ENGINE ASSEMBLY INSTALLATION

INSTALL ENGINE HANGER

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 }

2. Install the engine mounting heat insulator with the 2 bolts.

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

1. Turn the crankshaft to gain access to the installation locations of the 6 bolts and install the bolts while holding the crankshaft pulley set bolt with a wrench.

   Torque:

   53 N*m  { 535 kgf*cm, 39 ft.*lbf }

   Note

   First install the black-colored bolt, and then the remaining 5 silver colored bolts.

INSTALL OIL COOLER TUBE

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

   Torque:

   14 N*m  { 143 kgf*cm, 10 ft.*lbf }

CONNECT TRANSMISSION OIL COOLER HOSE

Text in Illustration

*a	Paint Mark
*b	Yellow Paint
*c	White Paint
*d	Upper
*e	-45 to 45°

1. Connect the 2 transmission oil cooler hoses to the oil cooler tube unions.

   Note

   
   

   • Make sure the pinching portion of each clip is facing the direction shown in the illustration.

   • Make sure the paint mark of each hose is facing outward.

INSTALL STARTER ASSEMBLY

1. Install the flywheel housing side cover.

2. Install the starter with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

3. Install the starter wire with the nut.

   Torque:

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

4. Connect the starter connector.

INSTALL STARTER COVER

1. Install the starter cover with the 3 bolts.

   Torque:

   12 N*m  { 117 kgf*cm, 8 ft.*lbf }

INSTALL EXHAUST MANIFOLD ASSEMBLY RH

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

1. Install the heat insulator with 3 new bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL EXHAUST MANIFOLD ASSEMBLY LH

INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

1. Install the heat insulator with 3 new bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL MANIFOLD STAY

INSTALL NO. 2 MANIFOLD STAY

INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here

INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

1. Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with the 2 nuts.

   Torque:

   54 N*m  { 554 kgf*cm, 40 ft.*lbf }

INSTALL CENTER EXHAUST PIPE ASSEMBLY

1. Install 2 new gaskets to the center exhaust pipe.

2. Connect the center exhaust pipe to the 3 exhaust pipe supports.

3. Install the center exhaust pipe with the 4 bolts.

   Torque:

   48 N*m  { 489 kgf*cm, 35 ft.*lbf }

INSTALL TAILPIPE ASSEMBLY

1. Install a new gasket to the center exhaust pipe.

2. Install the tailpipe to the 2 exhaust pipe supports.

3. 

   Text in Illustration

   *a	Top
   *b	LH Side

   Install a new clamp.

   Torque:

   32 N*m  { 326 kgf*cm, 24 ft.*lbf }

   Tech Tips

   Install the clamp within the angle range shown in the illustration.

INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

1. Temporarily install the sensor to the front exhaust pipe by hand.

2. 

   Text in Illustration

   *1	Fulcrum Length

   Using SST, tighten the heated oxygen sensor.

   SST

   09224-00010

   Torque:

   without SST

   44 N*m  { 449 kgf*cm, 32 ft.*lbf }

   with SST

   40 N*m  { 408 kgf*cm, 30 ft.*lbf }

   Tech Tips

   
   

   • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

   • Make sure SST and the wrench are connected in a straight line.

3. Attach the clamp and connect the heated oxygen sensor connector.

INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

1. Temporarily install the sensor to the front No. 2 exhaust pipe by hand.

2. 

   Text in Illustration

   *1	Fulcrum Length

   Using SST, tighten the heated oxygen sensor.

   SST

   09224-00010

   Torque:

   without SST

   44 N*m  { 449 kgf*cm, 32 ft.*lbf }

   with SST

   40 N*m  { 408 kgf*cm, 30 ft.*lbf }

   Tech Tips

   
   

   • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

   • Make sure SST and the wrench are connected in a straight line.

