Installation [09/2015 - ]: Procedure
- INSTALL IGNITION COIL ASSEMBLY
Refer to PROCEDURE - Step 2
- INSTALL ENGINE COOLANT TEMPERATURE SENSOR
Refer to PROCEDURE - Step 1
- INSTALL ENGINE OIL LEVEL SENSOR
Refer to PROCEDURE - Step 1
- INSTALL WATER INLET HOUSING
- Install a new gasket and water inlet housing with the 3 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Using needle-nose pliers, grip the claws of the clips and slide the clips to connect the water by-pass hoses and water inlet hose.
- Install a new gasket and water inlet housing with the 3 bolts.
- INSTALL WATER PUMP PULLEY
Refer to PROCEDURE - Step 2
- INSTALL NO. 1 IDLER PULLEY SUBASSEMBLY
- INSTALL NO. 2 IDLER PULLEY SUBASSEMBLY
- Install the No. 2 idler pulley SUBASSEMBLY with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Install the No. 2 idler pulley SUBASSEMBLY with the bolt.
- INSTALL KNOCK SENSOR
Refer to PROCEDURE - Step 1
- INSTALL NO. 4 ENGINE COVER SUBASSEMBLY
- Install the No. 4 engine cover SUBASSEMBLY.
- INSTALL ENGINE WIRE
- INSTALL SEPARATOR CASE
Refer to PROCEDURE - Step 2
- INSTALL FUEL INJECTOR SEAL (for Direct Injection)
Refer to PROCEDURE - Step 3
- INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)
Refer to PROCEDURE - Step 4
- INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection)
Refer to PROCEDURE - Step 5
- INSTALL FUEL DELIVERY PIPE (for Direct Injection)
Refer to PROCEDURE - Step 6
- INSTALL NO. 4 FUEL PIPE SUBASSEMBLY
Refer to PROCEDURE - Step 8
- INSTALL NO. 2 ENGINE COVER SUBASSEMBLY LH
- INSTALL NO. 2 ENGINE COVER SUBASSEMBLY
- INSTALL NO. 1 ENGINE COVER SUBASSEMBLY
- INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)
Refer to PROCEDURE - Step 1
- INSTALL FUEL DELIVERY PIPE (for Port Injection)
Refer to PROCEDURE - Step 2
- INSTALL FUEL PUMP ASSEMBLY (for Bank 1)
Refer to PROCEDURE - Step 1
- INSTALL NO. 3 FUEL PIPE SUBASSEMBLY
Refer to PROCEDURE - Step 2
- INSTALL ENGINE COVER SUBASSEMBLY (for Bank 1)
Refer to PROCEDURE - Step 3
- INSTALL FUEL PUMP ASSEMBLY (for Bank 2)
Refer to PROCEDURE - Step 4
- INSTALL NO. 2 FUEL PIPE SUBASSEMBLY
Refer to PROCEDURE - Step 5
- INSTALL ENGINE COVER SUBASSEMBLY (for Bank 2)
Refer to PROCEDURE - Step 6
- INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
Refer to PROCEDURE - Step 1
- CONNECT FUEL TUBE SUBASSEMBLY
Refer to PROCEDURE - Step 3
- INSTALL INTAKE MANIFOLD
Refer to PROCEDURE - Step 1
- INSTALL THROTTLE BODY ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL VENTILATION HOSE
- INSTALL PURGE VSV
Refer to PROCEDURE - Step 2
- INSTALL WATER BY-PASS PIPE SUBASSEMBLY
Refer to PROCEDURE - Step 3
- INSTALL NO. 1 ENGINE COVER
- Install the No. 1 engine cover.
- INSTALL INJECTOR DRIVER
Refer to PROCEDURE - Step 4
- INSTALL ENGINE WIRE
Install the engine wire with the 4 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Connect the 2 clamps and 2 clamp brackets with the 2 bolts.
for bolt A
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
for bolt B
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
- Connect the intake air control valve actuator connector.
- Connect the purge VSV connector.
