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Engine Assembly, Intake Manifold, Exhaust Manifold: Installation

WARNING: This page is about a different car, the 2008 Toyota RAV4. 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 sensor and a new gasket.

      Torque: 20 N*m (204 kgf*cm, 14 ft.*lbf) 

      Fig 1: Identifying ECT Sensor
      G04485087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL KNOCK SENSOR (See  INSTALLATION  ) 
  3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.

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

    2. Using a 24 mm deep socket wrench, install the oil pressure switch.

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

      Fig 2: Installing Oil Pressure Switch
      G04485088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Install the mounting bracket with the 6 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      Fig 3: Identifying No. 1 Front Engine Mounting Bracket Bolts
      G04485089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL WATER PUMP PULLEY (See  INSTALLATION  ) 
  6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the idler pulley and cover plate with the bolt.

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

      Fig 4: Installing Idler Pulley Plate Bolt
      G04485090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL NO. 2 TIMING GEAR COVER 
    1. Install the gear cover with the 2 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

  8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    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: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

    3. Tighten the other bolts.

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

      Fig 5: Installing V-Ribbed Belt Tensioner Assembly
      G04485091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Each bolt length is as follows: 

      BOLT LENGTH SPECIFICATION

      A 70 mm (2.76 in.)
      B 35 mm (1.37 in.)
  9. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

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

      Fig 6: Identifying Drive Shaft Bearing Bracket Bolts
      G04485092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Install a new gasket as shown in the illustration.
      Fig 7: Identifying Exhaust Manifold Gasket
      G04485093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manifold with the 6 nuts.

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

      Fig 8: Identifying Exhaust Manifold Sub-Assembly Nuts LH
      G04485094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 2 heat insulator with the 3 bolts.

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

  12. INSTALL NO. 2 MANIFOLD STAY 
    1. Install the No. 2 manifold stay with the bolt and nut.

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Fig 9: Identifying No. 2 Manifold Stay Bolt And Nut
      G04485095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL OIL DIPSTICK GUIDE 
    1. Install 2 new O-rings to the guide.
    2. Apply a light coat of engine oil to the O-rings.
    3. Push in the guide end into the guide hole.
    4. Install the No. 1 guide with the bolt.

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

    5. Install the No. 2 guide with the bolt.

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

    6. Install the dipstick.
      Fig 10: Identifying Oil Dipstick Guide
      G04485096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  15. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (See  INSTALLATION  ) 
  16. INSTALL FAN AND GENERATOR V BELT (See  REMOVAL  ) 
  17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket as shown in the illustration.
      Fig 11: Identifying Exhaust Manifold Gasket
      G04485097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the manifold with the 6 nuts.

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

      Fig 12: Identifying Exhaust Manifold Sub-Assembly Nuts RH
      G04485098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL INTAKE MANIFOLD 
    1. Set a new gasket on each cylinder head.
      NOTE:
      • Align the port holes of the gasket and cylinder head.
      • Be careful of the installation direction.
      Fig 13: Identifying Gasket On Cylinder Head
      G04485099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Set the intake manifold on the cylinder heads.
    3. Install and uniformly tighten the 6 bolts and 4 nuts in several passes.

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

      Fig 14: Identifying Intake Manifold Bolts And Nuts
      G04485100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 6 fuel injector connectors.
  19. INSTALL FUEL INJECTOR ASSEMBLY (See  INSTALLATION  ) 
  20. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the mounting stay with the bolt.

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

  21. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the 6 ignition coils with the 6 bolts to the cylinder head.

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

  22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    NOTE: Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them.
    1. Install a new gasket to the surge tank.
    2. Using a 5 mm hexagon socket wrench, install the 4 bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    3. Install the surge tank with the 2 nuts and 2 bolts.

      Torque: 

      21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt 

      16 N*m (163 kgf*cm, 12 ft.*lbf) for nut 

      Fig 15: Identifying Intake Air Surge Tank Assembly Nuts And Bolts
      G04485101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connector.
      Fig 16: Identifying Connector
      G04485102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the vacuum hose clamp with the bolt.

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

      Fig 17: Identifying Vacuum Hose Clamp Bolt
      G04485103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the union to check valve hose.
    7. Connect the No. 2 ventilation hose.
      8. Fig 18: Identifying Hoses And Clamps
      G04485104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the clamp and connect the throttle body connector.
    9. Connect the vapor feed hose.
    10. Connect the 2 water by-pass hoses to the throttle body.
      Fig 19: Connecting Water By-Pass Hoses To Throttle Body
      G04485105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE ENGINE FROM ENGINE STAND 
    1. Install a sling device and chain block to the engine.
    2. Remove the engine from the engine stand.
  24. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Clean the bolt and its hole.
    2. Apply adhesive to 2 or 3 threads of the bolt end.

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

      Fig 20: Applying Adhesive To 2 Or 3 Threads Of Bolt End
      G04485106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, hold the crankshaft.