3. Connect the heated oxygen sensor connector.

INSTALL PROPELLER SHAFT HEAT INSULATOR

CONNECT COOLER COMPRESSOR ASSEMBLY

1. Install the cooler compressor and stud bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Install the 3 bolts and nut.

   Torque:

   24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

   Tech Tips

   Tighten the bolts and nut in the order shown in the illustration.

3. Connect the connector.

INSTALL VANE PUMP ASSEMBLY

Tech Tips

Before performing the following procedures, move the spacer until the vane pump can be installed.

Text in Illustration

Spacer

1. Connect the vane pump to the timing chain cover with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

CONNECT PRESSURE FEED TUBE

1. Install a new gasket to the pressure feed tube.

2. Connect the pressure feed tube with the union bolt.

   Torque:

   50 N*m  { 510 kgf*cm, 37 ft.*lbf }

CONNECT SUCTION HOSE

1. Connect the suction hose to the vane pump assembly with the clip.

INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

1. Apply engine oil to a new O-ring, and then install the O-ring to the engine oil level dipstick guide.

2. Install the engine oil level dipstick guide with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

3. Attach the engine wire clamp.

4. Install the engine oil level dipstick.

INSTALL INTAKE MANIFOLD

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

1. Install the air tube.

2. Install the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

3. Install the bracket with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

4. Attach the clamp and connect the manifold absolute pressure sensor connector.

5. 

   Text in Illustration

   *1	Projection
   *2	Paint Mark

   Align the paint mark with the projection and connect the No. 2 air injection system hose.

   Tech Tips

   Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL PCV HOSE ASSEMBLY

1. Install the PCV hose with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Connect the PCV hose to the PCV pipe of the cylinder head cover LH and RH.

INSTALL EGR VALVE BRACKET

1. Install the EGR valve bracket with the 3 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

2. Attach the 2 wire harness clamps and PCV hose clamp.

INSTALL NO. 5 WATER BY-PASS PIPE

1. Install the No. 5 water by-pass pipe with the 2 bolts and connect the 2 water by-pass hoses.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL RADIATOR ASSEMBLY

INSTALL FAN SHROUD

INSTALL AIR CLEANER AND HOSE

1. Install the air cleaner and hose with the 3 bolts, and then tighten the hose clamp.

   Torque:

   for bolt

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

   for hose clamp

   2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

2. Attach the clamp and connect the mass air flow meter connector.

3. Connect the No. 2 PCV hose and No. 1 air hose.

INSTALL FRONT FENDER APRON TRIM PACKING C

1. Install the front fender apron trim packing C with the 4 clips.

INSTALL FRONT FENDER APRON TRIM PACKING A

1. Install the front fender apron trim packing A with the 3 clips.

INSTALL FRONT FENDER APRON TRIM PACKING D

1. Install the front fender apron trim packing D with the 4 clips.

INSTALL FRONT FENDER APRON TRIM PACKING B

1. w/ KDSS

   Install the front fender apron trim packing B with the 3 clips.

2. w/o KDSS

   Install the front fender apron trim packing B with the 4 clips.

ADJUST HOOD SUB-ASSEMBLY

INSTALL RADIATOR SIDE DEFLECTOR LH

1. Install the deflector with the 4 clips.

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

1. Install the deflector with the 4 clips.

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

1. Install the oil cooler air duct with the 4 bolts.

   Torque:

   4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

ADD ENGINE OIL

1. Add fresh oil and install the oil filler cap.

   Standard Oil Grade
   Oil Grade Oil Viscosity (SAE) API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil 0W-20 5W-20 5W-30 10W-30 API grade SL, SM or SN multigrade engine oil 15W-40 20W-50

   Standard Oil Capacity
   Item Specified Condition Drain and refill without oil filter change 7.1 liters (7.5 US qts, 6.2 Imp. qts) Drain and refill with oil filter change 7.5 liters (7.9 US qts, 6.6 Imp. qts) Dry fill 9.3 liters (9.8 US qts, 8.2 Imp. qts)