- Connect the 8 injector driver connectors and 2 clips as shown in the illustration.
for Engine Rear Side:
- Install the ground wire with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Attach the 8 wire harness clamps.
- Connect the fuel relief valve connector.
- Connect the engine wire connector.
- Install the ground wire with the 2 bolts.
for Engine RH Side:
- Connect the engine oil level sensor connector.
- Connect the crankshaft position sensor connector. Then install the wire harness with the 2 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
- Attach the 4 clamps.
- Connect the camshaft position sensor connector.
- Connect the fuel pump connector (for high pressure).
- Connect the 2 VVT sensor connectors.
- Connect the 4 ignition coil connectors.
- Connect the camshaft timing control valve connector.
for Engine Front Side:
- Install the clamp bracket with the bolt.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
- Attach the clamp and install the 3 ground wire with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Connect the 2 camshaft timing control motor connectors (for Bank 2).
- Connect the 2 camshaft timing control motor connectors (for Bank 1).
- Connect the engine coolant temperature sensor connector.
- Install the clamp bracket with the bolt.
for Engine LH Side:
- Attach the 4 wire harness clamps.
- Connect the No. 8 engine wire connector.
- Connect the fuel pump connector (for high pressure).
- Connect the 2 VVT sensor connectors.
- Connect the 4 ignition coil connectors.
- Connect the camshaft timing control valve connector.
- Connect the throttle body connectors.
- INSTALL NO. 6 ENGINE COVER SUBASSEMBLY
Refer to PROCEDURE - Step 3
- INSTALL NO. 5 ENGINE COVER SUBASSEMBLY
Refer to PROCEDURE - Step 4
- INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL COOLER COMPRESSOR ASSEMBLY
- Install 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 (250 kgf*cm, 18 ft.*lbf)
for bolts
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
- Install the cooler compressor assembly with the 2 stud bolts, 2 nuts and 2 bolts.
- INSTALL NO. 1 ENGINE HANGER
See step 52
- REMOVE ENGINE STAND
- 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.
- Place the engine onto a work bench.
- Lift the engine and remove it from the engine stand.
- INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY
- Using SST, hold the crankshaft.
- SST: 09213-54015
- 90119-08216
- SST: 09330-00021
- SST: 09213-54015
- Clean the installation holes.
- Install the crankshaft position sensor rotor.
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.
- 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.
- Apply a few drops of adhesive to 2 or 3 threads of the bolt end.
Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
- Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.
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.
- Mark the upside of each drive plate installation bolt with paint.
- Retighten the drive plate installation bolts by 90°.
- Check that the painted marks are now at a 90° angle to the upside.
- Using SST, hold the crankshaft.
- INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
Refer to PROCEDURE - Step 4
- INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT
Refer to PROCEDURE - Step 5
- CONNECT WIRE HARNESS AND CONNECTOR
Refer to PROCEDURE - Step 6
- INSTALL NO. 3 COVER SUBASSEMBLY
Refer to PROCEDURE - Step 2
- INSTALL NO. 1 OIL COOLER TUBE
Refer to PROCEDURE - Step 11
- INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(Refer to INSTALLATION [09/2015 - ] )
- INSTALL STARTER ASSEMBLY
Refer to PROCEDURE - Step 2
- INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 3
- INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH
- INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET RH
- INSTALL EXHAUST MANIFOLD SUBASSEMBLY LH
Refer to PROCEDURE - Step 3
- INSTALL EXHAUST MANIFOLD SUBASSEMBLY RH
Refer to PROCEDURE - Step 4
- INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
- Install the front No. 1 engine mounting bracket LH with the 5 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
- Install the front No. 1 engine mounting bracket LH with the 5 bolts.
- INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
- Install the front No. 1 engine mounting bracket RH with the 5 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
- Install the front No. 1 engine mounting bracket RH with the 5 bolts.
- INSTALL FRONT ENGINE MOUNTING INSULATOR
- Install the 2 engine mounting spacers and 2 front engine mounting insulators with the 2 nuts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
- Install the 2 engine mounting spacers and 2 front engine mounting insulators with the 2 nuts.
- INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 8
- INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 9
- INSTALL GENERATOR ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
- Apply a light coat of engine oil to a new O-ring.
- Install the O-ring to the engine oil level dipstick guide.
- Install the engine oil level dipstick guide with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the engine oil level dipstick.
- INSTALL FRONT FRAME ASSEMBLY
- Slowly lower the engine and set it to the front frame assembly.
- Install the 4 nuts.
Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
- INSTALL ENGINE AND TRANSMISSION
HINT:
Perform "Inspection After Repairs" after replacing the engine assembly (Refer to INITIALIZATION [09/2015 - ] ).
- 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.
- Remove the 2 bolts and 2 No. 1 engine hangers.
- Operate the engine lifter and install the engine to the vehicle.NOTE:
Make sure that the engine is clear of all wiring and hoses.
- Align the front frame to the marks on the vehicle, and temporarily install the front frame with the 4 bolts.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.
Install the 4 rear engine mounting member's bolts.
Torque: 35 N*m (354 kgf*cm, 26 ft.*lbf)
- Tighten the 4 front frame bolts.
Torque: 165 N*m (1683 kgf*cm, 122 ft.*lbf)
- Place the engine on an engine lifter.
- INSTALL FRONT LOWER SHOCK ABSORBER BRACKET SUBASSEMBLY LH
- Connect the front lower shock absorber bracket SUBASSEMBLY LH. Then install the bolt.
Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)
- Connect the front lower shock absorber bracket SUBASSEMBLY LH. Then install the bolt.
- INSTALL FRONT LOWER SHOCK ABSORBER BRACKET SUBASSEMBLY RH
- Connect the front lower shock absorber bracket SUBASSEMBLY RH. Then install the bolt.
Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)
- Connect the front lower shock absorber bracket SUBASSEMBLY RH. Then install the bolt.
- CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUBASSEMBLY
Refer to PROCEDURE - Step 4
- INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(Refer to INSTALLATION [09/2015 - ] )
- INSTALL FRONT EXHAUST PIPE ASSEMBLY
(Refer to INSTALLATION [09/2015 - ] )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY
(Refer to INSTALLATION [09/2015 - ] )
- INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
Refer to PROCEDURE - Step 2
- INSTALL NO. 1 AIR DUCT SUBASSEMBLY
- Attach the 2 claws to install the No. 1 air duct SUBASSEMBLY with the bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- Attach the 2 claws to install the No. 1 air duct SUBASSEMBLY with the bolt.
- INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
(Refer to INSTALLATION [09/2015 - ] )
- CONNECT HOSES AND CONNECTORS
Connect the purge line hose.
Connect the 2 heater hoses.
Attach the 5 clamps and connect the 2 connectors.
Connect the ground wire with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Connect the 2 power steering ECU connectors and attach the 2 clamps.
HINT:
Refer to the following procedures to connect A the power steering ECU connector (Refer to PROCEDURE - Step 1 ).
Connect the 3 connectors with front controller with the clamp.
Connect the wires with No. 1 engine room junction block with the 2 nuts. Then attach the 2 clamps.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
Lift up the wiring harness support and connect the 4 ECM connectors.
- Install the wiring harness support to the ECU box.
- Attach the clip of connector A to the ECU box.
- Connect the 4 TCM connectors and 2 wiring harness support connectors.
Install the engine room ECU cover with the 3 bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
- CONNECT SUCTION HOSE SUBASSEMBLY
Refer to PROCEDURE - Step 4
- CONNECT DISCHARGE HOSE SUBASSEMBLY
Refer to PROCEDURE - Step 3
- CONNECT NO. 1 FUEL PIPE SUBASSEMBLY
Refer to PROCEDURE - Step 3
- CONNECT NO. 3 FUEL HOSE
Refer to PROCEDURE - Step 4
- INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
Refer to PROCEDURE - Step 1
- INSTALL V-RIBBED BELT
See step 1
- INSTALL RESONATOR BRACKET SUBASSEMBLY
See step 9
- CONNECT NO. 2 RADIATOR HOSE
- CONNECT NO. 1 RADIATOR HOSE
- INSTALL RADIATOR RESERVOIR ASSEMBLY
Refer to PROCEDURE - Step 3
- INSTALL ENGINE ROOM ECU OUTLET DUCT
- Install the engine room ECU outlet duct to the fan shroud and ECU box.
