Engine Assembly - Installation

1. Install oil level gauge sub-assembly

2. Install spark plug

3. Install ignition coil assembly

4. Install oil filler cap housing

5. Install oil filler cap sub-assembly

6. Install water by-pass joint rr

7. Install camshaft timing oil control valve assembly

8. Install intake manifold

9. Install oil filter bracket sub-assembly

10. Install water inlet

11. Install v-ribbed belt tensioner assembly

12. Install no. 1 idler pulley sub-assembly

13. Install no. 2 idler pulley sub-assembly

14. Install front no. 1 engine mounting bracket lh

15. Install front no. 1 engine mounting bracket rh

16. Install exhaust manifold sub-assembly lh

17. Install exhaust manifold sub-assembly rh

18. Install no. 2 ventilation hose

19. Install ventilation hose

20. Install heater water outlet hose a (from heater unit)

21. Install heater water inlet hose a

22. Install radiator outlet, no. 2 hose clamp or clip

23. Install no. 1 radiator hose

24. Install engine wire

25. Install drive plate & ring gear sub-assembly

26. Install engine assembly

27. Install no. 2 engine wire

28. Install engine wire

29. Install intake air surge tank

30. Connect heater water outlet hose a (from heater unit)

31. Connect heater water inlet hose b

32. Connect no. 2 fuel pipe sub-assembly

33. Connect no. 1 fuel pipe sub-assembly

34. Install cooler compressor

35. Install generator assembly

36. Install vane pump assembly

37. Install fan pulley

38. Install fan with fluid coupling

39. Install fan and generator v belt

40. Fully tighten fan with fluid coupling

41. Install fan shroud

42. Install radiator assembly

43. Install radiator support seal upper

44. Install air cleaner assembly

45. Connect no. 2 ventilation hose

46. Install hood sub-assembly

47. Adjust hood sub-assembly

48. Install battery

49. Add engine oil

50. Add engine coolant

51. Install automatic transmission assembly (for 2wd)

52. Install automatic transmission assembly (for 4wd)

53. Check for engine coolant leakage

54. Check for fuel leakage

55. Check for engine oil leakage

56. Install v-bank cover

57. Inspect ignition timing

58. Inspect engine idle speed

59. Inspect co/hc

​

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Torque:

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

1. Install a new gasket and oil filler cap housing with the 2 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Install a new O-ring to the water outlet pipe.

2. Apply soapy water to the O-ring.

3. Install 2 new gaskets and water by-pass joint RR with the 2 bolts and 4 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

4. Connect the heater hose.

5. Connect the engine coolant temperature sensor connector.

1. Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Set a new gasket on each cylinder head.

   NOTICE:

   1. Align the port holes of the gasket and cylinder head.
      
   2. Be careful of the installation direction.
      

2. Set the intake manifold on the cylinder heads.

3. Install and tighten the 10 bolts uniformly in several steps.

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

4. Connect the 6 fuel injector connectors.

1. Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts.

   Torque:

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

1. Install a new O-ring to the water outlet pipe.

2. Install a new gasket to the water pump.

3. Apply soapy water to the O-ring.

4. Install the water inlet with the 5 bolts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

5. Connect the 5 water by-pass hoses.

6. Connect the 2 radiator hoses.

7. Connect the 2 oil cooler hoses (with oil cooler).

1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

2. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

3. Tighten the other bolts.

   Torque:

   36 N*m{367 kgf*cm, 27 ft.*lbf}

   HINT:

   Each bolt length is as follows:

   A: 70 mm (2.76 in.)

   B: 33 mm (1.30 in.)

1. Install the idler pulley with the bolt.

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

   HINT:

   "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

1. Install the 2 idler pulleys with the 2 bolts.

   Torque:

   39 N*m{398 kgf*cm, 29 ft.*lbf}

1. Install the engine mounting bracket with engine mounting insulator with the 3 bolts.

   Torque:

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

1. Install the engine mounting bracket with engine mounting insulator with the 4 bolts.

   Torque:

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

1. Set a new gasket to the LH cylinder head with the oval shape facing backward.

   NOTICE:

   Be careful of the installation direction.

2. Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.

