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Installation [09/2015 - ]: Procedure

  1. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  2. INSTALL KNOCK SENSOR 

    Refer to PROCEDURE - Step 1

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  4. INSTALL ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 1

  5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  6. INSTALL WATER INLET HOUSING 

    Refer to PROCEDURE - Step 3

  7. INSTALL WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 2

  8. INSTALL NO. 1 IDLER PULLEY SUBASSEMBLY 
    1. Install the No. 1 idler pulley SUBASSEMBLY with the bolt.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT: 

      Install the No. 1 idler pulley SUBASSEMBLY in the direction shown in the illustration.

      GTY685922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 IDLER PULLEY SUBASSEMBLY 
    1. Install the No. 2 idler pulley SUBASSEMBLY with the bolt.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  10. INSTALL NO. 4 ENGINE COVER SUBASSEMBLY 
    1. Install the No. 4 engine cover SUBASSEMBLY.
  11. INSTALL ENGINE WIRE 
    1. Install the engine wire with the 2 bolts.

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

    2. Connect the 4 knock sensor connectors.
  12. INSTALL SEPARATOR CASE 

    Refer to PROCEDURE - Step 2

  13. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 4

  14. INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection) 

    Refer to PROCEDURE - Step 5

  15. INSTALL FUEL DELIVERY PIPE (for Direct Injection) 

    Refer to PROCEDURE - Step 6

  16. INSTALL NO. 4 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 8

  17. INSTALL FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

  18. INSTALL NO. 3 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. INSTALL NO. 2 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 5

  20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  21. INSTALL ENGINE COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  22. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection) 

    Refer to PROCEDURE - Step 1

  23. INSTALL FUEL DELIVERY PIPE (for Port Injection) 

    Refer to PROCEDURE - Step 2

  24. INSTALL FUEL TUBE SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  25. INSTALL NO. 3 COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 2

  26. INSTALL NO. 2 ENGINE COVER SUBASSEMBLY LH 
  27. INSTALL NO. 2 ENGINE COVER SUBASSEMBLY 
  28. INSTALL NO. 1 ENGINE COVER SUBASSEMBLY 
  29. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 1

  30. INSTALL THROTTLE BODY ASSEMBLY 

    Refer to PROCEDURE - Step 1

  31. INSTALL VENTILATION HOSE 
  32. INSTALL WATER BY-PASS PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  33. INSTALL NO. 2 ENGINE COVER 

    Refer to PROCEDURE - Step 5

  34. INSTALL NO. 1 ENGINE COVER 
  35. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 4

  36. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH 
    1. Install the front No. 1 engine mounting bracket RH with the 6 bolts.

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

  37. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Install the front No. 1 engine mounting bracket LH with the 6 bolts.

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

  38. INSTALL ENGINE MOUNTING DAMPER 
    1. Install the 2 engine mounting dampers with the 2 nuts.

      Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

  39. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  40. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Install the 2 front engine mounting insulators with the 2 nuts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

  41. INSTALL ENGINE MOUNTING SPACER 
    1. Install the 2 engine mounting spacers.
  42. INSTALL NO. 1 ENGINE HANGER 

    See step  50

  43. REMOVE ENGINE STAND 
    1. 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.

    2. Place the engine onto a work bench.
  44. INSTALL FRONT SUSPENSION CROSSMEMBER SUBASSEMBLY 
    1. Install the front suspension crossmember SUBASSEMBLY with the 2 nuts.

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

  45. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY 
    1. Using SST, hold the crankshaft.
      GTY101803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
        1. 90119-08216
      • SST: 09330-00021 
    2. Clean the their installation holes.
    3. Install the crankshaft position sensor rotor.
      GTY648091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Align the pin of the crankshaft with the pin hole of the crankshaft position sensor rotor.
      • As the crankshaft position sensor rotor are not reversible, be sure to install it in the direction shown in the illustration.
    4. GTY397213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the drive plate and ring gear SUBASSEMBLY and rear spacer plate on the crankshaft.

      HINT: 

      As the drive plate and ring gear SUBASSEMBLY and rear spacer plate are not reversible, be sure to install it in the direction shown in the illustration.

