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Installation [07/2020 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL SPACER BRACKET 
    1. Install the 2 spacer brackets (1).

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

  2. REMOVE ENGINE STAND 

    HINT: 

    Conduct the following operation with the assistance of a second person.

    1. Connect both hooks of the special tool 0 490 561 (11 0 000) to the front and back of the engine with the engine hangers.
      GTY995160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09200-WA870 

      HINT: 

      The workshop crane, lifting gear and the engine hangers on the engine must all be connected to each other so that the engine hangs straight upon lifting.

    2. Raise the engine slowly.
    3. Release the bolts (1) and remove the engine stand attachment No. 1.
      GTY994997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH 
    1. Install the No. 1 front engine mounting bracket RH (2).
      GTY994828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the E12 bolts (1).

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

  4. INSTALL ENGINE ASSEMBLY 
    WARNING:
    • Components connected to the engine joint or cross member.

      Danger of injury!

      • Check lifting eyes and engine mounting brackets for damage, e.g. cracks.
      • Attach the component to correctly mounted engine joints or cross members only.
      • Exclusively lift the component, do not move it forwards, backwards or in transverse direction.
    1. Install and lower the engine.
    2. Make sure that the No. 1 front engine mounting brackets rest completely on the front engine mounting insulators.
  5. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    NOTE:

    In order to prevent play, lower the engine completely before screwing the front engine mounting insulator LH and front No. 1 engine mounting bracket LH.

    1. Tighten down E14 bolt (1).
      GTY1154433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

  6. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH 
    NOTE:

    In order to prevent play, lower the engine completely before screwing the front engine mounting insulator RH and front No. 1 engine mounting bracket RH.

    1. Tighten down E14 bolt (1).
      GTY1154434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) 

    2. Release both hooks (1) and (2) of the special tool 0 490 561 (11 0 000) at the front and back of the engine from the engine hangers.
      GTY994519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09200-WA870 
    3. Unscrew the bolts (1) of the special tool 2 459 012.
      GTY946360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09200-WA610 
    4. Feed out the special tool 2 459 012 at the cylinder head and remove.
      • SST: 09200-WA610 
  7. INSTALL SUCTION PIPE SUB-ASSEMBLY 
    1. Replace O-ring.
      GTY995167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Position suction pipe sub-assembly (2).
    3. Tighten the T45 bolts (1).

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

  8. INSTALL AIR CONDITIONING TUBE ASSEMBLY 
    1. Replace O-ring.
      GTY995161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Position air conditioning tube assembly (2).
    3. Tighten the T45 bolts (1).

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

  9. INSTALL OIL COOLER TUBE 
    1. Position the oil cooler tube in the No. 1 automatic transmission oil cooler tube clamp (2).
      GTY946468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten down T25 screw (1).

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

  10. TEMPORARILY TIGHTEN AUTOMATIC TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. FULLY TIGHTEN AUTOMATIC TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 6

  12. INSTALL NO. 2 MANIFOLD STAY 

    Refer to PROCEDURE - Step 5

  13. INSTALL PROPELLER SHAFT ASSEMBLY 

    Refer to INSTALLATION [03/2019 - 07/2022] , or refer to INSTALLATION [07/2022 - ]

  14. INSTALL REAR ENGINE MOUNTING MEMBER 

    Refer to PROCEDURE - Step 17

  15. INSTALL FLOOR HEAT INSULATOR 

    Refer to PROCEDURE - Step 18

  16. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR 

    Refer to PROCEDURE - Step 4 [03/2019 - 07/2022] , or refer to PROCEDURE - Step 4 [07/2022 - ]

  17. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 6 [03/2019 - 07/2022] , or refer to PROCEDURE - Step 8 [07/2022 - ]

  18. INSTALL FRONT FLOOR COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  19. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 

    Refer to INSTALLATION [07/2020 - ]

  20. INSTALL STARTER ASSEMBLY 

    Refer to INSTALLATION [07/2020 - ]

  21. CONNECT WATER HOSE 

    HINT: 

    Make sure that the connections are locked correctly. The locks must engage audibly.

