ENGINE ASSEMBLY INSTALLATION


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 front engine mounting insulators with the 2 nuts.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  2. INSTALL ENGINE HANGER


    1. A00K090E01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install an engine hanger to each location shown in the illustration.

      Tech Tips

      No. 1 Engine Hanger 12281-54080
      No. 2 Engine Hanger 12282-54070
      Bolt (No. 1 Engine Hanger) 90119-10736
      Bolt (No. 2 Engine Hanger) 91622-61022
      Torque:
      for No. 1 Engine Hanger
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }
      for No. 2 Engine Hanger
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

  3. REMOVE ENGINE FROM 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.

  4. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Install the engine with the 4 bolts and 4 nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      For RHD vehicles only:

      A00O8I8E01

      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.

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

    3. Remove the 2 bolts and 2 engine hangers.

  5. INSTALL FLYWHEEL HOUSING DUST SEAL

  6. INSTALL REAR END PLATE


    1. Install the rear end plate with the 2 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  7. INSTALL FLYWHEEL SUB-ASSEMBLY

    A00OAALE01

    1. Using SST, hold the crankshaft.

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

    2. Clean the bolts and bolt holes.

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the flywheel to the crankshaft.

    5. Temporarily install the flywheel with the 8 bolts.

    6. A00O3ZIE01

      Tighten the 8 bolts uniformly in several steps in the order shown in the illustration.

      Torque:
      123 N*m  { 1249 kgf*cm, 90 ft.*lbf }

      Note

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

  8. INSTALL CLUTCH DISC ASSEMBLY


    1. A00JW1TE01

      Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel to install the clutch disc.

      SST
      09301-00110
      Text in Illustration
      A00JWY4 Flywheel Side

      Note

      Be sure to install the clutch disc so that it is facing in the correct direction.

  9. INSTALL CLUTCH COVER ASSEMBLY

    A00JUITE02
    Text in Illustration
    *a Matchmark

    1. Align the matchmarks on the clutch cover and flywheel.

    2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      SST
      09301-00110
      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Tech Tips

      Move SST up and down, and right and left lightly after checking that the clutch disc assembly is in the center, and then tighten the bolts.

  10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


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

      Note

      Perform this procedure when replacement of the engine mounting insulator is necessary.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  11. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. Install the manual transmission Click here.

  12. INSTALL PROPELLER SHAFT ASSEMBLY


    1. Align the matchmarks on the propeller shaft flange and differential flange.

    2. Install the propeller shaft assembly with the 4 washer, 4 bolts and 4 nuts.

      Torque:
      88 N*m  { 899 kgf*cm, 65 ft.*lbf }

    3. Align the matchmarks on the propeller shaft flange and transfer flange.

    4. Install the propeller shaft assembly with the 4 washers and 4 nuts.

      Torque:
      88 N*m  { 899 kgf*cm, 65 ft.*lbf }

  13. INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Align the matchmarks on the yoke and differential flange.

    2. Install the propeller shaft assembly with the 4 washers, 4 bolts and 4 nuts.

      Torque:
      88 N*m  { 899 kgf*cm, 65 ft.*lbf }

    3. Align the matchmarks on the yoke and transfer flange.

    4. Install the propeller shaft assembly with the 4 washers and 4 nuts.

      Torque:
      88 N*m  { 899 kgf*cm, 65 ft.*lbf }

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe to the exhaust manifold with 3 new nuts.

      Torque:
      54 N*m  { 554 kgf*cm, 40 ft.*lbf }

    2. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

    3. Install the clamp with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  15. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter installation surface.

    2. Apply clean engine oil to the gasket of a new oil filter.

    3. Install the oil filter and tighten it by hand until the gasket contacts the installation surface.

    4. Using SST, tighten the oil filter. Choose from the following to further tighten the oil filter.

      SST
      09228-44011

      1. A00K14UE01

        Using a torque wrench, tighten the oil filter.

        Torque:
        17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      2. Tighten the oil filter a 3/4 turn by hand or with a common wrench.

        Text in Illustration
        A00JYOS 3/4 turn

  16. INSTALL STARTER ASSEMBLY


    1. Install the starter assembly with the 2 bolts and nut.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

    2. Connect the starter wire with the nut.

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

    3. Install the terminal cap.

    4. Connect the starter connector.

  17. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. Connect the release cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  18. INSTALL VANE PUMP ASSEMBLY


    1. Temporarily install the vane pump with the 2 bolts and nut.

    2. A00O4V0E01

      Install the pulley to the pump shaft.

