSTALL VENTILATION HOSE

  32. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  33. INSTALL NO. 2 ENGINE COVER (for LHD)

    Click here

  34. INSTALL NO. 1 ENGINE COVER

  35. INSTALL INJECTOR DRIVER

    Click here

  36. 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 }

  37. 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 }

  38. 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 }

  39. INSTALL GENERATOR ASSEMBLY

    Click here

  40. 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:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  41. INSTALL ENGINE MOUNTING SPACER


    1. Install the 2 engine mounting spacers.

  42. INSTALL NO. 1 ENGINE HANGER

    Click here

  43. 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.

  44. 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 }

  45. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A001EXDE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021

    2. Clean the their installation holes.

    3. A0019HAE09
      *1 Pin Hole
      *2 Pin
      *3 Front Side

      Install the crankshaft position sensor rotor.

      Tech Tips


      • Align the pin of the crankshaft with the pin hole of the crankshaft position sensor rotor.

      • As the crankshaft position sensor rotor are not reversible, be sure to install it in the direction shown in the illustration.

    4. A001B51E08
      *1 Drive Plate
      *2 Front Side
      *3 Rear Spacer Plate

      Install the drive plate and ring gear sub-assembly and rear spacer plate on the crankshaft.

      Tech Tips

      As the drive plate and ring gear sub-assembly and rear spacer plate are not reversible, be sure to install it in the direction shown in the illustration.

    5. A001C6ZE01
      *1 Adhesive

      Apply a few drops of adhesive to 2 or 3 threads of the bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A001APLE03

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

      Torque:
      30 N*m  { 301 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.

    7. Mark the upside of each drive plate installation bolt with paint.

    8. Retighten the drive plate installation bolts by 90°.

    9. Check that the painted marks are now at a 90° angle to the upside.

  46. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  47. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

  48. INSTALL STARTER ASSEMBLY

    Click here

  49. INSTALL ENGINE WIRE


    1. A001B4V

      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 purge VSV connector.

    5. A001A5C

      Connect the 4 injector driver connectors as shown in the illustration.

    6. for Engine RH Side:


      1. A001FZP

        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 fuel pump connector. (for high pressure)

      10. Connect the 2 VVT sensor connectors.

      11. Connect the 4 ignition coil connectors.

      12. Connect the camshaft timing control valve connector.

    7. for Engine LH Side:


      1. A001F2E

        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. A001C40

        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 fuel pump connector. (for high pressure)

      9. Connect the 2 VVT sensor connectors.

      10. Connect the 4 ignition coil connectors.

      11. Connect the camshaft timing control valve connector.

    8. Connect the throttle body connectors.

  50. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  51. INSTALL OIL COOLER TUBE

    Click here

  52. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 2)

    Click here

  53. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  54. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the 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.

  55. 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 No. 1 engine hangers.

    3. Operate the engine lifter and install the engine to the vehicle.

      Note

      Make sure that the engine is clear of all wiring and hoses.

    4. A001B8U

      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. A001AJU

      Tighten the 4 bolts.

      Torque:
      165 N*m  { 1683 kgf*cm, 122 ft.*lbf }
    6. A001FQ6

      Install the 6 engine rear mounting member's bolts.

      Torque:
      35 N*m  { 354 kgf*cm, 26 ft.*lbf }

  56. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  57. CONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY

    Click here

  58. 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 }

  59. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)

    Click here

  60. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  61. INSTALL POWER STEERING LINK ASSEMBLY (w/ VGRS)

    Click here

  62. INSTALL POWER STEERING LINK ASSEMBLY (w/o VGRS)

    Click here

  63. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  64. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS)

    Click here

  65. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)

    Click here

  66. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  67. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  68. INSTALL FRONT STABILIZER BAR

    Click here

  69. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  70. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  71. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  72. CONNECT HOSES AND CONNECTORS


    1. A001AZW

      Connect the purge line hose.

    2. A0018XL

      Connect the 2 heater hoses.

    3. A0019OP

      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. A001FBT

      Connect the ground wire with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    5. A001A27

      Connect the 3 connectors with front controller with the clamp.

    6. A001EBF

      Attach the clamp and connect the cooler compressor connector.

    7. A001EMF

      Connect the 3 TCM connectors and 4 ECM connectors.

    8. Install the engine room ECU cover.

  73. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  74. CONNECT NO. 3 FUEL HOSE

    Click here

  75. INSTALL ENGINE ROOM ECU OUTLET DUCT


    1. Install the engine room ECU outlet duct.

  76. CONNECT NO. 2 RADIATOR HOSE

  77. CONNECT NO. 1 RADIATOR HOSE

  78. INSTALL AIR CLEANER ASSEMBLY RH

    Click here

  79. INSTALL AIR CLEANER ASSEMBLY LH

    Click here

  80. INSTALL V-RIBBED BELT

    Click here

  81. INSTALL INTAKE AIR CONNECTOR PIPE

    Click here

  82. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  83. INSTALL REAR FRAME SIDE RAIL


    1. A001CEAE03

      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 }

  84. INSTALL FRONT SUSPENSION LOWER CROSSMEMBER

    Click here

  85. INSTALL FRONT BUMPER COVER

    Click here

  86. CONNECT NO. 1 OIL COOLER OUTLET HOSE

    Click here

  87. CONNECT NO. 1 OIL COOLER INLET HOSE

    Click here

  88. ADD ENGINE OIL

    Click here

  89. ADD ENGINE COOLANT

    Click here

  90. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  91. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  92. INSPECT FOR OIL LEAK

    Click here

  93. INSPECT FOR COOLANT LEAK

    Click here

  94. INSPECT FOR FUEL LEAK

    Click here

  95. INSPECT FOR EXHAUST GAS LEAK

    Click here

  96. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  97. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  98. CHECK SHIFT LEVER POSITION

    Click here

  99. 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 }

  100. INSTALL NO. 2 ENGINE UNDER COVER


    1. A001B00E01

      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 }

  101. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  102. CHECK IGNITION TIMING

    Click here

  103. CHECK IDLE SPEED

    Click here

  104. CHECK CO/HC

    Click here

  105. CHECK ENGINE OIL LEVEL

    Click here

  106. INSTALL ENGINE ROOM SIDE COVER RH

    Click here

  107. INSTALL ENGINE ROOM SIDE COVER LH

    Click here

  108. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY

    Click here

  109. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  110. INSTALL COWL TOP VENTILATOR LOUVER

    Click here