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Engine Assembly: Installation

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  1. INSTALL ENGINE HANGER 
    1. Install the 2 engine hangers with the 4 bolts shown below.
      Fig 1: Locating Engine Hangers & Bolts
      G05682483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Part No.: 

      ITEM REFERENCE

      Item Part No.
      No. 1 engine hanger 12281-31060
      No. 2 engine hanger 12282-31040
      Bolt 90119-08A87

      Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

  2. REMOVE ENGINE STAND 
    1. Attach an engine sling device and hang the engine with a chain block.
    2. Lift the engine, and remove it from the engine stand.
    3. Place the engine onto a working bench.
  3. INSTALL DRIVE PLATE AND RING GEAR 
    1. Using SST, hold the crankshaft.

      SST 09213-54015 (91651-60855), 09330-00021 

    2. Temporarily install the front spacer, drive plate and rear spacer with the 8 bolts.
      Fig 2: Holding Crankshaft Using SST
      G05682484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 8 bolts uniformly in several steps in the order shown below.

      Torque: 83 N*m (46 kgf*cm, 61 ft.*lbf) 

      NOTE: Do not start the engine for at least 1 hour after installing.
      Fig 3: Identifying Bolt Tightening Sequence
      G05682485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL ENGINE ASSEMBLY 
    1. Attach the engine sling device and hang the engine with the chain block.
    2. Slowly lower the engine into the engine compartment.
      Fig 4: Hanging Engine With Chain Block
      G05682486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the front engine mounting insulator LH.

      Torque: for bolt 

      79 N*m (806 kgf*cm, 58 ft.*lbf) 

      for nut 

      72 N*m (734 kgf*cm, 53 ft.*lbf) 

    4. Install the front engine mounting insulator RH.

      Torque: for bolt 

      79 N*m (806 kgf*cm, 58 ft.*lbf) 

      for nut 

      72 N*m (734 kgf*cm, 53 ft.*lbf) 

      Fig 5: Locating Front Engine Mounting Insulator Nuts And Bolts
      G05682487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 engine hangers and 4 bolts.
  5. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY  (See INSTALLATION )
  6. CONNECT NO. 1 WATER BY-PASS PIPE  (See INSTALLATION )
  7. CONNECT WIRE HARNESS AND CONNECTOR  (See INSTALLATION )
  8. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR  (See INSTALLATION  )
  9. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY  (See INSTALLATION  )
  10. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover.
      Fig 6: Identifying Flywheel Housing Under Cover
      G05682488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT  (See INSTALLATION )
  12. INSTALL STARTER ASSEMBLY 
    1. Install the starter (for 1.6 kW Type) (see INSTALLATION ).
    2. Install the starter (for 2.0 kW Type) (see INSTALLATION ).
  13. INSTALL FRONT FENDER APRON SEAL RH 
  14. INSTALL FRONT FENDER APRON SEAL LH 
  15. INSTALL BATTERY 
  16. CONNECT NO. 1 AND NO. 2 FUEL PIPE 
    1. Check that there is no damage or contamination in the connected part of pipe.
    2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
      Fig 7: Pushing Pipe Into Connector Until Connector Makes Click Sound
      G05682489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
      Fig 8: Pulling Apart Pipe And Connector
      G05682490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the fuel pipe clamp to the connector.
      Fig 9: Identifying Fuel Pipe Clamp
      G05682491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL COOLER COMPRESSOR 
    1. Install the cooler compressor with the 2 nuts and 2 bolts in several steps in the sequence shown below.

      Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

      Fig 10: Identifying Cooler Compressor Nuts And Bolt Tightening Sequence
      G05682492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the cooler compressor connector.
  18. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  19. CONNECT VANE PUMP ASSEMBLY  (See INSTALLATION )
  20. CONNECT HEATER WATER INLET HOSE 
    1. Install the heater water pipe bracket with the nut.

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

    2. Connect the heater water inlet and outlet hose.

      HINT:

      The direction of the hose clamp is indicated below.