ADD ENGINE COOLANT

1. Add engine coolant.

   Standard Capacity (w/o ATF Warmer)
   Item Specified Condition w/ Rear Heater 16.5 liters (17.4 US qts, 14.5 Imp. qts) w/o Rear Heater 13.8 liters (14.6 US qts, 12.1 Imp. qts)

   Standard Capacity (w/ ATF Warmer)
   Item Specified Condition w/ Rear Heater 17.0 liters (18.0 US qts, 15.0 Imp. qts) w/o Rear Heater 14.2 liters (15.0 US qts, 12.5 Imp. qts)

   Note

   Do not substitute plain water for engine coolant.

   Tech Tips

   
   

   • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

   • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

2. Slowly pour coolant into the radiator reservoir until it reaches the F line.

3. Install the reservoir cap.

4. Install the radiator cap.*1

5. Start the engine and stop it immediately.*2

6. Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

7. Repeat steps *1, *2 and *3 until the coolant level does not decrease.

   Tech Tips

   Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

8. Install the radiator cap.*4

9. Set the air conditioning as follows.*5

   Item	Condition
   Fan speed	Any setting except off
   Temperature	Toward WARM
   Air conditioning switch	Off

10. Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

    CAUTION:

    
    

    • Wear protective gloves. Hot areas on the parts may injure your hands.

    • Be careful of the fan.

    • Be careful as the engine, radiator and radiator hoses are hot and can cause burns.

    Note

    
    

    • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

    • Do not start the engine when there is no coolant in the radiator reservoir.

    • Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.

    • If there is not enough coolant, the engine may burn out or overheat.

    Tech Tips

    
    

    • Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.

    • The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.

11. Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

12. If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

13. If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

    If the coolant level is below the F line, repeat steps *4 through *8.

    If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

BLEED POWER STEERING FLUID

1. Check the fluid level.

2. Jack up the front of the vehicle and support it with stands.

3. Turn the steering wheel.

   
   

   1. With the engine stopped, turn the wheel slowly from lock to lock several times.

4. Lower the vehicle.

5. Start the engine.

6. Idle the engine for a few minutes.

7. Turn the steering wheel.

   
   

   1. With the engine idling, turn the wheel left or right to the full lock position and keep it there for 2 to 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds. *1

   2. Repeat *1 several times.

      Note

      For vehicles with VGRS, if the steering wheel is turned from lock to lock repeatedly, the system may stop operating and the amount of rotation before the steering wheel locks may increase due to operation of the overheating prevention function. When the system temperature drops, the system operation automatically returns to normal.

8. Stop the engine.

9. 

   Text in Illustration

   *a	Correct
   *b	Incorrect

   Check for foaming or emulsification.

   If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

10. Check the fluid level.

INSPECT FOR OIL LEAK

1. Start the engine. Make sure that there are no oil leaks from the area that was worked on.

INSPECT FOR COOLANT LEAK

1. Remove the radiator cap.

2. Check for excessive deposits of rust or scales around the radiator reservoir cap and radiator reservoir filler hole. Also, the engine coolant should be free of oil.

   If excessively dirty, replace the engine coolant.

3. Install the radiator cap.

INSPECT FOR FUEL LEAK

1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the engine switch on (IG) and turn the GTS on.

      Note

      Do not start the engine.

   3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

   4. Check that there are no leaks from the fuel system.

      If there are fuel leaks, repair or replace parts as necessary.

   5. Turn the engine switch off.

   6. Disconnect the GTS from the DLC3.

INSPECT ENGINE OIL LEVEL

1. Warm up the engine. Then stop the engine and wait for 5 minutes.

2. 

   Text in Illustration

   *a	Measuring Surface
   *b	Low Level Mark
   *c	Full Level Mark

   Check that the engine oil level is between the dipstick low level mark and full level mark.

