ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. B001AUC

      Install the engine mounting bracket LH with the bolt.

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

  2. INSTALL FRONT ENGINE MOUNTING INSULATOR RH


    1. B001AA4

      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. B001A13

      Install the mounting insulator with the nut.

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

  4. REMOVE ENGINE STAND


    1. B0019QT

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

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

      Tech Tips

      Item Part No.
      Engine hanger 12281-38150
      Bolt 90119-14120

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

    3. Remove the bolts and engine assembly 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.

  5. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine assembly into the engine compartment.

      Note

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

    2. Attach the engine mounting insulators to the vehicle.

    3. B001AIEE06

      Install the 4 engine mounting insulator bolts.

      Torque:
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }

    4. Remove the 2 bolts and 2 engine hangers.

  6. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY


    1. B00197U

      Connect the hose and install the water pipe and hose with the 2 bolts.

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

  7. CONNECT OIL COOLER PIPE ASSEMBLY


    1. B0019A5

      Connect the oil cooler pipe with the 2 bolts.

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

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. B0019HKE08

      Using SST, hold the crankshaft.

      SST
      09213-70011
      09330-00021
    2. B001A25E02
      *1 Engine Side

      Install the crankshaft angle sensor rotor.

      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. B001960E01
      *1 Drive Plate
      *2 Automatic Transmission Side
      *3 Rear Drive Plate Spacer

      Install the drive plate and rear drive plate spacer onto the crankshaft.

      Tech Tips

      As the rear drive plate spacer and the drive plate are not reversible, be sure to install them so that they are facing in the direction 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. B0019YDE01
        *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. B0018BGE03

        Step 1:

        Install and uniformly 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 flywheel installation bolts.

        • Do not strike or damage the flywheel installation bolts. Be sure to handle them carefully.

      4. B0019Y1E05
        *1 Up
        *2 Painted Mark

        Mark the upside of each flywheel installation bolt with paint.

      5. Step 2:

        Tighten the flywheel installation bolts 90° as shown in the illustration.

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

        Note

        Do not start the engine for at least an hour after installing the drive plate.

  9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. B0018A0

      Install the rear engine mounting insulator to the transmission with the 4 bolts.

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

    2. Install the front engine mounting insulator RH with the 2 bolts.

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

  10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  11. INSTALL STARTER ASSEMBLY

    Click here

  12. INSTALL STARTER COVER

    Click here

  13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  14. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  15. INSTALL NO. 1 MANIFOLD STAY

    Click here

  16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  18. INSTALL NO. 2 MANIFOLD STAY

    Click here

  19. INSTALL PROPELLER SHAFT HEAT INSULATOR

    Click here

  20. INSTALL REAR PROPELLER SHAFT ASSEMBLY

    Click here

  21. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  22. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  23. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  24. INSTALL CENTER EXHAUST PIPE ASSEMBLY

    Click here

  25. INSTALL TAILPIPE ASSEMBLY

    Click here

  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  27. INSTALL GENERATOR ASSEMBLY


  28. CONNECT VANE PUMP ASSEMBLY

    Click here

  29. CONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  30. CONNECT WIRE HARNESS AND HOSE


    1. Connect the 2 clamps and 2 connectors.

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

    3. Install the engine wire with the nut. Then connect the 2 clips.

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

    4. w/ Secondary Air Injection System:

      Connect the 4 air injection control driver connectors.

    5. Connect the ground wire and clamp to the body with the bolt.

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

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

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    8. B001ANB

      w/ Secondary Air Injection System:

      Connect the 2 air injection system hoses.

    9. Install the ground wire with the bolt.

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

    10. w/ Secondary Air Injection System:

      Connect the 3 clamps and 2 air pump connectors.

    11. w/ Secondary Air Injection System:

      Install the connector bracket with the nut.

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

    12. Connect the connectors.


      1. for RHD:

        Connect the 4 connectors and 2 clips to the connector holder block.

      2. for LHD:

        Connect the 5 connectors and clip to the connector holder block.

    13. Connect the ECM connector.


      1. for RHD:

        Connect the 2 clamps and ECM connector.

        Tech Tips

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

      2. for LHD:

        Connect the clamp and ECM connector.

        Tech Tips

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

    14. B0018RP

      Connect the purge line hose.

  31. CONNECT FUEL MAIN AND RETURN HOSE


    1. B0019XE

      Connect the fuel main and return hoses Click here.

    2. Install the fuel pipe clamp.

  32. INSTALL WATER HOSE SUB-ASSEMBLY

    B0019PT

  33. INSTALL RADIATOR ASSEMBLY

    Click here

  34. INSTALL FAN SHROUD

    Click here

  35. INSTALL NO. 2 RADIATOR HOSE

  36. INSTALL NO. 1 RADIATOR HOSE

  37. INSTALL AIR CLEANER ASSEMBLY


    1. B0018FM

      Install the air cleaner with the 3 bolts.

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

  38. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  39. INSTALL HOOD SUB-ASSEMBLY


    1. B0019A4

      Install the hood with the 4 bolts.

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

    2. Connect the 2 hood supports with the 2 hood support bolts.

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

      CAUTION:

      Install the hood support while supporting the hood by hand.

      Note

      Check that the hood support is engaged in the ball joint and that it cannot be pulled out.

  40. ADJUST HOOD SUB-ASSEMBLY

    Click here

  41. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  42. INSTALL HOOD TO COWL TOP SEAL

    Click here

  43. INSTALL FRONT FENDER MAIN SEAL LH

    Click here

  44. INSTALL FRONT FENDER MAIN SEAL RH

    Click here

  45. INSTALL FRONT WIPER ARM LH

    Click here

  46. INSTALL FRONT WIPER ARM RH

    Click here

  47. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

  48. INSTALL TRANSMISSION OIL COOLER AIR DUCT

    Click here

  49. INSTALL FRONT FENDER APRON SEAL REAR RH

    Click here

  50. INSTALL FRONT FENDER APRON SEAL FRONT RH

    Click here

  51. INSTALL FRONT FENDER APRON SEAL REAR LH

    Click here

  52. INSTALL FRONT FENDER APRON SEAL FRONT LH

    Click here

  53. INSTALL OIL PAN PROTECTOR ASSEMBLY

    Click here

  54. INSTALL NO. 2 ENGINE UNDER COVER

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

    Click here

  56. ADD ENGINE OIL

    Click here

  57. ADD ENGINE COOLANT

    Click here

  58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  59. INSPECT FOR OIL LEAK

    Click here

  60. INSPECT FOR COOLANT LEAK

    Click here

  61. INSPECT FOR EXHAUST GAS LEAK

  62. INSPECT FOR FUEL LEAK

    Click here

  63. INSPECT SHIFT LEVER POSITION

    Click here

  64. INSPECT IGNITION TIMING

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  65. INSPECT ENGINE IDLE SPEED

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  66. INSPECT CO/HC

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  67. INSPECT ENGINE OIL LEVEL

    Click here

  68. INSPECT ENGINE COOLANT LEVEL

    Click here

  69. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B0019D8E06
      *1 Bracket
      *2 Hook
      *3 Pin
      *4 Grommet

      Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

  70. INSTALL FRONT BUMPER COVER

    Click here