Engine Assembly: Installation

1. Install the transverse engine mounting insulator with the 2 nuts.

   Torque: 52 N*m (525 kgf*cm, 38 ft.*lbf) 

   Fig 1: Locating Transverse Engine Mounting Insulator And Nuts

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2. Install the 2 hole plugs.
   Fig 2: Locating Hole Plugs

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1. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

   Part No.: 

   No. 1 Engine hanger 12281-31120 

   No. 2 Engine hanger 12282-31100 

   Bolts 91671-10825 

   Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

2. Attach the engine sling device and hang the engine with the chain block.
   Fig 3: Locating Engine Hangers With Bolts

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1. Install the transverse engine mount bracket with the 3 bolts.

   Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 

   Fig 4: Locating Transverse Engine Mounting Bracket Bolt

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1. Temporarily install the front engine mounting insulator assembly with the nut.
   Fig 5: Locating Front Engine Mounting Insulator Assembly And Nut

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1. Temporarily install the transverse engine mounting insulator with the nut.
   Fig 6: Locating Transverse Engine Mounting Insulator And Nut

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1. Temporarily install the transverse mounting insulator with the nut.
   Fig 7: Locating Transverse Engine Mounting Insulator And Nut

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1. Temporarily install the engine assembly with transaxle with the 9 nuts and 2 bolts.
   Fig 8: Locating Engine Assembly, Transaxle Nuts And Bolts

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2. Tighten the 4 nuts.

   Torque: A 

   87 N*m (887 kgf*cm, 64 ft.*lbf) 

   B 

   52 N*m (525 kgf*cm, 38 ft.*lbf) 

   Fig 9: Locating Transaxle Nuts

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3. Tighten the 4 nuts.

   Torque: A 

   95 N*m (969 kgf*cm, 70 ft.*lbf) 

   B 

   87 N*m (887 kgf*cm, 64 ft.*lbf) 

   Fig 10: Locating Transaxle Nuts

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4. Tighten the 4 nuts.

   Torque: A 

   95 N*m (969 kgf*cm, 70 ft.*lbf) 

   B 

   87 N*m (887 kgf*cm, 64 ft.*lbf) 

   Fig 11: Locating Transaxle Nuts

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5. Tighten the 2 bolts.

   Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

   Fig 12: Locating Transaxle Bolts

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6. Connect the duty vacuum switching valve connector and clamp.
   Fig 13: Locating Duty Vacuum Switching Valve Connector And Clamp

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7. Install the 5 hole plugs.
   Fig 14: Locating Hole Plugs

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HINT:

(See INSTALLATION ).

1. Remove the 4 bolts and 2 engine hangers.
   Fig 15: Locating Engine Hangers With Bolts

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1. Install the bolt, nut and manifold stay.

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

1. Install the 3 bolts.
   Fig 17: Locating Engine Wire Bolts

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   Torque: 8.3 N*m (85 kgf*cm, 74 in.*lbf) 

2. Connect the 2 clamps, 3 ignition coil assembly connectors, 2 camshaft timing oil control valve assembly connectors, 2 VVT sensor connectors, 3 injector assembly connectors and radio setting condenser connector.
3. Install the bolt and 2 nuts.
   Fig 18: Locating Air Fuel Ratio Sensor Connector And Clamp

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   Torque: 8.3 N*m (85 kgf*cm, 74 in.*lbf) 

4. Connect the 2 clamps, 3 ignition coil assembly connectors, 2 camshaft timing oil control valve assembly connectors, 2 VVT sensor connectors and 3 injector connectors.
5. Connect the air fuel ratio sensor connector.
6. Connect the 2 clamps, engine coolant temperature sensor connector and knock control sensor wire connector.
7. Install the ground cable bolt.
   Fig 19: Locating Engine Coolant Temperature Sensor Connector And Bolt

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8. Connect the purge VSV connector, air fuel ratio sensor connector and 2 clamps.
   Fig 20: Locating Purge VSV Connector, Air Fuel Ratio Sensor Connector And Clamps

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9. Install the nut.

   Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

10. Connect the generator assembly connector and clamp.
    Fig 21: Locating Generator Assembly Connector And Clamp

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11. Connect the crankshaft position sensor connector and clamp.
    Fig 22: Locating Crankshaft Position Sensor Connector And Clamp

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12. Connect the oil pressure switch assembly connector.
    Fig 23: Locating Oil Pressure Switch Assembly Connector

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13. Connect the oil pressure switch assembly cover.

Fig 24: Identifying Oil Pressure Switch Cover And Clamp

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1. Install a new gasket to the intake air surge tank.
2. Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.

   Torque: Bolt 

   18 N*m (184 kgf*cm, 13 ft.*lbf) 

   Nut 

   16 N*m (163 kgf*cm, 12 ft.*lbf) 

3. Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.

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

   Fig 25: Installing Throttle Body Bracket, No. 1 Surge Tank Stay And Bolts

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4. Connect the connector.
5. Connect the No. 1 ventilation hose.
   Fig 26: Identifying No. 1 Ventilation Hose

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6. Install the clamp and connect the throttle with motor body assembly connector.
7. Connect the vapor feed hose.
8. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
   Fig 27: Connecting Water By-Pass Hoses To Throttle With Motor Body Assembly

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1. Using pliers, grip the claws of the 2 clips and slide the 2 clips to the intake air surge tank assembly and ventilation valve.

1. Install the compressor and magnetic clutch with the 4 bolts.

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

   NOTE: Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
   Fig 29: Locating Magnetic Clutch And Bolts

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2. Engage each clamp.
3. Engage the clamp.
4. Connect the connector.

1. Set the engine assembly with transaxle on the engine lifter.
2. Install the engine assembly to the vehicle.
   Fig 30: Identifying Compressor Clamp

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3. Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.

   Torque: A 

   85 N*m (867 kgf*cm, 63 ft.*lbf) 

   B 

   32 N*m (327 kgf*cm, 24 ft.*lbf) 

   Fig 31: Locating Frame Side Rail Plates, Bolts And Nuts

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4. Install the front suspension member rear braces RH and LH with the 6 bolts and 2 nuts.

   Torque: A 

   85 N*m (867 kgf*cm, 63 ft.*lbf) 

   B 

   32 N*m (327 kgf*cm, 24 ft.*lbf) 

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

1. Connect the 3 ECM connectors, 2 junction block connectors and clamp.
   Fig 33: Identifying Junction Block Connectors And Clamp

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2. Install the engine wire with the 2 nuts.

   Torque: 8.3 N*m (84 kgf*cm, 73 in.*lbf) 

   Fig 34: Identifying Engine Wire, Clamp And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the clip and 2 ground cables with the 2 bolts.

   Torque: 8.3 N*m (84 kgf*cm, 73 in.*lbf) 

   Fig 35: Locating Ground Cables, Clip And Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the heated oxygen sensor clamp and connector.
   Fig 36: Locating Heated Oxygen Sensor Connector And Clamp

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5. Connect the engine wire clamp.
   Fig 37: Identifying Engine Wire Clamp

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6. Install the ground cable with the bolt.

   Torque: 8.3 N*m (84 kgf*cm, 73 in.*lbf) 

   Fig 38: Locating Ground Cables Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Connect the engine wire to the engine room relay block. Then, install it with the nut.

   Torque: 8.3 N*m (84 kgf*cm, 73 in.*lbf) 

8. Connect the engine wire connector.
9. Install the No. 1 relay block cover.
   Fig 39: Locating Engine Room Relay Block

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1. Connect the control cable to the control cable clamp.
   Fig 40: Identifying Control Cable And Control Cable Clamp

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2. Install the transmission control cable assembly to the control shaft lever with the nut.

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

   Fig 41: Locating Control Shaft Lever

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3. Connect the transmission control cable assembly to the bracket with a new clip.
   Fig 42: Identifying Control Cable Bracket

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1. Push in the fuel tube connector to the fuel pipe until the fuel tube makes a "click" sound.
   NOTE:

   • Check for damage or dirt and foreign objects on the connected part of the pipe.
   • Check if the pipe and the connector are securely connected by trying to pull them apart.
     Fig 43: Pushing Fuel Tube Connector To Fuel Pipe

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the No. 1 fuel pipe clamp.
   Fig 44: Identifying No. 1 Fuel Pipe Clamp

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1. Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler outlet hose.
   Fig 45: Locating Oil Cooler Outlet Hose And Claws