      SST 09213-70011, 09330-00021 

      Fig 21: Holding Crankshaft Using SST
      G04485107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the flywheel, drive plate and drive plate spacer on the crankshaft.
    5. Uniformly install and tighten the 8 bolts.

      Torque: 178 N*m (1,815 kgf*cm, 132 ft.*lbf) 

      NOTE: Do not start the engine for at least 1 hour after the installation.
      Fig 22: Installing Drive Plate Bolts
      G04485108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. 2WD: Install the automatic transaxle (see INSTALLATION ).
    2. 4WD: Install the automatic transaxle (see INSTALLATION ).
  26. INSTALL TRANSFER ASSEMBLY (for 4WD) (See  INSTALLATION  ) 
  27. INSTALL STARTER ASSEMBLY (See  INSTALLATION  ) 
  28. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine.
  29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Attach the engine together with the transaxle to the suspension crossmember and mounting.
    2. Install the bolt which secures the engine mounting bracket to the mounting insulator.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 23: Identifying Front Suspension Crossmember Sub-Assembly
      G04485109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY 
    1. Install the bolt and nut which secures the engine mounting bracket to the mounting insulator.

      Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf) 

      Fig 24: Identifying Engine Mounting Bracket To Mounting Insulator
      G04485110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL ENGINE WITH TRANSAXLE 
    1. Place the engine on an engine lifter.

      HINT:

      Place the engine on wooden blocks or an equivalent so that the engine is level.

    2. Using the chain block, slowly install the engine to the vehicle and the intermediate shaft to the pinion.
      CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
      NOTE:
      • Make sure that the engine is clear of all wiring and hoses.
      • While raising the engine into the vehicle, do not allow it to contact the vehicle.
      • Align the matchmarks on the intermediate shaft and pinion.
    3. Temporarily install the suspension member and crossmember with the 10 bolts.
      Fig 25: Identifying Suspension Member And Crossmember Bolts
      G04485111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the member brace rear RH and LH with the 6 bolts.
    5. Install the engine mounting insulator LH with the bolt and nut.

      Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

      NOTE: While holding the bolt in place, tighten the nut.
      Fig 26: Identifying Engine Mounting Insulator LH
      G04485112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the engine mounting insulator RH with the 2 bolts and 2 nuts.

      Torque: 

      95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt and nut A 

      52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B 

      Fig 27: Identifying Engine Mounting Insulator RH
      G04485113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Tighten the suspension member and crossmember's bolts. (See Fig 28).

      Torque: 

      96 N*m (979 kgf*cm, 71 ft.*lbf) for bolt A 

      145 N*m (1,478 kgf*cm, 107 ft.*lbf) for bolt B 

      Fig 28: Tightening Suspension Member And Crossmember Bolts
      G04485114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tighten the member brace rear's bolts. (See Fig 28).

      Torque: 

      145 N*m (1,478 kgf*cm, 107 ft.*lbf) for bolt C 

      93 N*m (948 kgf*cm, 69 ft.*lbf) for bolt D 

    9. Remove the sling device and chain block.
    10. Remove the 2 bolts and No. 1 and No. 2 engine hangers.
  32. INSTALL FRONT DRIVE SHAFT LH 
    1. 2WD: Install the drive shaft (see INSTALLATION ).
    2. 4WD: Install the drive shaft (see INSTALLATION ).
  33. INSTALL FRONT DRIVE SHAFT RH 
    1. 2WD: Install the drive shaft (see INSTALLATION ).
    2. 4WD: Install the drive shaft (see INSTALLATION ).
  34. CONNECT TIE ROD END SUB-ASSEMBLY LH (See  INSTALLATION  ) 
  35. CONNECT TIE ROD END SUB-ASSEMBLY RH (See  INSTALLATION  ) 
  36. CONNECT STEERING INTERMEDIATE SHAFT (See  INSTALLATION  ) 
  37. CONNECT FRONT STABILIZER LINK ASSEMBLY LH (See  INSTALLATION  ) 
  38. CONNECT FRONT STABILIZER LINK ASSEMBLY RH (See  INSTALLATION  ) 
  39. INSTALL FRONT AXLE HUB NUT LH 
    1. Install the hub nut (see INSTALLATION ).
  40. INSTALL FRONT AXLE HUB NUT RH 
    1. Install the hub nut (see INSTALLATION ).
  41. INSTALL FRONT WHEELS 
  42. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See  INSTALLATION  ) 
  43. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See  EXHAUST (2GR-FE)  ) 
  44. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  EXHAUST (2GR-FE)  ) 
  45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. 2WD: Connect the control cable (see REPLACEMENT ).
    2. 4WD: Connect the control cable (see REPLACEMENT ).
  46. CONNECT RADIATOR HOSE INLET 
  47. CONNECT RADIATOR HOSE OUTLET 
  48. CONNECT OIL COOLER HOSE 
  49. CONNECT SUCTION HOSE SUB-ASSEMBLY (See  INSTALLATION  ) 
  50. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (See  INSTALLATION  ) 
  51. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY 
    1. Install the reservoir tank with the 2 bolts.