    5. Apply a few drops of adhesive to 2 or 3 threads of the bolt end.
      GTY224609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.
      GTY614207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      NOTE:
      • Do not reuse the drive plate installation bolts.
      • Do not impact or damage the drive plate installation bolts. Be sure to handle them carefully.
    7. Mark the upside of each drive plate installation bolt with paint.
    8. Retighten the drive plate installation bolts by 90°.
    9. Check that the painted marks are now at a 90° angle to the upside.
  46. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 4

  47. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT 

    Refer to PROCEDURE - Step 5

  48. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  49. INSTALL ENGINE WIRE 
    1. GTY624267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the engine wire with the 4 nuts.

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

    2. Connect the clamp and 2 clamp brackets with the 2 bolts.

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

    3. Connect the intake air control valve actuator connector.
    4. Connect the purge VSV connector.
    5. Connect the 4 injector driver connectors as shown in the illustration.
      GTY676427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. GTY685888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for Engine RH Side:

      1. Connect the 2 clamps and install the 3 clamp brackets with the 3 bolts.

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

      2. Connect the engine oil level sensor connector.
      3. Connect the crankshaft position sensor connector.
      4. Connect the starter connector and starter wire with the nut.

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

      5. Connect the generator connector and generator wire with the nut.

        Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      6. Connect the camshaft position sensor connector.
      7. Connect the engine wire connector.
      8. Connect the 2 camshaft timing control motor connectors (for Bank 2).
      9. Connect the fuel pump connector (for high pressure).
      10. Connect the 2 VVT sensor connectors.
      11. Connect the 4 ignition coil connectors.
      12. Connect the camshaft timing control valve connector.
    7. GTY651474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for Engine LH Side:

      1. Install the clamp bracket with the bolt.

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

      2. Connect the 3 clamps and 3 ground wires with the 3 bolts.

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

      3. Connect the 2 camshaft timing control motor connectors (for Bank 1).
      4. Connect the oil pressure switch connector.
      5. Connect the engine coolant temperature sensor connector.
      6. GTY685976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Connect the clamp and install the 2 clamp brackets with the 2 bolts.

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

      7. Connect the No. 8 engine wire connector.
      8. Connect the fuel pump connector (for high pressure).
      9. Connect the 2 VVT sensor connectors.
      10. Connect the 4 ignition coil connectors.
      11. Connect the camshaft timing control valve connector.
    8. Connect the throttle body connectors.
  50. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3

  51. INSTALL OIL COOLER TUBE 

    Refer to PROCEDURE - Step 8

  52. INSTALL EXHAUST MANIFOLD SUBASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 5

  53. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 6

  54. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the engine oil level dipstick guide.
    3. Install the engine oil level dipstick guide with the 2 bolts.

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

    4. Install the engine oil level dipstick.
  55. INSTALL ENGINE AND TRANSMISSION 

    HINT: 

    Perform "Inspection After Repairs" after replacing the engine assembly (Refer to INITIALIZATION [09/2015 - ] ).

    1. Place the engine on an engine lifter.
      NOTE:
      • Place wooden blocks or plate lift attachments so that the engine is level.
      • 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.
      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
    2. Remove the 2 bolts and 2 No. 1 engine hangers.
    3. Operate the engine lifter and install the engine to the vehicle.
      NOTE:

      Make sure that the engine is clear of all wiring and hoses.

    4. Align the crossmember to the marks on the vehicle, and temporarily install the engine and transmission with crossmember with the 4 bolts.
      GTY685740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.

    5. Tighten the 4 bolts.
      GTY629186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 165 N*m (1683 kgf*cm, 122 ft.*lbf) 

    6. GTY652886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the 6 engine rear mounting member's bolts.

      Torque: 35 N*m (354 kgf*cm, 26 ft.*lbf) 

  56. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUBASSEMBLY 

    Refer to PROCEDURE - Step 10

  57. CONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

  58. CONNECT COOLER COMPRESSOR ASSEMBLY 
    1. Connect the cooler compressor assembly with the 2 stud bolts, 2 nuts and 2 bolts.

      for stud bolts 

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

      for nuts 

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      for bolts 

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  59. INSTALL EXHAUST MANIFOLD SUBASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 3

  60. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  61. INSTALL POWER STEERING LINK ASSEMBLY (w/ VGRS) 

    Refer to PROCEDURE - Step 2

  62. INSTALL POWER STEERING LINK ASSEMBLY (w/o VGRS) 

    Refer to PROCEDURE - Step 2

  63. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/ VGRS) 