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1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 2 oil cooler hose.
   Fig 46: Locating No. 2 Oil Cooler Hose And Claws

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1. Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose B to water outlet.
   Fig 47: Locating Heater Water Inlet Hose Clip

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1. Using pliers, grip the claws of the clip and slide the clip to connect the heater water outlet hose B to water inlet.
   Fig 48: Locating Heater Water Outlet Hose And Claws

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 1 radiator hose to the water outlet.
2. Install the clamp with the air fuel ratio sensor connector.
   Fig 49: Locating No. 1 Radiator Hose And Clamp

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1. Using pliers, grip the claws of the clip and slide the clip to connect the No. 2 radiator outlet hose to the water inlet.
   Fig 50: Locating No. 2 Radiator Hose And Clip

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1. Using pliers, grip the claws of the clip and slide the clip to connect the union to check valve hose to the intake air surge tank assembly.
   Fig 51: Locating Front Exhaust Pipe Clip

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1. Install the clamp and connect the No. 1 fuel vapor feed hose.
   Fig 52: Locating No. 1 Fuel Vapor Feed Hose And Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the engine moving control rod with the 3 bolts.
2. First install bolts A, and then bolt B.

   Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf) 

   Fig 53: Locating Engine Moving Control Rod And Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the No. 2 engine mounting stay RH with the bolt.

   Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf) 

2. Tighten the 2 nuts.

   Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 

   Fig 54: Locating Nuts On No. 2 Engine Mounting Stay RH

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1. Install the reservoir bracket with the 2 bolts.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Fig 55: Locating Reservoir Bracket And Bolt

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1. Install the brake master cylinder reservoir assembly with the bolt.

   Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

2. Connect the level warning switch connector.
   Fig 56: Locating Brake Master Cylinder Reservoir Assembly And Bolt

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1. Install the 2 bolts and air cleaner bracket.

   Torque: 12 N*m (123 kgf*cm, 9 ft.*lbf) 

   Fig 57: Locating Air Cleaner Bracket And Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the battery tray and battery.
2. Install the battery clamp with the bolt and nut.

   Torque: Bolt 

   5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Nut A 

   5.4 N*m (55 kgf*cm, 48 in.*lbf) 

   Nut B 

   13 N*m (131 kgf*cm, 9 ft.*lbf) 

   Nut C 

   6.4 N*m (64 kgf*cm, 57 in.*lbf) 

   Fig 58: Locating Battery Clamp Bolt And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the positive battery terminal and nut.
4. Connect the negative battery terminal, and tighten the nut.

1. Install the air cleaner filter element sub-assembly.

1. Install the front outer cowl top panel sub-assembly with the 8 bolts and 6 nuts.
   Fig 60: Identifying Front Outer Cowl Top Panel Sub-Assembly, Bolts And Nuts

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   Torque: Bolt 

   8.8 N*m (90 kgf*cm, 78 in.*lbf) 

   Nut A 

   8.8 N*m (90 kgf*cm, 78 in.*lbf) 

   Nut B 

   85 N*m (867 kgf*cm, 63 ft.*lbf) 

2. Install the 4 clips.

Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

HINT:

(See FRONT WHEEL ALIGNMENT ).

1. Install the front fender apron seal RH with the 2 bolts and clip.
   Fig 62: Locating Front Fender Apron Seal RH, Clip And Bolts

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1. Install the front fender apron seal LH with the 2 bolts and clip.

1. Install the No. 2 engine under cover with the 2 bolts.
   Fig 64: Locating No. 2 Engine Under Cover And Bolts

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1. Install the No. 1 engine under cover with the 6 bolts and 2 clips.
   Fig 65: Locating No. 1 Engine Under Cover, Bolt And Clips

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1. Install the engine under cover assembly with the 4 bolts and 5 clips.
   Fig 66: Locating Engine Under Cover Assembly, Bolt And Screw

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2. Install the engine under cover assembly RR with the 2 bolts.
   Fig 67: Locating Engine Under Cover Assembly RR And Bolts

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1. Fit the 3 retainers and install the V-bank cover.

TEST MODE PROCEDURE

HINT:

See INITIALIZATION .

Fig 68: Identifying Clip On Rear Of Cover

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