ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 2 engine mounting bracket LH with the bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  2. INSTALL ENGINE HANGER

    Click here

  3. REMOVE ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

    2. 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.

      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    3. Place the engine onto a work bench.

  4. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. B001Y0R

      Install the front engine mounting insulator LH with the 2 bolts and nut.

      Torque:
      for bolt
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      for nut
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      Text in Illustration
      B001XPG Bolt
      B001WGT Nut

    3. Install the front engine mounting insulator RH with the 2 bolts and nut.

      Torque:
      for bolt
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      for nut
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    4. Remove the 2 engine hangers and 4 bolts.

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. B001YOVE05

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and their installation holes.

    3. B001WAZE01
      Text in Illustration
      *1 Front Spacer
      *2 Drive Plate and Ring Gear
      *3 Rear Spacer
      B001XPG Automatic Transmission Side

      Install the front spacer, drive plate and rear spacer to the crankshaft.

      Tech Tips

      As the front spacer, the drive plate and ring gear, and the rear spacer are not reversible, be sure to install them in the direction shown in the illustration.

    4. Apply adhesive to 2 or 3 threads at the end of the 8 new bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. B001ZPQE05

      Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

      Torque:
      83 N*m  { 846 kgf*cm, 61 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after installing.

  6. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. B001YOVE05

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and their installation holes.

    3. Temporarily install the flywheel with 8 new bolts.

    4. Install and tighten the 8 bolts uniformly in several steps.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    5. Mark the top of the bolts with paint.

    6. Tighten the 8 bolts 90° in the same sequence.

    7. Check that the paint marks are now at a 90° angle to the top.

  7. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  8. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  9. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  10. CONNECT NO. 1 OIL COOLER HOSE TUBE SUB-ASSEMBLY


    1. Connect the cooler hose tube with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  11. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


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

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

  12. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    Click here

  13. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  14. CONNECT NO. 1 AND NO. 2 FUEL PIPE


    1. Connect the No. 1 and No. 2 fuel pipes Click here.

  15. INSTALL COOLER COMPRESSOR ASSEMBLY

    Click here

  16. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  17. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  18. INSTALL GENERATOR ASSEMBLY

    Click here

  19. CONNECT VANE PUMP ASSEMBLY

    Click here

  20. CONNECT WATER HOSE SUB-ASSEMBLY


    1. Connect the water hoses.

  21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  22. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  23. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)

    Click here

  24. INSTALL NO. 2 MANIFOLD STAY

    Click here

  25. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  26. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  27. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT

    Click here

  28. INSTALL AIR TUBE (w/ Secondary Air Injection System)

    Click here

  29. INSTALL MANIFOLD STAY

    Click here

  30. INSTALL FRONT FENDER APRON TRIM PACKING D

    Click here

  31. INSTALL FRONT FENDER APRON TRIM PACKING C

    Click here

  32. INSTALL FRONT FENDER APRON TRIM PACKING B

    Click here

  33. INSTALL FRONT FENDER APRON TRIM PACKING A

    Click here

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  35. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

    Click here

  36. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  37. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  38. INSTALL TAILPIPE ASSEMBLY

    Click here

  39. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  40. CONNECT ENGINE WIRE


    1. B001Y3F

      w/ Secondary Air Injection System:

      Attach the clamp and connect the air pump connector.

    2. B001ZG3

      Attach the clamp and connect the power steering switch connector.

    3. A01X3LL

      w/ Winch:

      Install the winch ground wire with the 2 bolts.

      Torque:
      19 N*m  { 196 kgf*cm, 14 ft.*lbf }
    4. B001ZNE

      Attach the 2 clamps and connect the connector.

    5. A01X40T

      Install the ground wire with the bolt and attach the wire harness clamp.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    6. Connect the cable to the positive (+) battery terminal.

    7. Connect the wire to the positive (+) battery cable with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    8. Connect the wire and 2 clips to the engine room junction block with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    9. Connect the 2 clips and 2 connectors to the engine room junction block.

    10. w/ Secondary Air Injection System:

      Attach the clamp and connect the 2 air injection control driver connectors.

    11. Connect the ground wire to the bracket with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    12. Install the engine room relay block cover.

    13. A01XBWR

      Connect the 4 connectors to the junction block.

    14. Attach the wire harness clamp.

    15. Connect the ECM connector Click here.

    16. Install the junction block cover.

  41. INSTALL INTAKE AIR SURGE TANK

    Click here

  42. INSTALL AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)

    Click here

  43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Install the air cleaner filter element.

  44. INSTALL AIR CLEANER CAP AND HOSE


    1. Install the air cleaner cap and hose.


      1. Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      2. Tighten the clamp.

        Torque:
        2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

      3. Attach the clamp and connect the ventilation hose, vacuum hose and mass air flow meter connector.

  45. INSTALL RADIATOR ASSEMBLY

    Click here

  46. CONNECT OUTLET OIL COOLER HOSE (for Automatic Transmission)

    Click here

  47. CONNECT INLET OIL COOLER HOSE (for Automatic Transmission)

    Click here

  48. INSTALL FAN SHROUD

    Click here

  49. CONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)

    Click here

  50. INSTALL NO. 2 RADIATOR HOSE

    Click here

  51. INSTALL NO. 1 RADIATOR HOSE

  52. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

  53. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)

    Click here

  54. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)

    Click here

  55. INSTALL V-BANK COVER

    Click here

  56. INSTALL FRONT BUMPER COVER


  57. INSTALL RADIATOR GRILLE

    Click here

  58. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  59. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  60. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    Click here

  61. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  62. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

  63. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  64. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  65. ADD ENGINE OIL

    Click here

  66. ADD ENGINE COOLANT

    Click here

  67. INSPECT FOR FUEL LEAK

    Click here

  68. INSPECT FOR COOLANT LEAK

    Click here

  69. INSPECT FOR OIL LEAK

    Click here

  70. INSPECT FOR EXHAUST GAS LEAK

    Click here

  71. CHECK ENGINE OIL LEVEL

    Click here

  72. CHARGE REFRIGERANT

    Click here

  73. WARM UP ENGINE

    Click here

  74. CHECK FOR REFRIGERANT GAS LEAK

    Click here

  75. PERFORM RESET MEMORY (for Automatic Transmission)


    1. Perform the Reset Memory procedures Click here.

  76. INSPECT IGNITION TIMING

    Click here

  77. INSPECT ENGINE IDLE SPEED

    Click here

  78. INSPECT CO/HC

    Click here

  79. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood with the 4 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

  80. INSPECT HOOD SUB-ASSEMBLY

    Click here

  81. ADJUST HOOD SUB-ASSEMBLY

    Click here

  82. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL

    Click here