    Refer to PROCEDURE - Step 3

  64. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS) 

    Refer to PROCEDURE - Step 3

  65. INSTALL STEERING SLIDING YOKE WITH SHAFT SUBASSEMBLY (w/ VGRS) 

    Refer to PROCEDURE - Step 4

  66. INSTALL STEERING SLIDING YOKE WITH SHAFT SUBASSEMBLY (w/o VGRS) 

    Refer to PROCEDURE - Step 5

  67. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH 

    Refer to PROCEDURE - Step 1

  68. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH 

    Refer to PROCEDURE - Step 2

  69. INSTALL FRONT STABILIZER BAR 

    (Refer to INSTALLATION [09/2015 - ] )

  70. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

  71. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUBASSEMBLY 

    Refer to PROCEDURE - Step 1

  72. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

  73. CONNECT HOSES AND CONNECTORS 
    1. GTY659873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the purge line hose.

    2. GTY685814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the 2 heater hoses.

    3. GTY629180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the wires with No. 1 engine room junction block with the 2 nuts.

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

    4. GTY629181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the ground wire with the bolt.

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

    5. GTY685738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the 3 connectors with front controller with the clamp.

    6. GTY624272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Attach the clamp and connect the cooler compressor connector.

    7. GTY685893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the 3 TCM connectors and 4 ECM connectors.

    8. Install the engine room ECU cover.
  74. CONNECT NO. 1 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  75. CONNECT NO. 3 FUEL HOSE 

    Refer to PROCEDURE - Step 4

  76. INSTALL ENGINE ROOM ECU OUTLET DUCT 
    1. Install the engine room ECU outlet duct.
  77. CONNECT NO. 2 RADIATOR HOSE 
  78. CONNECT NO. 1 RADIATOR HOSE 
  79. INSTALL AIR CLEANER ASSEMBLY RH 

    Refer to PROCEDURE - Step 10

  80. INSTALL AIR CLEANER ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  81. INSTALL V-RIBBED BELT 

    See step  1

  82. INSTALL INTAKE AIR CONNECTOR PIPE 

    Refer to PROCEDURE - Step 13

  83. INSTALL NO. 1 AIR CLEANER INLET 

    Refer to PROCEDURE - Step 3

  84. INSTALL REAR FRAME SIDE RAIL 
    1. Install the 2 rear frame side rails with the 6 bolts and 4 nuts.

      for bolt A 

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      for nut B 

      Torque: 44 N*m (453 kgf*cm, 33 ft.*lbf) 

      GTY684007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL FRONT SUSPENSION LOWER CROSSMEMBER 

    Refer to PROCEDURE - Step 6

  86. INSTALL FRONT BUMPER COVER 

    (Refer to INSTALLATION [09/2015 - ] )

  87. CONNECT NO. 1 OIL COOLER OUTLET HOSE 

    Refer to PROCEDURE - Step 13

  88. CONNECT NO. 1 OIL COOLER INLET HOSE 

    Refer to PROCEDURE - Step 14

  89. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  90. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 8

  91. ADD AUTOMATIC TRANSMISSION FLUID 

    (Refer to ADJUSTMENT [09/2015 - ] )

  92. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2015 - ] ).

  93. INSPECT FOR OIL LEAK 

    (Refer to PROCEDURE - Step 5 )

  94. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  95. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  96. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 9

  97. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  98. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [09/2015 - 09/2016] Refer to ADJUSTMENT [09/2016 - ] )

  99. CHECK SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 6

  100. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER 
    1. Install the front suspension member protector lower with the 8 bolts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  101. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 8 bolts.
      GTY685717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

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

      for bolt B 

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

  102. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 13

  103. CHECK IGNITION TIMING 

    See step  4

  104. CHECK IDLE SPEED 

    See step  5

  105. CHECK CO/HC 

    See step  7

  106. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 2

  107. INSTALL ENGINE ROOM SIDE COVER RH 

    Refer to PROCEDURE - Step 15

  108. INSTALL ENGINE ROOM SIDE COVER LH 

    Refer to PROCEDURE - Step 16

  109. INSTALL AIR CLEANER INLET COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 7

  110. INSTALL V-BANK COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 8

  111. INSTALL COWL TOP VENTILATOR LOUVER RH 

    Refer to PROCEDURE - Step 17

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