ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 FRONT ENGINE MOUNTING BRACKET LH


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

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

  2. INSTALL FRONT ENGINE MOUNTING INSULATOR RH


    1. Install the mounting insulator with the nut.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  3. INSTALL FRONT ENGINE MOUNTING INSULATOR LH


    1. Install the mounting insulator with the nut.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  4. INSTALL ENGINE HANGER

    Click here

  5. REMOVE ENGINE STAND


    1. B001WOBE02
      Text in Illustration
      *1 Engine Hanger
      *2 Engine
      *a 50° or less

      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 angle of the sling device at 50° or less. Otherwise, the engine or engine hangers may be damaged.

    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 workbench.

  6. 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. B001Y2K

      Install the front engine mounting insulator LH and RH with the 2 nuts and 4 bolts.

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

    4. Remove the 2 bolts and 2 engine hangers.

  7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. Using SST, hold the crankshaft.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. B001WVV

      Install the crankshaft angle sensor rotor.

      Text in Illustration
      B001XPG Engine Side

      Tech Tips


      • 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. B001W87E01
      Text in Illustration
      *1 Drive Plate and Ring Gear
      *2 Rear Drive Plate Spacer
      B001XPG Transmission Side

      Install the drive plate and ring gear and the rear drive plate spacer to the crankshaft.

      Tech Tips

      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.

      Tech Tips

      The bolts are tightened in 2 progressive steps.


      1. Clean the bolts and bolt holes.

      2. B001WHFE03
        Text in Illustration
        *1 Adhesive

        Apply adhesive to 2 or 3 threads at the end of each of the 10 bolts.

        Adhesive
        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      3. B001WS1E03

        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 }

      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.

  8. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Click here

  9. INSTALL NO. 1 WATER BY-PASS PIPE (w/o ATF Warmer)


    1. Install the No. 1 water by-pass pipe with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Connect the water hose.

  10. INSTALL NO. 1 WATER BY-PASS PIPE (w/ ATF Warmer)


    1. Install the No. 1 water by-pass pipe with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. w/ Rear Heater:

      Connect the 6 water hoses.

    3. w/o Rear Heater:

      Connect the 4 water hoses.

  11. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  12. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

  13. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  14. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  15. INSTALL OIL COOLER TUBE

    Click here

  16. CONNECT TRANSMISSION OIL COOLER HOSE

    Click here

  17. CONNECT ENGINE WIRE


    1. w/ Secondary Air Injection System:

      Connect the connector and clamp.

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

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

      Torque:
      7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

    4. Connect the clamp and ground wire with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    5. w/ Secondary Air Injection System:

      Connect the 2 air injection control driver connectors.

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

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

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

    8. Connect the ground wire with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    9. Connect the 4 connectors and 2 clamps to the connector holder block.

    10. Connect the wire harness clamp and ECM connector.

      Tech Tips

      Refer to the following procedures to connect the ECM connector Click here.

  18. CONNECT FUEL HOSE AND FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel hose and fuel tube sub-assembly Click here.

    2. Attach the clamp and install the fuel pipe clamp to the fuel tube connector.

  19. INSTALL STARTER ASSEMBLY

    Click here

  20. INSTALL STARTER COVER

    Click here

  21. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

    Click here

  22. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  23. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

    Click here

  24. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  25. INSTALL MANIFOLD STAY

    Click here

  26. INSTALL NO. 2 MANIFOLD STAY

    Click here

  27. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  28. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  29. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  30. INSTALL TAILPIPE ASSEMBLY

    Click here

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

    Click here

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

    Click here

  33. INSTALL PROPELLER SHAFT HEAT INSULATOR

    Click here

  34. CONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  35. INSTALL GENERATOR ASSEMBLY


  36. INSTALL VANE PUMP ASSEMBLY

    Click here

  37. CONNECT PRESSURE FEED TUBE

    Click here

  38. CONNECT SUCTION HOSE

    Click here

  39. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  40. INSTALL INTAKE MANIFOLD

    Click here

  41. INSTALL AIR TUBE SUB-ASSEMBLY (w/ Secondary Air Injection System)

    Click here

  42. INSTALL PCV HOSE ASSEMBLY

    Click here

  43. INSTALL EGR VALVE BRACKET

    Click here

  44. INSTALL NO. 5 WATER BY-PASS PIPE

    Click here

  45. CONNECT NO. 3 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)


    1. Connect the No. 3 air injection system hose.

  46. INSTALL RADIATOR ASSEMBLY

    Click here

  47. INSTALL NO. 2 RADIATOR HOSE

  48. INSTALL FAN SHROUD

    Click here

  49. INSTALL NO. 1 RADIATOR HOSE

  50. INSTALL AIR CLEANER AND HOSE

    Click here

  51. INSTALL BATTERY


    1. Install the battery.

    2. Temporarily install the nut and install the bolt.

    3. Adjust the battery clamp's position.

    4. Tighten the 2 nuts and bolt.

      Torque:
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for nut
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  52. INSTALL FRONT FENDER APRON TRIM PACKING C

    Click here

  53. INSTALL FRONT FENDER APRON TRIM PACKING A

    Click here

  54. INSTALL FRONT FENDER APRON TRIM PACKING D

    Click here

  55. INSTALL FRONT FENDER APRON TRIM PACKING B

    Click here

  56. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  57. INSTALL HOOD SUB-ASSEMBLY


    1. B001VYC

      Install the hood with the 6 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
      Text in Illustration
      B001XPG for Bolt A
      B001WGT for Bolt B

  58. ADJUST HOOD SUB-ASSEMBLY

    Click here

  59. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

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

    Click here

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

    Click here

  62. INSTALL FRONT BUMPER COVER


  63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  64. ADD ENGINE OIL

    Click here

  65. ADD ENGINE COOLANT

    Click here

  66. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  67. ADD POWER STEERING FLUID

  68. BLEED POWER STEERING FLUID

    Click here

  69. INSPECT FOR OIL LEAK

    Click here

  70. INSPECT FOR COOLANT LEAK

    Click here

  71. INSPECT FOR FUEL LEAK

    Click here

  72. INSPECT ENGINE OIL LEVEL

    Click here

  73. INSPECT FOR POWER STEERING FLUID LEAK

  74. INSPECT FOR EXHAUST GAS LEAK

    Click here

  75. INSPECT SHIFT LEVER POSITION

    Click here

  76. PERFORM RESET MEMORY

    Click here

  77. INSPECT IGNITION TIMING

    Click here

  78. INSPECT ENGINE IDLE SPEED

    Click here

  79. INSPECT CO/HC

    Click here

  80. INSTALL OIL PAN PROTECTOR ASSEMBLY


    1. Install the oil pan protector assembly with the 4 bolts.

      Torque:
      63 N*m  { 642 kgf*cm, 46 ft.*lbf }

  81. 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 }

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


    1. Install the No. 1 engine under cover sub-assembly with the 10 bolts.

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

  83. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here