   Torque:

   30 N*m{306 kgf*cm, 22 ft.*lbf}

3. Connect the A/F sensor connector.

1. Set a new gasket to the RH cylinder head with the oval shape facing forward.

   NOTICE:

   Be careful of the installation direction.

2. Install the exhaust manifold with the 6 nuts. Tighten the nuts uniformly in several steps.

   Torque:

   30 N*m{306 kgf*cm, 22 ft.*lbf}

3. Connect the A/F sensor connector.

1. Using SST, hold the crankshaft.

   SST

   09213-54015 (91651-60855)
   09330-00021
   

2. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive:

   Part No. 08833-00070, THREE BOND 1324 or equivalent
   

3. Install the front spacer, drive plate and rear spacer on the crankshaft.

4. Using several steps, install and tighten the 8 mounting bolts uniformly in the sequence as shown in the illustration.

   Torque:

   83 N*m{846 kgf*cm, 61 ft.*lbf}

1. Attach the engine sling device and hang the engine with the chain block.

2. Lower the engine into the engine room carefully.

3. Attach the engine mounting brackets to the frame brackets.

4. Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts.

   Torque:

   38 N*m{387 kgf*cm, 28 ft.*lbf}

5. Remove the 4 bolts and 2 engine hangers.

1. Install the ground cable to the cylinder block.

   Torque:

   13 N*m{133 kgf*cm, 9 ft.*lbf}

1. Connect the front differential connector.

2. Insert the engine wire to the cabin space, and install the grommet.

3. Connect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire.

4. Install the glove compartment door.

5. Install the cowl side trim board RH.

6. Install the front door scuff plate RH.

1. Install a new gasket to the intake air surge tank.

2. Using the socket hexagon wrench 8, install the intake air surge tank with the 4 bolts.

   Torque:

   28 N*m{286 kgf*cm, 21 ft.*lbf}

3. Install the 2 intake air surge tank nuts.

   Torque:

   28 N*m{286 kgf*cm, 21 ft.*lbf}

4. Install the 2 surge tank stays with the 4 bolts.

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

5. Install the oil baffle plate with the bolt.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

6. Install the throttle body bracket with the 2 bolts.

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

7. Install the 3 wire harness clamps and hose clamp.

8. Connect the throttle body with motor connector.

9. Connect the 2 VSV connectors.

10. Connect the ventilation hose.

11. Connect the fuel vapor feed hose.

12. Connect the 2 water by-pass hoses.

1. Push the tube connector into the pipe until the tube connector makes a "click" sound.

   NOTICE:

   1. Check if there is any damage or foreign objects on the connected part of the fuel pipe.
      
   2. After connecting, check that the pipe and connector are securely connected by pulling them.
      

2. Install the fuel pipe clamp.

1. Push the tube connector into the pipe until the tube connector makes a "click" sound.

   NOTICE:

   1. Check if there is any damage or foreign objects on the connected part of the fuel pipe.
      
   2. After connecting, check that the pipe and connector are securely connected by pulling them.
      

2. Install the fuel pipe clamp.

1. Install the cooler compressor assembly with the 4 bolts.

   Torque:

   25 N*m{255 kgf*cm, 18 ft.*lbf}

2. Connect the cooler compressor assembly connector.

3. Install the suction hose sub-assembly with the bolt.

   Torque:

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

1. Install the generator assembly with the 2 bolts.

   Torque:

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

2. Install the wire harness clamp bracket with the 2 bolts.

   Torque:

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

3. Connect the wire harness.
   

   1. Connect the wire harness to the terminal B and install the nut.

      Torque:

      9.8 N*m{100 kgf*cm, 7 ft.*lbf}

   2. Connect the connector to the generator assembly.

   3. Install the wire harness stay with the bolt.

      Torque:

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

1. Install the vane pump with the 2 bolts.

   Torque:

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

   NOTICE:

   Do not hit the pulley to other parts when installing the vane pump.

2. Connect the P/S oil pressure switch connector.

1. Temporarily install the fan with fluid coupling with the 4 nuts.

1. While turning the belt tensioner counterclockwise, align with its holes, and then insert a bar of 6 mm (0.24 in.) into the holes to fix the belt tensioner.