    1. Connect and lock the No. 1 radiator hose (1) and (2).
      GTY994833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect and lock the radiator reserve tank hose (4).
      GTY994815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect and lock the No. 5 water by-pass hose (3) in the marked area.
    4. Clip in the No. 5 water by-pass hose (3) in the marked area.
    5. Connect and lock the heater water hose (1) and No. 1 water by-pass hose (2).
    6. Connect and lock the No. 7 water by-pass hose and No. 6 radiator hose (1).
      GTY994724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL NO. 2 RADIATOR HOSE 

    Refer to PROCEDURE - Step 1

  23. INSTALL CYLINDER BLOCK COVER 

    Refer to INSTALLATION [07/2020 - ]

  24. INSTALL NO. 2 AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 1

  25. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  26. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  27. INSTALL AIR CLEANER HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  28. INSTALL AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  29. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY 

    Refer to INSTALLATION [07/2020 - ]

  30. INSTALL FRONT FENDER UPPER PROTECTOR LH 

    Refer to PROCEDURE - Step 2

  31. INSTALL FRONT FENDER UPPER PROTECTOR RH 

    HINT: 

    Use the same procedure described for the LH side.

  32. CONNECT NO. 2 FUEL VAPOR FEED HOSE 
    1. Connect and lock the No. 2 fuel vapor feed hose (1).
      GTY946083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the clamp.
  33. CONNECT CONNECTOR TO BRAKE BOOSTER TUBE 
    1. Connect and lock the connector to brake booster tube (1).
      GTY946077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FLOOR WIRE 
    1. Clip in the floor wire (1) for the voltage supply of the power distribution box in the marked area.
      GTY946075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL ENGINE ROOM ECM BOX 
    NOTE:
    • Improper routing of cables and wiring harnesses.

      Trapped, crushed or damaged cables may cause short circuits and malfunctions.

      • Route all cables without abrasions, do not trap and crush.
    1. Feed the engine room ECM box (2) into the guide and install.
      GTY946386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten down bolts (1).

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

    3. Feed the wiring harnesses into the holder at the engine room ECM box.
    4. Engage the 3 clamps (marks).
      GTY941847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the connectors (1).
      GTY909256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. The locks (1) and (2) must engage audibly.
      GTY946387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 1 INTEGRATION RELAY 

    Refer to INSTALLATION [07/2020 - ]

  37. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install wire harness clamp bracket (2) for the generator wire.
      GTY946087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the E8 screws (1).

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

    3. Clip in the lines in the marked areas.
  38. INSTALL POSITIVE BATTERY CABLE 
    1. Position the starter wire (3).
      GTY946446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Secure clamps (2).
    3. Tighten nut (1).

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

    4. Insert and install the generator wire (3).
      GTY946455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Secure clamps (2).
    6. Tighten nut (1).

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

    7. Insert and install the cover (2) in the direction of the arrow.
      GTY945956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. The locks (1) must engage audibly.
  39. INSTALL REAR CYLINDER BLOCK COVER 
    1. Make sure the rear cylinder block cover (1) is correctly fitted on rear side of the engine.
      GTY994425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the rear cylinder block cover (1) from the top and clip it in at the grommets (2).
      GTY994718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    NOTE:
    • Damage to the No. 1 engine cover sub-assembly.

      Jerky movements during disassembly and excessive application of force during installation may result in breakage of the No. 1 engine cover sub-assembly.

      • Disassemble or mount the No. 1 engine cover sub-assembly carefully.
      • Disassemble or mount snap-lock couplings of the ball pivots one after the other.
      • Disassemble or mount No. 1 engine cover sub-assembly only at temperatures >20 °C.

