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Engine Assembly: Installation

WARNING: This page is about a different car, the 2008 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, install the temperature sensor.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 1: Identifying Temperature Sensor
      G05823500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 2: Applying Adhesive To Threads Of Oil Pressure Switch
      G05823501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 24 mm deep socket wrench, install the oil pressure switch.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

      NOTE: Do not start the engine within 1 hour after installation for prevent oil leaks.
      Fig 3: Removing/Installing Oil Pressure Switch
      G05823502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL ENGINE OIL LEVEL SENSOR 
    1. Install the engine oil level sensor and a new gasket with the 4 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      2. Fig 4: Locating Oil Level Sensor And Bolts
      G05823503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the 6 ignition coils with the 6 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  5. INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY 
    1. Install the V-bank cover bracket with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 5: Locating V-bank Cover Bracket And Bolt
      G05823504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE RADIO SETTING CONDENSER 
    1. Install the 2 bolts and 2 radio setting condensers.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 6: Locating Radio Setting Condenser And Bolt
      G05823505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL KNOCK SENSOR  (See INSTALLATION )
  8. INSTALL FUEL INJECTOR ASSEMBLY 

    HINT:

    See INSTALLATION .

  9. INSTALL FUEL PUMP 

    HINT:

    See INSTALLATION .

  10. INSTALL FUEL TUBE SUB-ASSEMBLY 
    1. Install the 2 bolts and fuel tube sub-assembly.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 7: Locating Fuel Tube Sub-Assembly Bolts
      G05823506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL INTAKE MANIFOLD  (See INSTALLATION )
  12. INSTALL WATER HOSE JOINT 
    1. Connect the 2 hoses, and install the bolt and water hose joint.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      2. Fig 8: Locating Water Hose Joint And Bolt
      G05823507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL NO. 2 SURGE TANK STAY 
    1. Install the bolt and No. 2 surge tank stay.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  14. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    HINT:

    See INSTALLATION

  15. INSTALL INJECTOR DRIVER 
    1. Install the injector driver with the bolt and 2 nuts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      2. Fig 9: Locating Injector Driver, Nuts And Bolts
      G05823508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly.
  17. INSTALL WATER PUMP PULLEY  (See INSTALLATION )
  18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

      Each bolt length is as follows 

      BOLT LENGTH REFERENCE

      Mark Specified Length
      A 70 mm (2.76 In.)
      B 35 mm (1.38 in.)
    2. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Fig 10: Locating V-Ribbed Belt Tensioner Bolt
      G05823509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the other bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

  19. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the mounting bracket with the 4 bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

    2. Connect the 2 clamps.
      Fig 11: Locating Mounting Bracket With Bolts
      G05823510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the mounting bracket with the 4 bolts.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Fig 12: Locating Mounting Bracket With Bolts
      G05823511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL COOLER COMPRESSOR ASSEMBLY  (See INSTALLATION )
  22. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  23. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the plate and idler pulley with the bolt.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Fig 13: Locating Idler Pulley, Plate And Bolts
      G05823512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover with the 3 clips.
      Fig 14: Locating No. 1 Engine Cover And Clips
      G05823513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 2 ENGINE COVER 
    1. Install the No. 2 engine cover with the 3 clips.
    2. Connect the clamp.
      3. Fig 15: Locating No. 2 Engine Cover, Clips And Clamp
      G05823514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL V-RIBBED BELT  (See INSTALLATION  )
  27. INSTALL ENGINE HANGERS 

    Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

  28. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.

      SST 09213-70011 (09213-70020), 09330-00021 

    2. Apply adhesive to 2 or 3 threads of the mounting bolts ends.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    3. Install the front spacer, drive plate and rear spacer on the crankshaft.
      Fig 16: Holding Crankshaft With SST
      G05823515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install and tighten the 8 mounting bolts uniformly in several steps.

      Torque: 83 N*m (846 kgf*cm, 61 ft.*lbf) 

      NOTE: Do not start the engine for at least 1 hour after installing.
      Fig 17: Locating Mounting Bolts Tightening Sequence
      G05823516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember sub-assembly with the 2 bolts.

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

      Fig 18: Locating Front Suspension Crossmember Sub-Assembly (For 2WD)
      G05823517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    HINT:

    See INSTALLATION .