   If the level is low, check for leakage and add oil up to the full level mark.

   Note

   Do not fill engine oil above the full level mark.

   Tech Tips

   A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.

   
   

   • When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.

   • If low quality oil or oil of an inappropriate viscosity is used.

   • When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.

   • When leaving the idling for a long time, or when driving frequently through heavy traffic.

   When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.

INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

INSPECT SHIFT LEVER POSITION

1. When moving the shift lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that it moves smoothly and correctly into position.

2. Check that the shift lever does not stop when moving the shift lever from R to P, and check that the shift lever does not stick when moving the shift lever from D to S.

3. Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D, and moves rearward after moving the shift lever to R.

   If there are problems during the above inspections, perform the adjustment using the following procedures.

   
   

   1. Move the shift lever to N

   2. 

      Text in Illustration

      *1

      Lever

      Loosen the nut of the floor shift gear shifting rod. Then, with the lever of the floor shift assembly lightly pushed towards the rear of the vehicle, tighten the nut.

      Torque:

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

INSPECT IGNITION TIMING

1. Warm up the engine.

2. When using the GTS:

   
   

   1. Connect the GTS to the DLC3.

   2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.

      Standard ignition timing
      7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

      Tech Tips

      Refer to the GTS operator's manual for further details.

   3. Check that the ignition timing advances immediately when the engine speed is increased.

   4. Disconnect the GTS from the DLC3.

3. When not using the GTS:

   
   
   1. 

      Text in Illustration

      *a	Front view of DLC3

      Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      SST

      09843-18040

      Note

      Be sure not to improperly connect the terminals. This may damage the engine.

   2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

      Note

      Use a timing light that detects primary signals.

   3. Inspect the ignition timing during idling.

      Standard ignition timing
      8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

   4. Remove SST from the DLC3.

   5. Inspect the ignition timing during idling.

      Standard ignition timing
      7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

   6. Disconnect the timing light from the engine.

INSPECT ENGINE IDLE SPEED

1. Warm up the engine.

2. When using the GTS:

   
   

   1. Connect the GTS to the DLC3.

   2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Engine Speed.

      Standard idle speed
      650 to 750 rpm (transmission in neutral and A/C switch off)

      Tech Tips

      Refer to the GTS operator's manual for further details.

   3. Disconnect the GTS from the DLC3.

3. When not using the GTS:

   
   
   1. 

      Text in Illustration

      *a	Front view of DLC3

      Connect SST to terminal 9 (TAC) of the DLC3.

      SST

      09843-18030

      Note

      Be sure not to improperly connect SST. This may damage the engine.

   2. Race the engine at 2500 rpm for approximately 90 seconds.

   3. Inspect the engine idle speed.

      Standard idle speed
      650 to 750 rpm (transmission in neutral and A/C switch off)

INSPECT CO/HC

1. Start the engine.

2. Run the engine at 2500 rpm for approximately 180 seconds.

3. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft) into the tailpipe during idling.

4. Immediately check the CO/HC concentration during idling and/or at 2500 rpm.

   Tech Tips

   When carrying out the 2 tests (idling and 2500 rpm), the measurement procedures are prescribed by applicable local regulations.

5. If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below.

   
   

   1. Check the air fuel ratio sensor operation Click here and heated oxygen sensor operation Click here.

   2. Refer to the table below for possible causes, and then inspect and correct the corresponding causes if necessary.

      CO	HC	Symptom	Causes
      Normal	High	Rough idling	Faulty ignition: Incorrect timing Plugs are contaminated or shorted, or plug gaps are incorrect Leaky intake and exhaust valves Leaky cylinders
      Low	High	Rough idling (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Lean mixture causing misfire
      High	High	Rough idle (Black smoke from exhaust)	Restricted air filter Plugged PCV valve Faulty SFI system: Faulty pressure regulator Defective engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Faulty throttle position sensor

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

   Text in Illustration

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

   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.