    3. Connect the wire harness clamp.
      4. Fig 11: Locating Heater Water Pipe Bracket Nut And Heater Water Inlet Hose
      G05682493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL RADIATOR ASSEMBLY  (See INSTALLATION )
  22. INSTALL RADIATOR SIDE DEFLECTOR RH  (See INSTALLATION )
  23. INSTALL RADIATOR SIDE DEFLECTOR LH  (See INSTALLATION )
  24. INSTALL FAN SHROUD  (See INSTALLATION )
  25. CONNECT RADIATOR HOSE OUTLET 
  26. CONNECT RADIATOR HOSE INLET 
  27. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH  (See INSTALLATION )
  28. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION )
  29. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH  (See INSTALLATION )
  30. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  31. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck) 
  32. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck) 
  33. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for Regular Cab Standard Deck)  (See INSTALLATION )
  34. INSTALL AIR SWITCHING VALVE ASSEMBLY  (See INSTALLATION )
  35. INSTALL NO. 2 AIR TUBE  (See INSTALLATION )
  36. INSTALL NO. 1 AIR TUBE  (See INSTALLATION )
  37. CONNECT NO. 4 AIR INJECTION SYSTEM HOSE  (See INSTALLATION )
  38. CONNECT NO. 5 AIR INJECTION SYSTEM HOSE  (See INSTALLATION )
  39. CONNECT ENGINE WIRE 
    1. Engine Room LH Side:
      1. Install the battery positive cable with the nut labeled H shown below.

        Torque: 12 N*m (125 kgf*cm, 9 ft.*lbf) 

      2. Connect the battery positive cable cover.
      3. Install the ground cable with the bolt labeled G shown below.

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

      4. Attach the wire harness clamp to the front engine mounting bracket LH, and connect the connector to the crankshaft position sensor labeled F shown below.
      5. Attach the front ABS junction connector's clamp to the engine room relay block side, and connect the connector labeled E shown below.
      6. Connect the wire harness bracket with the nut labeled D shown below.

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

      7. Connect the No. 2 engine wire's cover to the engine room relay block, and install the No. 2 engine wire with the nut labeled C shown below.

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

      8. Connect the 2 connectors to the engine room relay block labeled B shown below.
      9. Connect the 4 connectors to the air injection control driver labeled A shown below.
        10. Fig 12: Identifying Engine Wire (Engine Room LH Side)
        G05682494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engine Room RH Side:
      1. Install the bracket with the bolt labeled F shown below.

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

      2. Attach the 2 wire harness clamps labeled E shown below.
      3. Connect the 2 air pump connectors labeled D shown below.
      4. Install the ground cable with the 2 bolts labeled C shown below.

        Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      5. Attach the 2 wire harness clamps labeled B shown below.
      6. Connect the 7 connectors to the junction block labeled B shown below.
      7. Install the junction block cover.
      8. Connect the ECM connector labeled A shown below.
      Fig 13: Identifying Engine Wire (Engine Room RH Side)
      G05682495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL INTAKE AIR SURGE TANK  (See INSTALLATION )
  41. INSTALL AIR CLEANER ASSEMBLY  (See INSTALLATION )
  42. INSTALL NO. 2 AIR CLEANER HOSE  (See INSTALLATION )
  43. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY  (See INSTALLATION )
  44. INSTALL FRONT WIPER MOTOR AND LINK 
    1. Install the front wiper motor and link (see INSTALLATION ).
  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  46. ADD ENGINE OIL  (See REPLACEMENT )
  47. INSPECT FOR FUEL LEAK  (See INSTALLATION )
  48. ADD AUTOMATIC TRANSMISSION FLUID  (See INSTALLATION )
  49. ADD ENGINE COOLANT  (See REPLACEMENT )
  50. INSPECT FOR COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  51. ADJUST SHIFT LEVER POSITION  (See ADJUSTMENT )
  52. INSPECT SHIFT LEVER POSITION  (See INSPECTION )
  53. INSPECT FOR OIL LEAK 
  54. INSPECT FOR EXHAUST GAS LEAK 
  55. CHECK ENGINE OIL LEVEL  (See ON-VEHICLE INSPECTION )
  56. PERFORM RESET MEMORY 
    1. Perform the RESET MEMORY procedures (A/T initialization) (see INITIALIZATION ).
  57. INSPECT IGNITION TIMING  (See ON-VEHICLE INSPECTION  )
  58. INSPECT ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION  )
  59. INSPECT CO/HC  (See ON-VEHICLE INSPECTION  )
  60. INSTALL V-BANK COVER  (See INSTALLATION )
  61. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION  )
  62. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood with the 4 bolts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  63. CONNECT HOOD SUPPORT ASSEMBLY  (See INSTALLATION )
  64. ADJUST HOOD SUB-ASSEMBLY  (See ADJUSTMENT )
  65. INSPECT COOLANT LEVEL AT RESERVOIR  (See ON-VEHICLE INSPECTION )
  66. INSPECT FOR LEAKAGE OF REFRIGERANT  (See REPLACEMENT )
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