  31. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  32. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Install a new gasket as shown in the illustration.
      Fig 19: Identifying Exhaust Manifold Gasket
      G05823518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold with 6 new nuts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      NOTE:
      • Do not damage the stud bolt when installing the exhaust manifold.
      • Be sure to tighten either of nuts A first as shown in the illustration.
        Fig 20: Locating Exhaust Manifold With Nuts
        G05823519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket as shown in the illustration.
      Fig 21: Identifying Exhaust Manifold Gasket
      G05823520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold with 6 new nuts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

      NOTE:
      • Do not damage the stud bolt when installing the exhaust manifold.
      • Be sure to tighten either of nuts A first as shown in the illustration.
  34. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY 
    1. Install a new O-ring to the oil dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Push in the oil dipstick guide end into the guide hole.
      Fig 22: Locating Exhaust Manifold With Nuts
      G05823521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No. 1 oil dipstick guide with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

    5. Connect the clamp.
      Fig 23: Locating No. 1 Oil Dipstick Guide, Bolt And Clamp
      G05823522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the No. 2 oil dipstick guide with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    7. Install the oil dipstick.
      8. Fig 24: Locating No. 2 Oil Dipstick Guide And Bolts
      G05823523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL ENGINE AND TRANSMISSION ASSEMBLY 
    1. Set the engine lifter.
    2. Operate the engine lifter, then install the engine to the vehicle.
    3. Install the engine and transmission assembly with crossmember with the 12 bolts.

      Torque: 

      167 N*m (1,700 kgf*cm, 123 ft.*lbf) for Nut 

      204 N*m (2,080 kgf*cm, 150 ft.*lbf) for bolt A 

      50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt B 

      49 N*m (500 kgf*cm, 36 ft.*lbf) for bolt C 

      Fig 25: Locating Transmission Assembly With Bolts
      G05823524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine rear mounting member with the 4 bolts.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Fig 26: Locating Engine Rear Mounting Member With Bolts
      G05823525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY  (See INSTALLATION )
  37. CONNECT POWER STEERING LINK WIRE HARNESS 
    1. Install the power steering earth wire to the power steering link assembly with bolt (B).

      Torque: 13 N*m (130 kgf*cm, 10 ft.*lbf) 

    2. Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.
    3. Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.
    4. Install the 2 wire harness clamps to the power steering link assembly.
    5. Connect the earth wire to the bracket with bolt (A).

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 27: Locating Power Steering Link Assembly With Bolt
      G05823526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH 
    1. Install the front lower ball joint with the 2 bolts.

      Torque: 120 N*m (1,224 kgf*cm, 89 ft.*lbf) 

      2. Fig 28: Locating Front Lower Ball Joint And Bolt
      G05823527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH 

    HINT:

    Install the RH side following the same procedures as for the LH side.

  40. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH 
    1. Install the bolt on the lower side of the front shock absorber while holding the nut.

      Torque: 157 N*m (1,600 kgf*cm, 116 ft.*lbf) 

  41. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT:

    Install the RH side following the same procedures as for the LH side.

    Fig 29: Locating Front Shock Absorber Bolts
    G05823528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. CONNECT HEIGHT CONTROL SENSOR LINK 
    1. Connect the height control sensor link and install it with the nut.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 30: Disconnecting Height Control Sensor Link And Bolt
      G05823529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY  (See INSTALLATION )
  44. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Install the protector with the 4 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 31: Locating Suspension Member Protector And Bolts
      G05823530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.

      HINT:

      • Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.
      • Check that the connector and fuel main pipe are securely connected by trying to pull them apart.
        Fig 32: Identifying Connector To Fuel Main Pipe
        G05823531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel pipe clamp.
      Fig 33: Locating Fuel Pipe Clamp
      G05823532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. CONNECT NO. 3 FUEL HOSE 
    1. Connect the No. 3 fuel hose and clamp.
      2. Fig 34: Locating No. 3 Fuel Hose
      G05823533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. CONNECT FUEL MAIN TUBE 

    HINT:

    See FUEL SYSTEM .