2. Install the V-ribbed belt.

3. While turning the belt tensioner counterclockwise, remove the bar.

4. If it is hard to install the V-ribbed belt, perform the following procedure.
   

   1. Put the V-ribbed belt on all parts except the P/S pump, as shown in the illustration.

   2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump.

1. Tighten the 4 fluid coupling bolts.

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

1. Put the fan shroud into the engine room.

2. Connect the 2 oil cooler hoses with the hose clamp.

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

2. Install the radiator assembly with the 4 bolts.

   Torque:

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

1. Install the air cleaner with the 2 bolts.

   Torque:

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

2. Tighten the 2 hose clamps.

3. Install the 2 wire harness clamps.

4. Connect the mass air flow meter connector.

5. Connect the vacuum hose.

6. Connect the ventilation hose No. 2.

1. Install the hood with the 4 bolts.

   Torque:

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

2. Tighten the 2 hood supports.

   Torque:

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

3. Connect the windshield washer hose.

1. Horizontally adjust the hood.

   HINT:

   1. Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments.
      
   2. A bolt without a torque specification is shown in the standard bolt chart (Click here).
      
   
   
   2. Loosen the hood side hinge bolts.

   4. Adjust the clearance so that it will be in the standard value, by moving the hood.

      Standard (A):

      3.9 +- 1.5 mm (0.154 +- 0.059 in.)
      

   5. Tighten the hood side hinge bolts after the adjustment.

      Torque:

      13 N*m{130 kgf*cm, 10 ft.*lbf}

2. Adjust the height of the hood front end by the cushion rubber.
   

   1. Adjust the cushion rubber so that the hood and the fender will be aligned.

      HINT:

      The cushion rubber goes up and down by turning it.

3. Adjust the hood lock.

   HINT:

   1. Centering bolts are used to mount the hood hinge and hood lock. The hood and hood lock cannot be adjusted with the centering bolts on. Substitute the centering bolts with standard bolts (w/ washers) when making adjustments.
      
   2. A bolt without a torque specification is shown in the standard bolt chart (Click here).
      
   
   

   1. Using a clip remover, disengage the clips, remove the 8 radiator support seal upper clips.

   2. Remove the radiator support seal upper.

   4. Using a screwdriver, disengage the 4 clips.

      HINT:

      Tape the screwdriver tip before use.

   5. Remove the hood lock release lever protector.

      NOTICE:

      Removing the protector damages the clips inside the protector, therefore the use of a new protector is necessary on the installation.

   7. Adjust the hood lock position so that the striker will come in, by moving the striker.

   8. Tighten the hood lock bolts after the adjustment.

      Torque:

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

1. Fill with fresh engine oil.

   Capacity:

   Drain and refill with oil filter change	5.2 liters (5.5 US qts, 4.6 lmp. qts)
   Drain and refill without oil filter change	4.9 liters (5.2 US qts, 4.3 lmp. qts)
   Dry fill	6.0 liters (6.3 US qts, 5.3lmp. qts)

2. Reinstall the oil filler cap.

1. Slowly fill the system with engine coolant.

   Capacity:

   9.8 liters (10.4 Us qts, 8.6 Imp. qts)
   

   HINT:

   1. Use of improper coolants may damage the engine cooling system.
      
   2. 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).
      
   3. New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50 % and freezing temperature is -35°C (-31°F)). When replacing the coolant, Toyota Super Long Life Coolant is recommended.
      
   4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.
      

   NOTICE:

   Do not substitute plain water for engine coolant.

2. Install the radiator cap securely.

3. Bleed the cooling system.
   

   1. Open the heater water valve while warming up the engine.

   2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine.

4. Stop the engine and wait until the coolant cools down.

5. Add coolant into the reservoir until the coolant level is FULL.

HINT:

(Click here)

HINT:

(Click here)

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

2. Pump it to 118 kPa (1.2 kgf/cm² 17.1 psi), then check for leakage.

1. When using the intelligent tester
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch ON and intelligent tester main switch ON.

      NOTICE:

      Do not start the engine.