- INSTALL AIR CLEANER ASSEMBLY RH
Refer to PROCEDURE - Step 10
- INSTALL AIR CLEANER ASSEMBLY LH
Refer to PROCEDURE - Step 9
- INSTALL INTAKE AIR CONNECTOR PIPE
Refer to PROCEDURE - Step 13
- INSTALL REAR FRAME SIDE RAIL
- INSTALL FRONT SUSPENSION LOWER CROSSMEMBER
Refer to PROCEDURE - Step 6
- INSTALL FRONT BUMPER COVER
(Refer to INSTALLATION [09/2015 - ] )
- CONNECT NO. 1 OIL COOLER OUTLET HOSE
Refer to PROCEDURE - Step 16
- CONNECT NO. 1 OIL COOLER INLET HOSE
Refer to PROCEDURE - Step 17
- INSTALL NO. 1 AIR CLEANER INLET
Refer to PROCEDURE - Step 3
- ADD ENGINE OIL
Refer to PROCEDURE - Step 5
- ADD ENGINE COOLANT
Refer to PROCEDURE - Step 8
- ADD DIFFERENTIAL OIL
Refer to PROCEDURE - Step 2
- ADD AUTOMATIC TRANSMISSION FLUID
(Refer to ADJUSTMENT [09/2015 - ] )
- 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 - ] ).
- CHARGE REFRIGERANT
Refer to PROCEDURE - Step 3
- INSPECT FOR REFRIGERANT
Refer to PROCEDURE - Step 5
- INSPECT FOR OIL LEAK
Refer to PROCEDURE - Step 5
- INSPECT FOR COOLANT LEAK
Refer to PROCEDURE - Step 1
- INSPECT FOR FUEL LEAK
Refer to PROCEDURE - Step 1
- INSPECT FOR EXHAUST GAS LEAK
Refer to PROCEDURE - Step 9
- CHECK SHIFT LEVER POSITION
Refer to PROCEDURE - Step 8
- CHECK IGNITION TIMING
See step 4
- CHECK IDLE SPEED
See step 5
- CHECK CO/HC
See step 7
- INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
- INSTALL NO. 1 ENGINE UNDER COVER
Refer to PROCEDURE - Step 13
- INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
Refer to PROCEDURE - Step 16
- INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
Refer to PROCEDURE - Step 15
- INSTALL NO. 2 ENGINE UNDER COVER
- Install the No. 2 engine under cover with the 4 screws and 2 clips.
- INSTALL FRONT CENTER FLOOR COVER
- Install the front center floor cover with the 3 screws, 2 bolts and clip.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Install the front center floor cover with the 3 screws, 2 bolts and clip.
- CHECK ENGINE OIL LEVEL
Refer to PROCEDURE - Step 2
- PLACE FRONT WHEELS FACING STRAIGHT AHEAD
- CHECK AND ADJUST FRONT WHEEL ALIGNMENT
(Refer to ADJUSTMENT [09/2015 - ] )
- INSTALL ENGINE ROOM SIDE COVER RH
Refer to PROCEDURE - Step 15
- INSTALL ENGINE ROOM SIDE COVER LH
Refer to PROCEDURE - Step 16
- INSTALL AIR CLEANER INLET COVER SUBASSEMBLY
Refer to PROCEDURE - Step 7
- INSTALL V-BANK COVER SUBASSEMBLY
Refer to PROCEDURE - Step 8
- INSTALL COWL TOP VENTILATOR LOUVER RH
Refer to PROCEDURE - Step 17