  48. CONNECT ENGINE WIRE 
    1. Install the bolt, clamp and engine wire No. 3.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    2. Connect the ground cable and install it with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      Fig 35: Locating Engine Wire No. 3, Bolt And Clamp
      G05823534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector and install the 4 clamps to the body.
    4. Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.

      Torque: 12 N*m (124 kgf*cm, 9 ft.*lbf) 

    5. Install the engine room No. 1 relay block cover.
    6. Connect the battery positive (+) cable and install it with the nut.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    7. Connect the ECM connectors.
      Fig 36: Locating Engine Room No. 1 Junction Block
      G05823535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the connector holder.
    Fig 37: Locating Engine Wire
    G05823536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL ECM COVER  (See INSTALLATION )
  50. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  51. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE  (See INSTALLATION )
  52. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose.
      Fig 38: Locating Outlet Heater Water Hose
      G05823537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose.
      Fig 39: Locating Inlet Heater Water Hose
      G05823538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. CONNECT INLET RADIATOR HOSE 
    1. Install the clamp and connect the inlet radiator hose.
  55. CONNECT OUTLET RADIATOR HOSE 
    1. Install the clamp and connect the outlet radiator hose.
  56. CONNECT RADIATOR RESERVOIR TANK HOSE 
    1. Install the clamp and connect the reservoir tank hose.
      Fig 40: Locating Inlet Radiator Hose And Clamp
      G05823539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. CONNECT NO. 2 FUEL VAPOR FEED HOSE 
    1. Install the clamp and connect the No. 2 fuel vapor feed hose.
  58. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the hose to the surge tank.
      Fig 41: Locating No. 2 Fuel Vapor Feed Hose
      G05823540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case, clamp and 2 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 42: Locating Air Cleaner Case And Clamp
      G05823541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE  (See INSTALLATION )
  61. INSTALL NO. 1 INLET AIR CLEANER 
    1. Install the inlet air cleaner with the bolt.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 43: Locating Inlet Air Cleaner And Clip
      G05823542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING 

    HINT:

    See INSTALLATION .

  63. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See INSTALLATION .

  64. ADD ENGINE OIL  (See REPLACEMENT )
  65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  66. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  67. CHARGE REFRIGERANT  (See REPLACEMENT )
  68. CHECK FOR FUEL LEAKS  (See ON-VEHICLE INSPECTION )
  69. CHECK FOR ENGINE COOLANT LEAKS  (See ON-VEHICLE INSPECTION )
  70. CHECK FOR ENGINE OIL LEAKS 
  71. CHECK FOR EXHAUST GAS LEAKS 
  72. CHECK FOR LEAKAGE OF REFRIGERANT  (See REPLACEMENT )
  73. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  74. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  75. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT )
  76. CHECK SHIFT LEVER POSITION  (See ADJUSTMENT )
  77. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 

    HINT:

    See ADJUSTMENT .

  78. CHECK IGNITION TIMING  (See ON-VEHICLE INSPECTION  )
  79. CHECK ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION  )
  80. CHECK CO / HC  (See ON-VEHICLE INSPECTION 
  81. CHECK ENGINE OIL LEVEL  (See ON-VEHICLE INSPECTION )
  82. INSTALL ENGINE UNDER COVER REAR LH 
    1. Install the engine under cover rear LH with the bolt.
  83. INSTALL ENGINE UNDER COVER REAR RH 

    HINT:

    Install the RH side following the same procedures as for the LH side.

    Fig 44: Identifying Engine Under Cover
    G05823543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL NO. 2 ENGINE UNDER COVER 
  85. INSTALL ENGINE UNDER COVER 
  86. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 3 clips to install the V-bank cover.
      NOTE:
      • Be sure to engage the clips securely.
      • Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
        Fig 45: Locating V-Bank Cover Clips
        G05823544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL ENGINE ROOM SIDE COVER LH 
    1. Install the side cover with the 5 clips.
      Fig 46: Identifying Side Cover And Clips
      G05823545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL ENGINE ROOM SIDE COVER RH 
    1. Install the side cover with the 2 clips.
      Fig 47: Identifying Side Cover And Clips
      G05823546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the intake duct seal with the 11 clips.
      2. Fig 48: Locating Intake Duct Seal With Clips
      G05823547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. PERFORM INITIALIZATION 
    1. Perform initialization (see PRECAUTION ).
      NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
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