   3. Select the ACTIVE TEST mode on the intelligent tester.

   4. Please refer to the intelligent tester operator's manual for further details.

2. When not using the intelligent tester
   

   1. Remove the circuit opening relay.

   2. Using a service wire, connect terminals FP and +B of the relay block.

      NOTICE:

      Pay due attention to the terminal connecting position to avoid a malfunction.

   3. Turn the ignition switch ON, and check that the fuel pump operates.

      NOTICE:

      Do not start the engine.

3. Check that there are no fuel leaks after doing maintenance to the fuel system.

4. Turn the ignition switch OFF.

5. Disconnect the intelligent tester from the DLC3.

1. Install the V-bank cover with the 2 nuts.

   Torque:

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

NOTICE:

1. Turn all electrical systems OFF.
   

1. Operate the inspection when the cooling fan motor is turned OFF.
   

1. Warm up the engine.

2. When using the intelligent tester.
   

   1. Connect the intelligent tester to the DLC3.

   2. Select the following menu items: DIAGNOSIS / ENHANCED OBD ll / DATA LIST / IGN ADVANCE.

   3. Inspect the ignition timing during idling.

      Ignition timing:

      7 to 24°CA BTDC during idling (Transmission in neutral position)
      

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

3. When not using intelligent tester.
   

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

      SST

      09843-18040
      

      NOTICE:

      Be sure not to connect the terminals wrongly. It causes breakage of the engine.

   2. Remove the air cleaner cap sub-assembly.

   4. Pull out the wire harness as shown in the illustration.

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

      NOTICE:

      1. Use a timing light that detects the first signal.
         
      1. After checking, be sure to wrap the wire harness with tape.
         

   7. Inspect the ignition timing during idling.

      Ignition timing:

      8 to 12°CA BTDC during idling (Transmission in neutral position)
      

   8. Remove the SST from the DLC3.

   9. Inspect the ignition timing during idling.

      Ignition timing:

      7 to 24°CA BTDC during idling (Transmission in neutral position)
      

   10. Disconnect the timing light from the engine.

   11. Install the air cleaner cap sub-assembly.

1. Warm up and stop the engine.

2. Remove the V-bank cover.

3. Remove the air cleaner assembly.

4. Remove the intake air surge tank (Click here).

5. Remove the 6 ignition coils.

6. Remove the 6 spark plugs.

7. Disconnect the 6 injector connectors.

8. Inspect the cylinder compression pressure.
   

   1. Insert a compression gage into the spark plug hole (Procedure "A").

      SST

      09992-00500
      

   2. Fully open the throttle (Procedure "B").

   3. While cranking the engine, measure the compression pressure (Procedure "C").

      Compression pressure:

      1,300 kPa (13.3 kgf/cm², 189 psi)
      

      Minimum pressure:

      1,000 kPa (10.2 kgf/cm², 145 psi)
      

      Difference between each cylinder:

      100 kPa (1.0 kgf/cm², 15 psi)
      

      NOTICE:

      1. Use a fully-charged battery so the engine speed can be increased to 250 rpm or more.
         
      2. Inspect the other cylinders in the same way.
         
      3. Measure the compression in as short a time as possible.
         

   4. Repeat procedures "A" through "C" for each cylinder.

   5. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat procedures "A" through "C" for cylinders with low compression.

      1. If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
         
      2. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket.
         

9. Connect the 6 injector connectors.

10. Install the 6 spark plugs.

11. Install the 6 ignition coils.

12. Install the intake air surge tank (Click here).

13. Install the air cleaner assembly.

14. Install the V-bank cover.

HINT:

This check is to determine whether or not the idle CO/HC complies with regulations.

1. Start the engine.

2. Run the engine at 2,500 rpm for approximately 180 seconds.

3. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.

4. Immediately check the CO/HC concentration during idling and/or at 2,500 rpm.

   HINT:

   1. Complete the measurement within 3 minutes.
      
   2. When carrying out the 2 modes (idling and 2,500 rpm) test, the measurement orders are prescribed by the applicable local regulations.
      

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

   1. Check the A/F sensor and heated oxygen sensor operation.

   2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.
      

      CO	HC	Symptom	Causes
      Normal	High	Rough idling	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance 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 idling (Black smoke from exhaust)	Restricted air filter Faulty EFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Faulty throttle position sensor