ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

for Automatic Transmission:

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, cylinder head LH, camshaft, No. 2 camshaft, No. 3 camshaft, No. 4 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring Click here.

PROCEDURE


  1. INSTALL ENGINE HANGER


    1. B001FK2E06
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-31110
      No. 2 Engine Hanger 12282-31140
      Bolt 91671-C0830

  2. 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.

    3. Place the engine onto a work bench.

  3. 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. B001CEZE04
      Text in Illustration
      *1 Claw (Stopper)
      *2 Bracket
      *a Correct
      *b Incorrect

      Install the front engine mounting insulator LH with the 3 nuts.

      Torque:
      for nut A
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      for nut B
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    4. Install the front engine mounting insulator RH with the 3 nuts.

      Torque:
      for nut A
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      for nut B
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      For RHD vehicles only:

      B001I7ZE03

      When tightening the nut closer to the rear of the vehicle for the engine mounting bracket on the right side, make sure that the claw (stopper) of the bolt does not protrude past the rear edge of the bracket.

    5. Remove the 2 engine hangers and 4 bolts.

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


    1. Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. B001HH2E01
      Text in Illustration
      *1 Front Spacer
      *2 Drive Plate and Ring Gear
      *3 Rear Spacer
      B001CHY Automatic Transmission Side

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

      Tech Tips

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

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    4. B001H86E06

      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.

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


    1. Using SST, hold the crankshaft.

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

    2. Temporarily install the flywheel with 8 new bolts.

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

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

    4. Mark the top of the bolts with paint.

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

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

  6. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

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

    Click here

  9. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. Connect the oil cooler tube with the bolt.

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

  10. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Connect the suction hose with the bolt.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  11. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for Manual Transmission)

    Click here

  12. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for Automatic Transmission)

    Click here

  13. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Install the manual transmission to the vehicle Click here.

  14. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Install the automatic transmission to the vehicle Click here.

  15. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  16. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  17. CONNECT NO. 1 AND NO. 2 FUEL PIPES


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

    2. Install the No. 2 fuel pipe clamp to the fuel tube connector.

  18. CONNECT HEATER WATER HOSE ASSEMBLY


    1. B001F0CE04
      Text in Illustration
      *A w/o Rear Heater
      *B w/ Rear Heater
      *a Top
      *b LH
      *c RR

      w/ Rear heater:

      Connect the 4 hoses and heater water hose.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

    2. w/o Rear heater

      Connect the 2 hoses and heater water hose.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  19. CONNECT ENGINE WIRE


    1. Connect the ECM connector.


      1. B001EQ8E01
        Text in Illustration
        *1 Grommet
        *2 Wire Harness Support

        Attach the grommet to the wire harness support.

      2. Pass the wire harness into the vehicle and install the wire harness support.

      3. B001F1OE02
        Text in Illustration
        *A for LHD
        *B for RHD

        Connect the 9 connectors and attach the clamp.

    2. Install the glove compartment door Click here.

    3. B001E9V

      Connect the connector and install the bolt.

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

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

    Click here

  21. INSTALL STARTER ASSEMBLY

    Click here

  22. INSTALL GENERATOR ASSEMBLY

    Click here

  23. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  24. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  25. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

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

    Click here

  27. INSTALL MANIFOLD STAY

    Click here

  28. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  29. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  30. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)


    1. for Power tilt and power telescopic steering column:

      Connect the No. 2 steering intermediate shaft Click here.

    2. for Manual tilt and manual telescopic steering column:

      Connect the No. 2 steering intermediate shaft Click here.

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

    Click here

  32. INSTALL NO. 2 MANIFOLD STAY

    Click here

  33. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the front exhaust pipe Click here.

  34. INSTALL COOLER COMPRESSOR ASSEMBLY

    Click here

  35. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  36. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  37. CONNECT VANE PUMP ASSEMBLY

    Click here

  38. INSTALL FAN AND GENERATOR V BELT

    Click here

  39. INSTALL INTAKE AIR SURGE TANK

    Click here

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

    Click here

  41. INSTALL RADIATOR ASSEMBLY

    Click here

  42. INSTALL FAN SHROUD

    Click here

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

    Click here

  44. CONNECT OIL COOLER TUBE (w/ Warmer)

    Click here

  45. INSTALL RADIATOR RESERVOIR

    Click here

  46. INSTALL NO. 2 RADIATOR HOSE

    Click here

  47. INSTALL NO. 1 RADIATOR HOSE

    Click here

  48. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

  49. INSTALL RADIATOR SIDE DEFLECTOR RH

    Click here

  50. INSTALL UPPER FRONT BUMPER RETAINER

    Click here

  51. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  52. INSTALL AIR CLEANER CAP AND HOSE

    Click here

  53. INSTALL FRONT BUMPER COVER


    1. Install the front bumper cover Click here.

  54. INSTALL V-BANK COVER

    Click here

  55. INSTALL BATTERY TRAY

  56. INSTALL BATTERY

  57. INSTALL BATTERY HOLD DOWN CLAMP

    Click here

  58. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  59. ADD ENGINE COOLANT

    Click here

  60. ADD ENGINE OIL

    Click here

  61. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Install the cowl top ventilator louver Click here.

  62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  63. INSPECT FOR FUEL LEAK

    Click here

  64. INSPECT FOR ENGINE OIL LEAK

    Click here

  65. INSPECT FOR EXHAUST GAS LEAK

    Click here

  66. CHECK ENGINE OIL LEVEL

    Click here

  67. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  68. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Install the front No. 1 fender apron to frame seal with the 5 clips.

  69. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH


    1. Install the front No. 1 fender apron to frame seal with the 5 clips.

  70. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal with the 5 clips.

  71. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal with the 5 clips.

  72. INSTALL REAR ENGINE UNDER COVER ASSEMBLY


    1. Install the rear engine under cover with the 4 bolts.

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

  73. INSTALL TRANSMISSION UNDER COVER


    1. Install the transmission under cover with the 2 bolts.

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

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


    1. B001IJW

      Hook the engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

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

  75. INSTALL FRONT BUMPER COVER LOWER


    1. Install the front bumper cover lower with the 5 bolts and clip.

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

  76. PERFORM RESET MEMORY (for Automatic Transmission)


    1. Perform the Reset Memory procedures Click here.

  77. INSPECT IGNITION TIMING

    Click here

  78. INSPECT ENGINE IDLE SPEED

    Click here

  79. INSPECT CO/HC

    Click here

  80. INSTALL HOOD SUB-ASSEMBLY


    1. B001CHC

      Install the hood with the 8 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Text in Illustration
      B001CHY Bolt A
      B001DEF Bolt B

    2. Connect the washer nozzle hose.

  81. ADJUST HOOD SUB-ASSEMBLY

    Click here

  82. CHARGE REFRIGERANT

    Click here

  83. WARM UP ENGINE

    Click here

  84. CHECK FOR REFRIGERANT GAS LEAK

    Click here