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

      Fig 29: Identifying Reservoir Tank Bolts
      G04485115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 hoses
  52. INSTALL ECM (See  INSTALLATION  ) 
  53. CONNECT HOSES AND CONNECTORS 
    1. Connect the 2 ECM connectors.
    2. Connect the 2 heater hoses.
    3. Connect the fuel hoses.
    4. Connect the starter wire with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) 

    5. Connect the 3 connectors and wire with the nut.

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

    6. Install the engine room junction block cover (upper).
  54. INSTALL AIR CLEANER CASE 
    1. Install the air cleaner case with the 3 bolts.

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

      Fig 30: Identifying Air Cleaner Case Bolts
      G04485116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the harness clamp.
  55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 
    1. Install the air cleaner filter element onto the air cleaner case.
    2. Insert the hinge part of the air cleaner cap into the air cleaner case, then hang the 2 hook clamps.
      Fig 31: Inserting Hinge Part Of Air Cleaner Cap Into Air Cleaner Case
      G04485117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the No. 1 air cleaner hose clamp.
    4. Connect the No. 2 ventilation hose to the air cleaner hose.
      5. Fig 32: Connecting No. 2 Ventilation Hose
      G04485118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the wire harness clamp and 3 vacuum hoses.
    6. Connect the VSV (intake air control) connector.
    7. Connect the mass air flow meter connector.
  56. INSTALL BATTERY BRACKET REINFORCEMENT 
    1. Install the bracket reinforcement with the 2 bolts.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      Fig 33: Identifying Battery Bracket Reinforcement Bolts
      G04485119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL FRONT BATTERY BRACKET 
    1. Install the bracket front with the 4 bolts.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

    2. Attach the 2 wire harness clamps.
      3. Fig 34: Identifying Front Battery Bracket Bolts And Clamps
      G04485120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL BATTERY 
  59. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
    1. Attach the hook of the battery clamp to the battery bracket front.
    2. Temporarily tighten the nut and install the bolt.
    3. Adjust the battery clamp's position.
    4. Fully tighten the nut and bolt.

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

    5. Attach the 2 wire harness clamps.
  60. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  61. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood (see INSTALLATION ).
    2. Adjust the hood (see ADJUSTMENT ).
  62. ADD AUTOMATIC TRANSAXLE FLUID 
    1. 2WD: Add automatic transmission fluid (see appropriate step(s) under INSTALLATION ).
    2. 4WD: Add automatic transmission fluid (see appropriate step(s) under INSTALLATION ).
  63. ADD TRANSFER OIL (for 4WD) (See  ON-VEHICLE INSPECTION  ) 
  64. ADD ENGINE OIL (See appropriate step(s) under  REPLACEMENT  ) 
  65. ADD ENGINE COOLANT (See  REPLACEMENT  ) 
  66. CHARGE REFRIGERANT (See appropriate step(s) under  REPLACEMENT  ) 
  67. CHECK FOR LEAKAGE OF REFRIGERANT (See appropriate step(s) under  REPLACEMENT  ) 
  68. CHECK FOR ENGINE OIL LEAKS (See appropriate step(s) under  REPLACEMENT  ) 
  69. CHECK FOR ENGINE COOLANT LEAKS (See appropriate step(s) under  ON-VEHICLE INSPECTION  ) 
  70. CHECK FOR FUEL LEAKS 
  71. INSPECT EXHAUST GAS LEAKS 
  72. INSPECT SHIFT LEVER POSITION 
    1. 2WD: Inspect the shift lever position (see ADJUSTMENT ).
    2. 4WD: Inspect the shift lever position (see ADJUSTMENT ).
  73. ADJUST TRANSMISSION CONTROL CABLE 
    1. 2WD: Adjust the shift lever position (see ADJUSTMENT ).
    2. 4WD: Adjust the shift lever position (see ADJUSTMENT ).
  74. INSTALL FRONT FLOOR COVER (See appropriate step(s) under  INSTALLATION  ) 
  75. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the under cover with the 2 clips.
  76. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the under cover with the 2 clips.
  77. INSTALL REAR ENGINE UNDER COVER RH 
    1. Install the under cover with the 2 clips.
  78. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the under cover with the 4 bolts and 12 clips.
  79. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Attach the 3 clips to install the engine cover.
      Fig 35: Identifying Engine Cover Clips
      G04485121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL RADIATOR SUPPORT OPENING COVER 
    1. Install the cover with the 9 clips.
      Fig 36: Identifying Radiator Support Opening Cover Clips
      G04485122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. ADJUST FRONT WHEEL ALIGNMENT 
    1. Adjust the front wheel alignment (see FRONT WHEEL ALIGNMENT ).
  82. INSPECT IDLE SPEED (See  ON-VEHICLE INSPECTION  ) 
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