ENGINE ASSEMBLY INSTALLATION

PROCEDURE

  1. INSTALL ENGINE HANGER

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  2. REMOVE ENGINE STAND

    1. A150148C01

      *1

      Engine Hanger

      *2

      Engine Assembly

      *a

      50° or less

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

      Note:

      When hanging the engine assembly, make sure to hang the engine assembly with the angle of the sling device at 50° or less. If not, the engine assembly or engine hangers may be damaged.

    2. Lift the engine assembly 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 assembly onto a workbench.

  3. INSTALL NO. 1 WATER BY-PASS PIPE

    1. A228363C02

      *a

      Upper Side

      *b

      RH Side

      *c

      Paint Mark

      Connect the 2 water by-pass hoses to the No. 4 water by-pass pipe and No. 2 water by-pass pipe, and slide the 2 clamps to secure the hoses and install the No. 1 water by-pass pipe.

      Tip:

      • When connecting the water by-pass hoses, make sure the paint marks and clamps 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 assembly with a chain block.

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

    3. A280687C02
      V100135

      Bolt
      V100136

      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. A228418C04
      V100135

      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. A228419C02

      *1

      Drive Plate and Ring Gear Sub-assembly

      *2

      Rear Drive Plate Spacer
      V100135

      Transmission Assembly Side

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

      Tip:

      As the rear drive plate spacer and the drive plate and ring gear sub-assembly 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 sub-assembly and bolts.

      Tip:

      The bolts are tightened in 2 progressive steps.

      1. Clean the bolts and bolt holes.

      2. A192239C70

        *a

        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 and ring gear sub-assembly.

  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 transfer with the 4 bolts.

      72.5 N*m

      739 kgf*cm

      53 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

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  8. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

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  9. INSTALL PROPELLER SHAFT ASSEMBLY

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  10. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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  11. CONNECT OIL COOLER TUBE SUB-ASSEMBLY

    1. Connect the oil cooler tube sub-assembly with the bolt.

      14 N*m

      143 kgf*cm

      10 ft.*lbf

  12. CONNECT ENGINE WIRE

    1. Connect the ECM connector.

      1. Attach the wire harness clamp.

      2. A226129C01

        *1

        Grommet

        *2

        Wire Harness Support

        Attach the grommet to the wire harness support.

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

      4. A227938

        Connect the 6 connectors and attach the clamp.

    2. Install the lower instrument panel.

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    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 sub-assembly.

      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

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  16. INSTALL STARTER COVER

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  17. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

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  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  19. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

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  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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

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  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

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  25. INSTALL EXHAUST PIPE STOPPER BRACKET

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  26. INSTALL COOLER COMPRESSOR ASSEMBLY

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  27. INSTALL SUCTION HOSE SUB-ASSEMBLY

    1. Remove the attached vinyl tape from the suction hose sub-assembly.

    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 sub-assembly.

    4. A271714C01

      Install the suction hose sub-assembly 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 sub-assembly.

    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 sub-assembly.

    4. A271715C01

      Install the discharge hose sub-assembly 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

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  30. INSTALL VANE PUMP ASSEMBLY

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  31. CONNECT PRESSURE FEED TUBE

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  32. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

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  33. INSTALL INTAKE MANIFOLD

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  34. INSTALL AIR TUBE SUB-ASSEMBLY

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  35. INSTALL VENTILATION HOSE ASSEMBLY

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  36. CONNECT NO. 4 WATER BY-PASS PIPE

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  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

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  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)

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  41. CONNECT NO. 13 WATER BY-PASS HOSE

    1. A306281C01

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      *c

      Paint Mark (Blue)

      w/ EGR System:

      Connect the No. 13 water by-pass hose to the EGR valve sub-assembly, and slide the clamp to secure the hose.

      Tip:

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

    2. A306282C01

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      *c

      Paint Mark (Blue)

      w/o EGR System:

      Connect the No. 13 water by-pass hose to the No. 5 water by-pass pipe, and slide the clamp to secure the hose.

      Tip:

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

  42. CONNECT NO. 12 WATER BY-PASS HOSE

    1. A306283C01

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      *c

      Paint Mark (Green)

      w/ EGR System:

      Connect the No. 12 water by-pass hose to the EGR valve sub-assembly, and slide the clamp to secure the hose.

      Tip:

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

    2. A306284C01

      *a

      13 to 17 mm (0.512 to 0.669 in.)