    3. Using SST, hold the pulley and install the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      43 N*m  { 443 kgf*cm, 31 ft.*lbf }

  19. CONNECT FUEL HOSE


    1. Connect the 2 fuel hoses.

  20. CONNECT HEATER WATER HOSE ASSEMBLY


    1. Connect the 2 water hoses.

    2. Install the heater water hose clamp with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  21. INSTALL WIRING HARNESS CLAMP BRACKET (for LHD)


    1. Install the wiring harness clamp bracket with the bolt.

      Torque:
      22 N*m  { 219 kgf*cm, 16 ft.*lbf }

  22. CONNECT ENGINE WIRE


    1. Connect the ECM connector.


      1. A00O7SWE01
        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.

    2. A00O7DIE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Connect the 5 ECM connectors and attach the clamp.

    3. A00OA11

      for LHD:

      Connect the 4 wire harness clamps.

    4. A00O39Q

      Attach the 2 clamps and connect the connector.

    5. Attach the 2 claws and install the nut.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    6. Install the No. 1 relay block cover.

    7. A00OA8UE01

      Attach the clamp and install the 3 bolts.

      Torque:
      for bolt A
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      for bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt C
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  23. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY


    1. Install the glove compartment door Click here.

  24. INSTALL GENERATOR ASSEMBLY


    1. Temporarily install the generator with the 2 bolts.

    2. Connect the vacuum pump oil outlet hose.

    3. Install 2 new gaskets and the vacuum pump oil inlet hose with the union bolt.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }

    4. Connect the vacuum pump hose.

    5. Attach the vacuum pump oil inlet hose to the cord clip.

    6. Install the generator wire with the nut.

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

    7. Install the terminal cap.

    8. Connect the generator connector.

  25. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. A00OAKME01

      Temporarily install the cooler compressor with the 2 bolts.

    2. Temporarily install the idle pulley bracket with the 4 bolts.

    3. Tighten the 6 bolts in the sequence shown in the illustration.

      Torque:
      for bolt A
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      except bolt A
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Connect the wire harness with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

    5. Connect the cooler compressor connector.

  26. INSTALL INTAKE PIPE ASSEMBLY


    1. Install the intake pipe with the 2 bolts.

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

    2. Tighten the intake pipe clamp.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  27. INSTALL RADIATOR ASSEMBLY


    1. Insert the tabs of the radiator support into the radiator service holes.

    2. A0099HR

      Install the radiator with the 4 bolts.

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

  28. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Install the shroud together with the coupling fan between the radiator and engine.

      Note

      Be careful not to damage the radiator core.

    3. Temporarily install the fluid coupling fan to the fan pulley with the 4 nuts. Tighten the nuts as much as possible by hand.

    4. A009713

      Attach the claws of the shroud as shown in the illustration.

    5. Install the shroud with the 2 bolts.

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

    6. Install the fan and generator V belt and vane pump V belt Click here.

    7. Tighten the 4 nuts of the fluid coupling fan.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

  29. INSTALL NO. 2 RADIATOR HOSE


    1. A0099UNE01
      Text in Illustration
      *a Upper
      *b Front Side of Vehicle
      *c LH Side
      *1 Protrusion
      *2 Paint Mark

      Install the radiator hose.

      Tech Tips

      Position the hose clamps as shown in the illustration.

  30. INSTALL NO. 1 RADIATOR HOSE


    1. Install the hose clamp with the 2 nuts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    2. A00991RE01
      Text in Illustration
      *a Upper
      *b RH Side

      Install the radiator hose.

      Tech Tips

      Position the hose clamps as shown in the illustration.

  31. INSTALL RADIATOR SIDE DEFLECTOR RH


    1. Attach the 3 claws.

    2. Install the deflector with the clip.

  32. INSTALL RADIATOR SIDE DEFLECTOR LH


    1. Attach the 3 claws.

    2. Install the deflector with the clip.

  33. INSTALL UPPER FRONT BUMPER RETAINER


    1. Install the upper retainer with the 3 bolts.

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

  34. INSTALL FRONT BUMPER COVER


    1. w/ TOYOTA Parking Assist-sensor System, w/ Fog Light:

      Connect the 3 connectors.

    2. w/ TOYOTA Parking Assist-sensor System, w/o Fog Light:

      Connect the 2 connectors.

    3. w/o TOYOTA Parking Assist-sensor System, w/ Fog Light:

      Connect the connector.

    4. w/ Headlight Cleaner System:

      Connect the headlight cleaner hose.

    5. Attach the 12 claws to install the front bumper cover.

    6. Install the 2 bolts labeled A, 2 bolts labeled B, 6 screws and 6 clips.

      Torque:
      bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      A0099DZE02
      Text in Illustration
      *1 Bolt A *2 Bolt B

  35. INSTALL AIR CLEANER CASE ASSEMBLY


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

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

  36. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  37. INSTALL RESONATOR WITH AIR CLEANER CAP SUB-ASSEMBLY


    1. Insert the hinge part of the air cleaner cap and hose into the air cleaner case, and then attach the 4 hook clamps.

    2. Connect the air cleaner cap sub-assembly with the clamp.

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

    3. Attach the wire harness clamp.

    4. Connect the 2 clamps and connector.

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


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

  39. INSTALL FRONT FENDER APRON SEAL LH


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

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


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

  41. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal with the 4 clips.

