ENGINE ASSEMBLY INSTALLATION

PROCEDURE

  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE STAND

    1. A150148C01

      *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. If not, 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.

  3. INSTALL NO. 1 WATER BY-PASS PIPE

    1. A228363C01

      *1

      Paint Mark

      *a

      Upper Side

      *b

      RH Side

      Connect the 2 water hoses and install the No. 1 water by-pass pipe.

      Tip:

      • When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.

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

  4. 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. A280687C01

      *1

      Nut

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

      for nut

      72 N*m

      734 kgf*cm

      53 ft.*lbf

      for bolt

      57 N*m

      581 kgf*cm

      42 ft.*lbf

    4. Remove the 2 bolts and 2 engine hangers.

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    1. Using SST, hold the crankshaft.

      09213-70011

      09213-70020

      09330-00021

    2. A228418C02

      *a

      Engine Side

      Install the crankshaft angle sensor rotor.

      Tip:

      • 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. A228419C01

      *1

      Drive Plate and Ring Gear

      *2

      Rear Drive Plate Spacer

      *a

      Transmission Side

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

      Tip:

      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.

      Tip:

      The bolts are tightened in 2 progressive steps.

      1. Clean the bolts and bolt holes.

      2. A192239C01

        *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. A271712C01

        Step 1:

        Uniformly install and tighten the 10 new bolts in several steps in the sequence shown in the illustration.

        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.

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tip:

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

    1. Install the rear No. 1 engine mounting insulator to the transmission with the 4 bolts.

      65 N*m

      663 kgf*cm

      48 ft.*lbf

    2. Install the rear engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    (Click here)

  8. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

    Click here

  9. INSTALL PROPELLER SHAFT ASSEMBLY

    (Click here)

  10. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    (Click here)

  11. CONNECT OIL COOLER TUBE SUB-ASSEMBLY

    1. Connect the oil cooler tube with the bolt.

      14 N*m

      143 kgf*cm

      10 ft.*lbf

  12. CONNECT ENGINE WIRE

    1. Connect the ECM connector.

      1. A226129C01

        *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. A227938

        Connect the 6 connectors and attach the clamp.

    2. Install the lower instrument panel (Click here).

    3. for Engine Room RH Side:

      1. A271711C01

        *1

        Engine Wire

        *2

        Ground Wire

        Attach the 3 wire harness clamps to connect the engine wire and connect the connector.

      2. Connect the ground wire with the bolt.

        8.0 N*m

        82 kgf*cm

        71 in.*lbf

    4. for Engine Room LH Side:

      1. A271713C01

        *1

        No. 2 Engine Wire

        *2

        Ground Wire

        Attach the wire harness clamp.

      2. Connect the No. 2 engine wire and ground wire with the 2 bolts.

        for bolt A

        8.0 N*m

        82 kgf*cm

        71 in.*lbf

        for bolt B

        19 N*m

        194 kgf*cm

        14 ft.*lbf

      3. A228381C01

        *1

        Engine Wire

        *2

        Engine Room Relay Block

        Attach the 2 claws and connect the engine wire to the engine room relay block.

      4. Install the nut to the engine room relay block.

        11 N*m

        112 kgf*cm

        8 ft.*lbf

      5. Connect the connector.

      6. A228375

        Connect the ground wire with the bolt.

        8.5 N*m

        87 kgf*cm

        75 in.*lbf

  13. CONNECT FUEL HOSE AND NO. 2 FUEL TUBE SUB-ASSEMBLY

    1. Connect the fuel hose and No. 2 fuel tube (Click here).

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

  14. INSTALL FLYWHEEL HOUSING SIDE COVER

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL STARTER COVER

    Click here

  17. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

    Click here

  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  19. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

    Click here

  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  21. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System)

    Click here

  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  25. INSTALL EXHAUST PIPE STOPPER BRACKET

    Click here

  26. INSTALL COOLER COMPRESSOR ASSEMBLY

    Click here

  27. INSTALL SUCTION HOSE SUB-ASSEMBLY

    1. Remove the attached vinyl tape from the suction hose.

    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the suction hose.

    4. A271714C01

      Install the suction hose with the 2 bolts and nut.

      for bolt A

      7.8 N*m

      80 kgf*cm

      69 in.*lbf

      for bolt B and nut

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  28. INSTALL DISCHARGE HOSE SUB-ASSEMBLY

    1. Remove the attached vinyl tape from the discharge hose.

    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the discharge hose.

    4. A271715C01

      Install the discharge hose with the 3 bolts.

      for bolt A

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

      for bolt B

      7.8 N*m

      80 kgf*cm

      69 in.*lbf

      for bolt C

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  29. INSTALL GENERATOR ASSEMBLY

    Click here

  30. INSTALL VANE PUMP ASSEMBLY

    Click here

  31. CONNECT PRESSURE FEED TUBE

    Click here

  32. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

    Click here

  33. INSTALL INTAKE MANIFOLD

    Click here

  34. INSTALL AIR TUBE SUB-ASSEMBLY

    Click here

  35. INSTALL VENTILATION HOSE ASSEMBLY

    Click here

  36. CONNECT NO. 4 WATER BY-PASS PIPE

    Click here

  37. INSTALL INTAKE FLANGE (w/o EGR System)

    1. Install a new gasket to the intake manifold.

    2. Install the intake flange with the 2 nuts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  38. INSTALL EGR VALVE BRACKET

    Click here

  39. INSTALL NO. 5 WATER BY-PASS PIPE (w/o EGR System)

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  40. INSTALL EGR VALVE ASSEMBLY (w/ EGR System)

    Click here

  41. CONNECT NO. 13 WATER BY-PASS HOSE

    1. A239701C01

      *1

      Paint Mark (Blue)

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      w/ EGR System:

      Connect the No. 13 water by-pass hose.

