ENGINE(for AWD) 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 ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  3. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  4. INSTALL WATER INLET HOUSING


    1. Install a new gasket and water inlet housing with the 3 bolts.

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

    2. Using needle-nose pliers, grip the claws of the clips and slide the clips to connect the water by-pass hoses and water inlet hose.

  5. INSTALL WATER PUMP PULLEY

    Click here

  6. 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

  7. 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 }

  8. INSTALL KNOCK SENSOR

    Click here

  9. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY


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

  10. INSTALL ENGINE WIRE


    1. A001E89E01

      Install the engine wire with the 2 bolts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the 4 knock sensor connectors and attach the 5 clamps.

  11. INSTALL SEPARATOR CASE

    Click here

  12. INSTALL FUEL INJECTOR SEAL (for Direct Injection)

    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 NO. 2 ENGINE COVER SUB-ASSEMBLY LH

  18. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY

  19. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

  20. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

    Click here

  21. INSTALL FUEL DELIVERY PIPE (for Port Injection)

    Click here

  22. INSTALL FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  23. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  24. INSTALL ENGINE COVER SUB-ASSEMBLY (for Bank 1)

    Click here

  25. INSTALL FUEL PUMP ASSEMBLY (for Bank 2)

    Click here

  26. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  27. INSTALL ENGINE COVER SUB-ASSEMBLY (for Bank 2)

    Click here

  28. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here

  29. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  30. INSTALL INTAKE MANIFOLD

    Click here

  31. INSTALL THROTTLE BODY ASSEMBLY

    Click here

  32. INSTALL VENTILATION HOSE

  33. INSTALL PURGE VSV

    Click here

  34. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  35. INSTALL NO. 1 ENGINE COVER


    1. Install the No. 1 engine cover.

  36. INSTALL INJECTOR DRIVER

    Click here

  37. INSTALL ENGINE WIRE


    1. A001BLCE01

      Install the engine wire with the 4 nuts.

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

    2. Connect the 2 clamps and 2 clamp brackets with the 2 bolts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the intake air control valve actuator connector.

    4. Connect the purge VSV connector.

    5. A00195SE01
      *1 Move
      *2 Lock Lever

      Connect the 8 injector driver connectors and 2 clips as shown in the illustration.

    6. A0019QE

      for Engine Rear Side:


      1. Install the ground wire with the 2 bolts.

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

      2. Attach the 8 wire harness clamps.

      3. Connect the fuel relief valve connector.

      4. Connect the engine wire connector.

    7. for Engine RH Side:


      1. A001DVR

        Connect the engine oil level sensor connector.

      2. Connect the crankshaft position sensor connector. Then install the wire harness with the 2 bolts.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      3. Attach the 4 clamps.

      4. Connect the camshaft position sensor connector.

      5. Connect the fuel pump connector (for high pressure).

      6. Connect the 2 VVT sensor connectors.

      7. Connect the 4 ignition coil connectors.

      8. Connect the camshaft timing control valve connector.

    8. A001CMR

      for Engine Front Side:


      1. Install the clamp bracket with the bolt.

        Torque:
        12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      2. Attach the clamp and install the 3 ground wire 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 2).

      4. Connect the 2 camshaft timing control motor connectors (for Bank 1).

      5. Connect the engine coolant temperature sensor connector.

    9. A0019R5

      for Engine LH Side:


      1. Attach the 4 wire harness clamps.

      2. Connect the No. 8 engine wire connector.

      3. Connect the fuel pump connector (for high pressure).

      4. Connect the 2 VVT sensor connectors.

      5. Connect the 4 ignition coil connectors.

      6. Connect the camshaft timing control valve connector.

    10. Connect the throttle body connectors.

  38. INSTALL NO. 6 ENGINE COVER SUB-ASSEMBLY

    Click here

  39. INSTALL NO. 5 ENGINE COVER SUB-ASSEMBLY

    Click here

  40. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY

    Click here

  41. INSTALL COOLER COMPRESSOR ASSEMBLY


    1. Install 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  { 250 kgf*cm, 18 ft.*lbf }
      for bolts
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  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 DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A001FZKE01

      Using SST, hold the crankshaft.

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

    2. Clean the 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. A001AAUE03
      *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. A001C0ZE01

      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.

  45. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  46. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

  47. CONNECT WIRE HARNESS AND CONNECTOR

    Click here

  48. INSTALL NO. 3 COVER SUB-ASSEMBLY

    Click here

  49. INSTALL NO. 1 OIL COOLER TUBE

    Click here

  50. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  51. INSTALL STARTER ASSEMBLY

    Click here

  52. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  53. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. A0019BO

      Temporarily install the front No. 2 engine mounting bracket LH with the 2 nuts.

    2. A001E9J

      Temporarily install the front No. 1 engine mounting bracket LH with the 5 bolts.

    3. Tighten the 2 nuts.

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

    4. Remove the 5 bolts and front No. 1 engine mounting bracket LH.

  54. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET RH


    1. A001BFM

      Temporarily install the front No. 2 engine mounting bracket RH with the 2 nuts.

    2. A001AHI

      Temporarily install the front No. 1 engine mounting bracket RH with the 5 bolts.

