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Engine Assembly: Installation

WARNING: This page is about a different car, the 2007 Toyota Tacoma. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (See  LUBRICATION SYSTEM  ) 
  2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket front No. 1 RH with the 4 bolts.

      Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf) 

      2. Fig 1: Installing Engine Mounting Bracket Front No. 1 RH
      G04408787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL EXHAUST MANIFOLD (See  INSTALLATION   ) 
  4. INSTALL AIR SWITCHING VALVE ASSEMBLY (See  INSTALLATION  ) 
  5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See  INSTALLATION  ) 
  6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See  INSTALLATION  ) 
  7. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See  INSTALLATION   ) 
  8. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  9. INSTALL SPARK PLUG 

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

  10. INSTALL IGNITION COIL ASSEMBLY (See  INSTALLATION   ) 
  11. INSTALL VENTILATION PIPE 
    1. Install the ventilation pipe with the bolt.

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

      Fig 2: Installing Ventilation Pipe With Bolt
      G04408788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 WATER BYPASS PIPE 
    1. Install a new gasket, then install the water bypass pipe No. 1.

      Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) 

      Fig 3: Installing Water By-Pass Pipe No. 1
      G04408789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Install a new gasket onto the engine coolant temperature sensor.
    2. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      3. Fig 4: Installing Engine Coolant Temperature Sensor
      G04408790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL KNOCK SENSOR (See  INSTALLATION  ) 
  15. INSTALL FUEL INJECTOR ASSEMBLY (See  INSTALLATION  ) 
  16. INSTALL THERMOSTAT (See  INSTALLATION  ) 
  17. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Install engine mounting bracket front No. 1 LH with the 4 bolts.

      Torque: 51 N*m (520 kgf*cm, 38 ft.*lbf) 

      Fig 5: Installing Engine Mounting Bracket Front No. 1 LH With Bolts
      G04408791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL OIL LEVEL GAUGE GUIDE 
    1. Install the oil level gauge guide with the bolt.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      2. Fig 6: Installing Oil Level Gage Guide With Bolt
      G04408792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY 
  20. INSTALL ENGINE WIRE 
  21. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System) (See  INSTALLATION  ) 
  22. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET (See  INSTALLATION  ) 
  23. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (See  INSTALLATION  ) 
  24. INSTALL NO. 2 FUEL HOSE (See  INSTALLATION  ) 
  25. INSTALL FUEL HOSE (See  INSTALLATION  ) 
  26. INSTALL INTAKE AIR CONNECTOR (See  INSTALLATION  ) 
  27. INSTALL REAR END PLATE (See  INSTALLATION   ) 
  28. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) (See  INSTALLATION   ) 
  29. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) (See  INSTALLATION   ) 
  30. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission) 
    TRANSMISSION REFERENCE TABLE

    Transmission Reference
    R155 CLUTCH UNIT (FOR R155)
    R155F CLUTCH UNIT (FOR R155F)
  31. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) 
    TRANSMISSION REFERENCE TABLE

    Transmission Reference
    R155 CLUTCH UNIT (FOR R155)
    R155F CLUTCH UNIT (FOR R155F)
  32. INSTALL ENGINE ASSEMBLY 
    1. Attach the engine sling device and chain block to the engine hangers.
    2. Keep the engine level, and align the engine mounting bracket front No. 1 RH w/ engine mounting insulator front and LH with the body mountings.
    3. Attach the engine mounting bracket front No. 1 RH w/ engine mounting insulator front and LH, and install the 4 bolts and nuts.

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

    4. Remove the bolts, then remove the engine hangers.
      5. Fig 7: Removing Engine Hangers With Bolts
      G04408793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    (See INSTALLATION )

  34. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY 
    TRANSMISSION REFERENCE TABLE

    Transmission Reference
    R155 INSTALLATION
    R155F INSTALLATION
  35. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  INSTALLATION  ) 
  36. INSTALL EXHAUST PIPE ASSEMBLY TAIL (See  INSTALLATION  ) 
  37. INSTALL ENGINE WIRE 
  38. CONNECT NO. 1 AIR INJECTION HOSE 
    1. Connect the fuel vapor feed hose.
      Fig 8: Connecting Fuel Vapor Feed Hose
      G04408794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Connect the fuel feed hose.
  40. CONNECT NO. 2 FUEL HOSE (See  INSTALLATION  ) 
  41. CONNECT FUEL HOSE (See  INSTALLATION  ) 
    Fig 9: Connecting Fuel Feed Hose
    G04408795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL WATER HOSE SUB-ASSEMBLY 
    1. Install the water hose.
      2. Fig 10: Installing Water Hose
      G04408796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL RADIATOR HOSE INLET 
  44. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) (See  INSTALLATION   ) 
  45. INSTALL NO. 2 RADIATOR HOSE 
  46. INSTALL VANE PUMP ASSEMBLY (See  INSTALLATION   ) 
  47. INSTALL AIR CLEANER CASE 
    1. Install the air cleaner case with the 3 bolts.

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

  48. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  49. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See  INSTALLATION  ) 
  50. INSTALL FAN SHROUD (See  INSTALLATION  ) 
  51. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH (See  INSTALLATION  ) 
  52. INSTALL BATTERY TRAY 
  53. INSTALL BATTERY 
  54. ADD ENGINE COOLANT (See  COOLANT  ) 
  55. ADD ENGINE OIL (See  INSTALLATION  ) 
  56. CHECK FOR ENGINE OIL LEVEL 
  57. CHECK FOR FUEL LEAKAGE 
  58. CHECK FOR ENGINE COOLANT LEAKAGE (See  COOLANT  ) 
  59. CHECK FOR OIL LEAKAGE 
  60. CHECK FOR EXHAUST GAS LEAKAGE 
  61. INSPECT IGNITION TIMING (See  ON-VEHICLE INSPECTION   ) 
  62. INSPECT ENGINE IDLE SPEED (See  ON-VEHICLE INSPECTION   ) 
  63. INSPECT CO/HC (See  ON-VEHICLE INSPECTION   ) 
  64. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type) 
    1. Install the engine under cover No. 1 with the 4 bolts.

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

  65. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type, Regular Cab) 
    1. Install the engine under cover No. 2 with the 4 bolts.

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

  66. INSTALL HOOD SUB-ASSEMBLY 

    (See REASSEMBLY )

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