  42. 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 }

  43. INSTALL TRANSMISSION UNDER COVER


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

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

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


    1. A00O712

      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 }

  45. 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 }

  46. INSTALL UPPER RADIATOR SUPPORT SEAL


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

  47. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Install the cowl top ventilator louver Click here.

  48. INSTALL HOOD SUB-ASSEMBLY


    1. A00O5C3

      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
      A00O9VA Bolt A
      A00O5SP Bolt B

    2. Connect the washer nozzle hose.

  49. ADJUST HOOD SUB-ASSEMBLY


    1. Adjust the hood position.


      1. A00K0BT

        Loosen the 4 hinge bolts on the hood.

      2. Move the hood and adjust the clearance between the hood and front fender.

      3. Tighten the 4 hinge bolts on the hood.

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

    2. Adjust the height of the front end of the hood using the cushion rubbers.


      1. A00K1I8

        Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.

        Tech Tips

        Raise or lower the front end of the hood by turning the 2 cushion rubbers.

    3. Adjust the hood lock.


      1. A00JZ89

        Loosen the 3 bolts.

      2. Adjust the hood lock and tighten the 3 bolts.

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

      3. Check that the striker can smoothly engage with the hood lock.

  50. INSTALL BATTERY TRAY

  51. INSTALL BATTERY

  52. INSTALL BATTERY HOLD DOWN CLAMP


    1. A00OB9LE01

      Install the battery hold down clamp with the 2 nuts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Connect the engine wire with the nut labeled A.

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

  53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  54. ADD ENGINE OIL


    1. Add fresh engine oil.

      Standard Engine Oil
      Oil Grade Oil Viscosity (SAE)
      API CF-4 or CF 10W-30
      Standard Capacity
      Item Specified Condition
      Drain and refill without oil filter change 6.0 liters (6.3 US qts, 5.3 Imp. qts)
      Drain and refill with oil filter change 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Dry fill 7.6 liters (8.0 US qts, 6.7 Imp. qts)

    2. Install the oil filler cap.

  55. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Slowly fill the system with engine coolant.

      Standard capacity
      8.6 liters (9.0 US qts, 7.6 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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.)

      • New Toyota vehicles are filled with Toyota Super Long Life Coolant. When replacing the coolant, Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50% and freezing temperature is -35°C (-31°F)) is recommended

    4. Slowly pour coolant into the radiator reservoir until it reaches the Full line.

    5. Install the reservoir cap.

    6. 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.

    7. Install the radiator cap.

    8. Start the engine and warm it up until the thermostat opens.

      Tech Tips

      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.

    9. Maintain the engine speed at 2000 to 2500 rpm.

      Note


      • Make sure that the radiator reservoir still has some coolant in it.

      • Pay attention to the needle of the water temperature meter. 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.

      • 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.

      • Run the engine at 2000 rpm until the coolant level has stabilized.

    10. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:


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

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

    11. Stop the engine, and wait until the engine coolant cools down to ambient temperature.

      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. Check that the coolant level is between the Full and Low lines.

      If the coolant level is below the Low line, repeat all of the steps above.

      If the coolant level is above the Full line, drain coolant so that the coolant level is between the Full and Low lines.

  56. TIGHTEN FUEL TANK CAP ASSEMBLY

  57. BLEED AIR FROM FUEL SYSTEM


    1. A00JYBZ

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

  58. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

      Tech Tips

      When checking for fuel leaks, make sure that there is pressure in the fuel line.

  59. INSPECT FOR ENGINE OIL LEAK


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

  60. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.

  61. ADD MANUAL TRANSMISSION OIL

  62. INSPECT FOR GAS LEAK


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

  63. INSPECT ENGINE IDLE SPEED


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Idle speed
        720 to 820 rpm

        Note


        • Turn all the electrical systems and the A/C off.

        • When checking the idling speed, the shift lever should be in neutral.

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

    3. A00OA3ME08
      Text in Illustration
      *a Front View of DLC3

      When not using an intelligent tester:


      1. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18040

      2. Check the idle speed.

        Standard idle speed
        720 to 820 rpm

        Note


        • Turn all the electrical systems and the A/C off.

        • When checking the idling speed, the shift lever should be in neutral.

        • Confirm the terminal number before connecting them. Connecting the wrong terminal can be damage the engine.

  64. INSPECT MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Check the maximum speed.

      Maximum engine speed
      4850 to 4950 rpm