      *b

      5 mm (0.197 in.)

      *c

      Paint Mark (Green)

      w/o EGR System:

      Connect the No. 12 water by-pass hose to the No. 5 water by-pass pipe, and slide the clamp to secure the hose.

      Tip:

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

  43. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Single Air Conditioning System)

    A294240C02

    *a

    Upper Side

    *b

    LH Side

    *c

    Rear

    *d

    Paint Mark

    1. Install the water pipe and hose sub-assembly with the 2 nuts.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. Connect the 4 water hoses to the water pipe, and slide the 4 clamps to secure the hoses.

      Tip:

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

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

  44. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Dual Air Conditioning System)

    A294204C02

    *a

    Upper Side

    *b

    LH Side

    *c

    Rear

    *d

    Paint Mark

    1. Install the water pipe and hose sub-assembly with the 2 nuts.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. Connect the 6 water hoses to the water pipe, and slide the 6 clamps to secure the hoses.

      Tip:

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

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

  45. INSTALL RADIATOR ASSEMBLY

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  46. CONNECT OIL COOLER ACCESSORY ASSEMBLY

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  47. CONNECT NO. 2 RADIATOR HOSE

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  48. INSTALL FAN SHROUD

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  49. INSTALL NO. 1 RADIATOR HOSE

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  50. INSTALL RADIATOR RESERVOIR ASSEMBLY

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  51. INSTALL RADIATOR SIDE DEFLECTOR RH

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  52. INSTALL RADIATOR SIDE DEFLECTOR LH

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  53. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    1. Install the air cleaner case sub-assembly with the 3 bolts.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  54. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  55. INSTALL AIR CLEANER CAP AND HOSE

    1. A228345C02

      *1

      Air Cleaner Hose

      *2

      Throttle Body Assembly

      *a

      Upper Side

      *b

      Front

      *c

      Groove

      *d

      Protrusion

      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 assembly 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 and No. 1 air hose and attach the wire harness clamp.

    4. Connect the No. 2 ventilation hose to the air cleaner hose, and slide the clamp the secure the hose.

  56. INSTALL FRONT BUMPER COVER

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  57. INSTALL BATTERY TRAY

  58. 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

  59. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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  60. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click here

  61. ADD ENGINE OIL

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  62. ADD ENGINE COOLANT

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  63. ADD POWER STEERING FLUID

  64. BLEED POWER STEERING FLUID

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  65. INSPECT FOR OIL LEAK

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  66. INSPECT FOR COOLANT LEAK

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  67. INSPECT FOR FUEL LEAK

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  68. INSPECT ENGINE OIL LEVEL

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  69. INSPECT FOR POWER STEERING FLUID LEAK

  70. INSPECT FOR EXHAUST GAS LEAK

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  71. PERFORM RESET MEMORY

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  72. INSPECT IGNITION TIMING

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  73. INSPECT ENGINE IDLE SPEED

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  74. INSPECT CO/HC

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  75. INSTALL HOOD SUB-ASSEMBLY

    1. A271717C01

      Install the hood sub-assembly 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.

  76. ADJUST HOOD SUB-ASSEMBLY

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  77. CHARGE REFRIGERANT

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  78. WARM UP ENGINE

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  79. CHECK FOR REFRIGERANT GAS LEAK

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  80. INSTALL ENGINE ROOM SIDE COVER

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

  81. INSTALL ENGINE ROOM SIDE COVER LH

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

  82. INSTALL V-BANK COVER SUB-ASSEMBLY

    1. A228417C01

      *1

      Pin

      *2

      V-bank Cover Grommet

      *3

      V-bank Cover 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 sub-assembly to attach the pins.

  83. INSTALL UPPER RADIATOR SUPPORT SEAL

    1. Install the upper radiator support seal with the 14 clips.

  84. 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.

  85. 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.

  86. INSTALL FRONT FENDER APRON SEAL RH

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

  87. INSTALL FRONT FENDER APRON SEAL LH

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

  88. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

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

      29 N*m

      296 kgf*cm

      21 ft.*lbf

  89. INSTALL TRANSMISSION UNDER COVER

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

      29 N*m

      296 kgf*cm

      21 ft.*lbf

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

    1. A224743

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

    2. Install the 4 bolts.

      29 N*m

      296 kgf*cm

      21 ft.*lbf

  91. 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