        Vehicle information / Control unit list / DME / Call up control unit functions / Diagnostic request / Diagnostic request / 117 Ambient temperature

      • Use only distilled water as an auxiliary material during installation, no lubricants.
    1. Check all grommets (1) of the No. 1 engine cover sub-assembly for correct fit.
      GTY994481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clip in the No. 1 engine cover sub-assembly (1) into the holders in the indicated areas.
      GTY994861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. The No. 1 engine cover sub-assembly (1) must audibly engage into place.
  41. INSTALL NO. 2 COWL TOP VENTILATOR LOUVER PROTECTOR 
    1. Position the No. 2 cowl top ventilator louver protector (1).
      GTY899591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten down bolts and nut (2).

      Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) 

  42. INSTALL COWL TOP VENTILATOR LOUVER PROTECTOR 
    1. Position the cowl top ventilator louver protector (2).
      GTY899602Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the screws (1).

      Torque: 2.6 N*m (27 kgf*cm, 23 in.*lbf) 

  43. INSTALL UPPER FRONT SUSPENSION CENTER BRACE 
    1. Position upper front suspension center brace (3).
      GTY899603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Replace E14 bolts (1) and bolts (2).
    3. Tighten the E14 bolts (1).

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

    4. Using SST, tighten the E14 bolts (1) an additional 90°.
      • SST: 09900-WA010 

      HINT: 

      • The magnetic portion is used to secure the gauge to the vehicle.
      • After first adjusting the needle of the gauge to 0°, tighten to the specified angle.
      • Perform the work procedure carefully so that the gauge, etc. does not become tilted.
      GTY859569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Example
      *b Before Tightening
      *c After Tightening
      *d Magnetic Portion
    5. Tighten the bolts (2).

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

    6. Using SST, tighten the bolts (2) an additional 90°.
      • SST: 09900-WA010 

      HINT: 

      • The magnetic portion is used to secure the gauge to the vehicle.
      • After first adjusting the needle of the gauge to 0°, tighten to the specified angle.
      • Perform the work procedure carefully so that the gauge, etc. does not become tilted.
      GTY859569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Example
      *b Before Tightening
      *c After Tightening
      *d Magnetic Portion
  44. INSTALL HOOD TO COWL TOP SEAL 
    1. Press the hood to cowl top seal (1) into the guide.
      GTY945554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Feed the floor cable into the brackets in the marked area.
    3. Make sure that the hood to cowl top seal (1) and the floor cable are fitted correctly.
  45. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [03/2019 - ]

  46. REMOVE AND INSTALL HOOD SUPPORT ASSEMBLY 
    1. Support the hood sub-assembly by hand.
    2. Remove the special tool 0 493 647 (51 2 170) (3) from the ball pin (2).
      • SST: 09800-WA030 
      GTY899615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull off the special tool 0 493 647 (51 2 170) (3) from the gas pressure spring (1).
      • SST: 09800-WA030 
    4. Continue to support the hood sub-assembly and repeat the operation on the other side of vehicle.
      WARNING:
      • Shutting hood sub-assembly or tailgate.

        Danger of injury!

        • Support hood sub-assembly/tailgate in fully open position with the aid of a suitable device.
    5. Check the clamp (3) is fitted correctly.
    6. Connect ball socket (1) to ball pin (2).
    7. Continue to support the hood sub-assembly and repeat the operation on the other side of vehicle.
  47. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 9

  48. INSTALL OIL FILLER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 10

  49. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to REPLACEMENT [03/2019 - ]

  50. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to INSTALLATION [07/2020 - ]

  51. ADD ENGINE COOLANT (for High Temperature) 

    Refer to REPLACEMENT [07/2020 - ]

  52. ADD ENGINE COOLANT (for Low Temperature) 

    Refer to REPLACEMENT [07/2020 - ]

  53. INSPECT FOR COOLANT LEAK (for High Temperature) 

    Refer to PROCEDURE - Step 1

  54. INSPECT FOR COOLANT LEAK (for Low Temperature) 

    Refer to PROCEDURE - Step 2

  55. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  56. ADJUST AUTOMATIC TRANSMISSION FLUID LEVEL 

    Refer to PROCEDURE - Step 2

  57. INSTALL FRONT SUSPENSION MEMBER LOWER PROTECTOR 

    Refer to INSTALLATION [03/2019 - ]

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