    3. Tighten the 2 nuts.

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

    4. Remove the 5 bolts and front No. 1 engine mounting bracket RH.

  55. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  56. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  57. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH with the 5 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  58. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH with the 5 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  59. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 engine mounting spacers and 2 front engine mounting insulators with the 2 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  60. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  61. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  62. INSTALL GENERATOR ASSEMBLY

    Click here

  63. 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.

  64. INSTALL FRONT FRAME ASSEMBLY


    1. Slowly lower the engine and set it to the front frame assembly.

    2. Install the 4 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

  65. 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. A001ASV

      Align the front frame to the marks on the vehicle, and temporarily install the front frame 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. A001B5J

      Install the 4 rear engine mounting member's bolts.

      Torque:
      35 N*m  { 354 kgf*cm, 26 ft.*lbf }
    6. A001ADQ

      Tighten the 4 front frame bolts.

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

  66. INSTALL FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH


    1. Connect the front lower shock absorber bracket sub-assembly LH. Then install the bolt.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  67. INSTALL FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH


    1. Connect the front lower shock absorber bracket sub-assembly RH. Then install the bolt.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  68. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  69. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  70. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  71. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  72. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  73. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY


    1. Attach the 2 claws to install the No. 1 air duct sub-assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  74. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Click here

  75. CONNECT HOSES AND CONNECTORS


    1. A001AZW

      Connect the purge line hose.

    2. A0018XL

      Connect the 2 heater hoses.

    3. A001B3W

      Attach the 5 clamps and connect the 2 connectors.

    4. A001FBT

      Connect the ground wire with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    5. A001A3IE01

      Connect the 2 power steering ECU connectors and attach the 2 clamps.

      Tech Tips

      Refer to the following procedures to connect A the power steering ECU connector Click here.

    6. A001A27

      Connect the 3 connectors with front controller with the clamp.

    7. A001DCU

      Connect the wires with No. 1 engine room junction block with the 2 nuts. Then attach the 2 clamps.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    8. A001A8K

      Lift up the wiring harness support and connect the 4 ECM connectors.

    9. A001AMOE01

      Install the wiring harness support to the ECU box.

    10. Attach the clip of connector A to the ECU box.

    11. Connect the 4 TCM connectors and 2 wiring harness support connectors.

    12. A001B2G

      Install the engine room ECU cover with the 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  76. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  77. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  78. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  79. CONNECT NO. 3 FUEL HOSE

    Click here

  80. INSTALL OIL TEMPERATURE SENSOR

    Click here

  81. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  82. INSTALL V-RIBBED BELT

    Click here

  83. INSTALL RESONATOR BRACKET SUB-ASSEMBLY

    Click here

  84. CONNECT NO. 2 RADIATOR HOSE

  85. CONNECT NO. 1 RADIATOR HOSE

  86. INSTALL RADIATOR RESERVOIR ASSEMBLY

    Click here

  87. INSTALL ENGINE ROOM ECU OUTLET DUCT


    1. Install the engine room ECU outlet duct to the fan shroud and ECU box.

  88. INSTALL AIR CLEANER ASSEMBLY RH

    Click here

  89. INSTALL AIR CLEANER ASSEMBLY LH

    Click here

  90. INSTALL INTAKE AIR CONNECTOR PIPE

    Click here

  91. INSTALL REAR FRAME SIDE RAIL


    1. A0019VOE03

      Install the rear frame side rail 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 }

  92. INSTALL FRONT SUSPENSION LOWER CROSSMEMBER

    Click here

  93. INSTALL FRONT BUMPER COVER

    Click here

  94. CONNECT NO. 1 OIL COOLER OUTLET HOSE

    Click here

  95. CONNECT NO. 1 OIL COOLER INLET HOSE

    Click here

  96. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  97. ADD ENGINE OIL

    Click here

  98. ADD ENGINE COOLANT

    Click here

  99. ADD DIFFERENTIAL OIL

    Click here

  100. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  101. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  102. CHARGE REFRIGERANT

    Click here

  103. INSPECT FOR REFRIGERANT

    Click here

  104. INSPECT FOR OIL LEAK

    Click here

  105. INSPECT FOR COOLANT LEAK

    Click here

  106. INSPECT FOR FUEL LEAK

    Click here

  107. INSPECT FOR EXHAUST GAS LEAK

    Click here

  108. CHECK SHIFT LEVER POSITION

    Click here

  109. CHECK IGNITION TIMING

    Click here

  110. CHECK IDLE SPEED

    Click here

  111. CHECK CO/HC

    Click here

  112. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER


    1. A0019ZJE03

      Install the front suspension member protector lower with the 9 bolts.

      Torque:
      for bolt A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      except bolt A
      58 N*m  { 593 kgf*cm, 43 ft.*lbf }

  113. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  114. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

    Click here

  115. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

    Click here

  116. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 screws and 2 clips.

  117. INSTALL FRONT CENTER FLOOR COVER


    1. Install the front center floor cover with the 3 screws, 2 bolts and clip.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  118. CHECK ENGINE OIL LEVEL

    Click here

  119. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  120. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  121. INSTALL ENGINE ROOM SIDE COVER RH

    Click here

  122. INSTALL ENGINE ROOM SIDE COVER LH

    Click here

  123. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY

    Click here

  124. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  125. INSTALL COWL TOP VENTILATOR LOUVER RH

    Click here