Engine Assembly - Installation

1. Install ventilation valve sub-assembly

2. Install oil cooler assembly

3. Install exhaust manifold sub-assembly lh

4. Install exhaust manifold sub-assembly rh

5. Install water by-pass joint fr

6. Install water inlet housing

7. Install knock sensor

8. Install starter assembly

9. Install air pump assembly with bracket

10. Install water by-pass joint rr

11. Install no. 2 air switching valve

12. Install water by-pass pipe sub-assembly

13. Install vvt sensor

14. Install crankshaft position sensor

15. Install camshaft position sensor

16. Install ignition coil assembly

17. Install fan bracket sub-assembly

18. Install v-ribbed belt tensioner assembly

19. Install no. 2 timing belt cover sub-assembly

20. Install no. 2 timing chain or belt cover

21. Install no. 3 timing belt cover sub-assembly lh

22. Install pump bracket

23. Install oil cooler pipe

24. Install drive plate & ring gear sub-assembly

25. Install heater hose

26. Install generator assembly

27. Install no. 1 engine mounting bracket front lh

28. Install no. 1 engine mounting bracket front rh

29. Install no. 2 engine wire

30. Install no. 2 wiring harness heat insulator

31. Install intake manifold assembly

32. Install engine wire

33. Install engine assembly

34. Install engine wire

35. Connect heater hose

36. Install oil level gauge guide

37. Install transmission oil filler tube sub-assembly

38. Install fan with fluid coupling

39. Install compressor

40. Install vane pump assembly

41. Install fan and generator v belt

42. Connect fuel vapor feed hose assembly

43. Connect fuel hose

44. Connect no. 2 fuel hose

45. Install fan shroud

46. Install radiator assembly

47. Add engine coolant

48. Add engine oil

49. Install engine under cover assembly rear

50. Install no. 1 engine under cover sub-assembly

51. Install air cleaner assembly

52. Install air cleaner hose assembly

53. Install throttle body cover sub-assembly

54. Install hood sub-assembly

55. Install automatic transmission assembly (for 2wd)

56. Install automatic transmission assembly (for 4wd)

57. Check for engine coolant leakage

58. Check for exhaust gas leakage

59. Check for fuel leakage

60. Inspect automatic transmission fluid

61. Check for engine oil leakage

​

1. Apply adhesive to 2 or 3 threads.

   Adhesive:

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

2. Install the ventilation valve.

   Torque:

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

   HINT:

   After tightening the valve to the specified torque, turn the ventilation valve clockwise with the port facing in the direction indicated in the illustration.

3. Install the ventilation valve cover to the ventilation valve.

4. Connect the ventilation hose to the ventilation valve.

1. Place a new gasket into the groove of the oil cooler.

2. Apply a light coat of engine oil to the gasket.

3. Install the oil cooler assembly with the 2 bolts and nut.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Place a new gasket on the cylinder head.

   NOTICE:

   Be careful of the installation direction.

2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in diagonally.

   Torque:

   44 N*m{450 kgf*cm, 33 ft.*lbf}

3. Install the heat insulator with the 4 bolts.

   Torque:

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

1. Place a new gasket on the cylinder head.

   NOTICE:

   Be careful of the installation direction.

2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts diagonally.

   Torque:

   44 N*m{450 kgf*cm, 33 ft.*lbf}

3. Install the heat insulator with the 4 bolts.

   Torque:

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

1. With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side.

2. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Install the water inlet with the 3 nuts.

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

1. Install the 2 knock sensors with the 2 nuts as shown in the illustration.

   Torque:

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

2. Connect the 2 knock sensor connectors.

1. Install the starter assembly with the 2 bolts.

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

2. Connect the No. 2 engine wire.

   Torque:

   9.8 N*m{100 kgf*cm, 7.2 ft.*lbf}

1. Install the air pump assembly with the 4 bolts.

   Torque:

   16 N*m{163 kgf*cm, 12 ft.*lbf}

2. Connect the pressure sensor connector for the air injection system.

3. Connect the air switching valve connector.

4. Connect the No. 2 air hose to the air switching valve.

1. With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side.

2. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Install 2 new gaskets and the 2 No. 2 air switching valves with the 4 bolts to the water by-pass joint rear.

   Torque:

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

2. Connect the 2 vacuum hoses to the No. 2 air switching valves.

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

2. Apply soapy water to the O-ring.

3. Push in the water by-pass pipe end into the pipe hole of the water pump.

4. Install the water by-pass pipe with the bolt.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

1. Install the VVT sensors with the 2 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the crankshaft position sensor with the bolt.

   Torque:

   6.5 N*m{65 kgf*cm, 58 in.*lbf}

1. Install the camshaft position sensor with the bolt and the stud bolt.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the 8 ignition coils with the 8 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the fan bracket with the 2 bolts and 2 nuts.