      Tip:

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

    2. A239686C01

      *1

      Paint Mark (Blue)

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      w/o EGR System:

      Connect the No. 13 water by-pass hose.

      Tip:

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

  42. CONNECT NO. 12 WATER BY-PASS HOSE

    1. A239702C01

      *1

      Paint Mark (Green)

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      w/ EGR System:

      Connect the No. 12 water by-pass hose.

      Tip:

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

    2. A239687C01

      *1

      Paint Mark (Green)

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      w/o EGR System:

      Connect the No. 12 water by-pass hose.

      Tip:

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

  43. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY

    A271716C01

    *1

    Paint Mark

    -

    -

    *a

    Upper Side

    *b

    LH Side

    *c

    Rear

    -

    -

    1. Install the water pipe and hose with the 2 nuts.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. Connect the 6 water hoses.

      Tip:

      • When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.

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

  44. INSTALL RADIATOR ASSEMBLY

    Click here

  45. CONNECT OIL COOLER ACCESSORY ASSEMBLY

    Click here

  46. CONNECT NO. 2 RADIATOR HOSE

    Click here

  47. INSTALL FAN SHROUD

    Click here

  48. INSTALL NO. 1 RADIATOR HOSE

    Click here

  49. INSTALL RADIATOR RESERVOIR ASSEMBLY

    Click here

  50. INSTALL RADIATOR SIDE DEFLECTOR RH

    Click here

  51. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

  52. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  53. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  54. INSTALL AIR CLEANER CAP AND HOSE

    1. A228345C01

      *1

      Air Cleaner Hose

      *2

      Throttle Body

      *3

      Groove

      *4

      Protrusion

      *a

      Upper Side

      *b

      Front

      Attach the 4 clamps to install the air cleaner cap and hose.

      Tip:

      When installing the air cleaner hose, align its groove with the protrusion of the throttle body as shown in the illustration.

    2. Tighten the hose clamp.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

      Tip:

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

    3. Connect the mass air flow meter connector, No. 1 air hose and No. 2 ventilation hose and attach the wire harness clamp.

  55. INSTALL FRONT BUMPER COVER

    (Click here)

  56. INSTALL BATTERY TRAY

  57. INSTALL BATTERY

    1. Install the battery.

    2. Install the battery hold down clamp with the 2 nuts.

      6.0 N*m

      61 kgf*cm

      53 in.*lbf

    3. Install the No. 2 engine wire with the nut.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  58. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    (Click here)

  59. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

  60. ADD ENGINE OIL

    Click here

  61. ADD ENGINE COOLANT

    Click here

  62. ADD POWER STEERING FLUID

  63. BLEED POWER STEERING FLUID

    Click here

  64. INSPECT FOR OIL LEAK

    Click here

  65. INSPECT FOR COOLANT LEAK

    Click here

  66. INSPECT FOR FUEL LEAK

    Click here

  67. INSPECT ENGINE OIL LEVEL

    Click here

  68. INSPECT FOR POWER STEERING FLUID LEAK

  69. INSPECT FOR EXHAUST GAS LEAK

    Click here

  70. PERFORM RESET MEMORY

    (Click here)

  71. INSPECT IGNITION TIMING

    Click here

  72. INSPECT ENGINE IDLE SPEED

    Click here

  73. INSPECT CO/HC

    Click here

  74. INSTALL HOOD SUB-ASSEMBLY

    1. A271717C01

      Install the hood with the 8 bolts.

      for bolt A

      13 N*m

      133 kgf*cm

      10 ft.*lbf

      for bolt B

      18 N*m

      178 kgf*cm

      13 ft.*lbf

    2. Connect the washer hose.

  75. ADJUST HOOD SUB-ASSEMBLY

    Click here

  76. CHARGE REFRIGERANT

    Click here

  77. WARM UP ENGINE

    Click here

  78. CHECK FOR REFRIGERANT GAS LEAK

    Click here

  79. INSTALL ENGINE ROOM SIDE COVER

    1. Install the engine room side cover with the 4 clips.

  80. INSTALL ENGINE ROOM SIDE COVER LH

    1. Install the engine room side cover LH with the 4 clips.

  81. INSTALL V-BANK COVER SUB-ASSEMBLY

    1. A228417C01

      *1

      Pin

      *2

      Grommet

      *3

      Hook

      *4

      No. 1 V-bank Cover Bracket

      Attach the 2 V-bank cover hooks to the No. 1 V-bank cover bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

  82. INSTALL UPPER RADIATOR SUPPORT SEAL

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

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

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

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

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

  85. INSTALL FRONT FENDER APRON SEAL RH

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

  86. INSTALL FRONT FENDER APRON SEAL LH

    1. Install the front fender apron seal LH with the 7 clips.

  87. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

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

      29 N*m

      296 kgf*cm

      21 ft.*lbf

  88. INSTALL TRANSMISSION UNDER COVER

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

      29 N*m

      296 kgf*cm

      21 ft.*lbf

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

    1. A224743

      Hook the No. 1 engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

      29 N*m

      296 kgf*cm

      21 ft.*lbf

  90. INSTALL LOWER FRONT BUMPER COVER

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

      8.0 N*m

      82 kgf*cm

      71 in.*lbf