   Torque:

   12 mm head:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

   14 mm head:

   32 N*m{326 kgf*cm, 24 ft.*lbf}

1. Install the v-ribbed belt tensioner with the bolt and 2 nuts.

   Torque:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

1. Install the No. 2 timing belt cover sub-assembly with the 2 bolts.

   Torque:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

1. Install the timing chain or belt cover with the nut and 3 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the timing belt cover sub-assembly with the 4 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

2. Install the camshaft position sensor connector and grommet to the timing belt cover.

1. Install the pump bracket with the 4 bolts.

   Torque:

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

1. Install the oil cooler pipe with the bolt and nut.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

2. Connect the 3 hoses.

1. Using SST, hold the crankshaft.

   SST

   09213-70011
   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. Install and uniformly tighten the 8 mounting bolts in several steps, in the order shown in the illustration.

   Torque:

   30 N*m{301 kgf*cm, 22 ft.*lbf}

   If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.
   

5. Mark the mounting bolt with paint (Procedure "A").

6. Retighten the mounting bolts by 90° in the order shown.

7. Check that the painted mark is now at a 90° angle to the mark placed in procedure "A".

1. Install the generator with the bolt and 2 nuts.

   Torque:

   Bolt:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

   Nut (M10):

   39 N*m{40 kgf*cm, 29 ft.*lbf}

   Nut (M8):

   16 N*m{158 kgf*cm, 11 ft.*lbf}

2. Connect the generator connector.

3. Connect the generator wire with the nut and rubber cap.

   Torque:

   9.8 N*m{100 kgf*cm, 86 in.*lbf}

4. Install the generator wire clamp to the cord clip on the generator.

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

   Torque:

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

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

   Torque:

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

1. Install the engine wire protector with the nut and 2 bolts.

2. Connect the ground cable wire clamp with the bolt.

1. Install the wiring harness heat insulator with the 2 bolts.

   Torque:

   17 N*m{175 kgf*cm, 13 ft.*lbf}

1. Place 2 new gaskets on the intake manifold.

2. Place the intake manifold on the cylinder heads.

3. Install and uniformly tighten the 6 bolts and 4 nuts in several steps.

   Torque:

   18 N*m{185 kgf*cm, 13 ft.*lbf}

4. Install the V-bank cover bracket to the intake manifold.

   Torque:

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

5. Install the wire bracket to the intake manifold with the bolt.

   Torque:

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

6. Connect the engine wire to the engine hanger and wire bracket.

7. Connect the wire protector to the intake manifold and cylinder heads with the bolt and nut.

8. Install the 2 ground cables with the 2 bolts to the RH and LH cylinder heads.

9. Connect the 2 water by-pass hoses to the throttle body.

10. Connect the 2 wire clamps to the wire clamp bracket on the RH delivery pipe.

1. Attach the engine chain hoist to the engine hangers.

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

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

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

   Torque:

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

5. Remove the engine chain hoist.

1. Install a new O-ring to the oil level gauge guide.

2. Install the oil level gauge guide with the bolt.

   Torque:

   15 N*m{155 kgf*cm, 11 ft.*lbf}

1. Install a new O-ring to the oil filler tube sub-assembly.

2. Install the transmission oil filler tube sub-assembly with the bolt.

   Torque:

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

1. Install the fan pulley to the engine.

2. Install the fan with fluid coupling with the 4 nuts.

   Torque:

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

1. Install the compressor with the stay, nut and 3 bolts.

   Torque:

   Bolt:

   47 N*m{475 kgf*cm, 34 ft.*lbf}

   Nut:

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

2. Connect the compressor connector.

1. Install the vane pump assembly with the nut and 2 bolts.

   Torque:

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

1. Set the V belt onto every parts except the No. 2 idler pulley, as shown in the illustration.

2. Loosen the V belt by turning the belt tensioner counterclockwise.

3. Set the V belt to the No. 2 idler pulley.

4. After installing a new belt, check that the mark is within the B range as shown in the illustration.

1. Install the fan shroud with the fan into the engine room.

   Torque:

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

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. Slowly fill the system with engine coolant.

   Capacity:

   12.3 liters (13.0 US qts, 10.8 lmp. 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.

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

   Torque:

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

2. Connect the wire harness clamp and the ground cable.

   Torque:

   8.3 N*m{85 kgf*cm, 73 in.*lbf}

1. Install the throttle body cover sub-assembly with the 2 nuts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the hood with the 4 bolts.

   Torque:

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

2. Connect the hood damper.

   Torque:

   18 N*m{180 kgf*cm, 13 ft.*lbf}

3. Connect the windshield washer hose.

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 anywhere on the fuel system.

4. Check that the pulsation damper screw rises up when the fuel pump operates.
   If operation is not as specified, check the following parts:

   1. Fusible link
      
   2. Fuses
      
   3. EFI main relay
      
   4. Fuel pump
      
   5. ECM
      
   6. Wiring connections
      

5. Turn the ignition switch OFF.

6. Disconnect the intelligent tester from the DLC3.

HINT:

(Click here)