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Engine Unit: Installation

WARNING: This page is about a different car, the 2003 Lexus RX 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. 2WD: ASSEMBLE ENGINE AND TRANSAXLE (See  OVERHAUL - U140E & U140F  ) 
  2. 4WD: ASSEMBLE ENGINE AND TRANSAXLE (See  OVERHAUL - U140E & U140F  ) 
  3. INSTALL REAR ENGINE MOUNTING BRACKET 

    Install the mounting bracket with the 4 bolts.

    • Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 
    Fig 1: Installing Mounting Bracket With Bolts (4WD)
    G01331860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Installing Mounting Bracket With Bolts (2WD)
    G01331861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    Install the mounting insulator with the 4 bolts.

    • Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 
    Fig 3: Installing Mounting Insulator With Bolts
    G01331862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL FRONT FRAME ASSEMBLY 
    1. Connect the rear engine mounting bracket with the nut.
      • Torque: 87 N.m (890 kgf.cm, 64 ft.lbf) 
      Fig 4: Connecting Rear Engine Mounting Bracket With Nut (2WD)
      G01331863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 5: Connecting Rear Engine Mounting Bracket With Nut (4WD)
      G01331864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the LH engine mounting insulator with the 4 bolts.
      • Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 
      Fig 6: Connecting LH Engine Mounting Insulator With Bolts
      G01331865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting absorber with the 4 bolts.
      • Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) 
      Fig 7: Installing Engine Mounting Absorber With Bolts
      G01331866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the front engine mounting insulator with the 3 bolts.
      • Torque: 80 N.m (820 kgf.cm, 59 ft.lbf) 
      Fig 8: Connecting Front Engine Mounting Insulator With Bolts
      G01331867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. 4WD: INSTALL PS GEAR ASSEMBLY 
    1. Install the PS gear assembly with the 2 bolts and nut.
      • Torque: 181 N.m (1,850 kgf.cm, 134ft.lbf) 
    2. Connect the PS hose to the pipe.
      Fig 9: Connecting PS Hose To Pipe
      G01331868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. 4WD: INSTALL FRONT STABILIZER 

    Install the stabilizer with the 4 bolts.

    • Torque: 19 N.m (195 kgf.cm, 14 ft.lbf) 
    Fig 10: Installing Stabilizer With Bolts
    G01331869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL PS VANE PUMP 
    1. Install the PS vane pump with the 2 bolts.
      • Torque: 43 N.m (440 kgf.cm, 31 ft.lbf) 
    2. Install the drive belt.
    3. Connect the PS pressure tube with the 3 bolts.
    4. Connect the PS oil pressure switch connector.
      Fig 11: Installing Drive Belt
      G01331870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE TRANSAXLE AND FRONT FRAME ASSEMBLY IN VEHICLE 
    1. Attach the engine sling device to the engine hangers.
    2. Lift the engine into the engine compartment.
      Fig 12: Attaching Engine Sling Device To Engine Hangers
      G01331871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL LOWER BRACES 

    Install the 4 lower braces with the 8 bolts.

    • Torque: 
    • Bolt A: 181 N.m (1,850 kgf.cm, 134 ft.lbf) 
    • Bolt B: 32 N.m (330 kgf.cm, 24 ft.lbf) 
    Fig 13: Installing Lower Braces
    G01331872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL No. 2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD 
    1. Temporarily install the No. 2 RH engine mounting bracket and engine moving control rod with the 3 bolts.
      Fig 14: Installing RH Engine Mounting Bracket And Engine Moving Control Rod
      G01331873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install and tighten the bolt (A).
      • Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 
    3. Tighten the other 3 bolts (B, C, D).
      • Torque: 
      • Bolts B and C: 64 N.m (650 kgf.cm, 47 ft.lbf) 
      • Bolt D: 32 N.m (320 kgf.cm, 23 ft.lbf) 
  12. REMOVE ENGINE SLING DEVICE 
  13. CONNECT FENDER APRON SEALS 
    Fig 15: Removing Engine Sling Device
    G01331874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT A/T OIL COOLER PIPE 

    Install A/T oil cooler pipe to front frame assembly with the bolt.

    Fig 16: Installing A/T Oil Cooler Pipe To Front Frame Assembly
    G01331875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. CONNECT PS HOSE TO PS RESERVOIR PIPE 
    Fig 17: Connecting PS Hose To PS Reservoir Pipe
    G01331876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. CONNECT PS HOSE TO PS OIL RESERVOIR 
  17. CONNECT VSV FOR ACM 
    1. Install the VSV with the screw.
    2. Connect the vacuum hoses to the front frame assembly.
    3. Connect the VSV connector and clamp.
  18. CONNECT INTERMEDIATE SHAFT ASSEMBLY (See  TILT STEERING COLUMN  ) 
  19. 2WD: INSTALL DRIVE SHAFTS (See  FRONT AXLE SHAFTS (FWD)  ) 
    Fig 18: Installing Drive Shafts
    G01331877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 4WD: INSTALL DRIVE SHAFTS (See  FRONT AXLE SHAFTS (AWD)  ) 
  21. CONNECT STABILIZER BAR LINKS (See  STABILIZER BAR  ) 
  22. 4WD: INSTALL PROPELLER SHAFT (See  PROPELLER SHAFT  ) 
  23. INSTALL RH FENDER APRON SEAL 
  24. INSTALL FRONT EXHAUST PIPE 
    1. Temporarily install 2 new gaskets and the front exhaust pipe with the 2 bolts, 2 springs and 2 nuts.
    2. Tighten the 2 nuts holding the RH exhaust manifold to the front exhaust pipe.
      • Torque: 62 N.m (630 kgf.cm, 46 ft.lbf) 
    3. Tighten the 2 bolts holding the front exhaust pipe to the center exhaust pipe.
      • Torque: 62 N.m (630 kgf.cm, 46 ft.lbf) 
      Fig 19: Tightening Bolts Holding Front Exhaust Pipe To Center Exhaust Pipe
      G01331878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL No. 2 FRONT EXHAUST PIPE 
    1. Temporarily install 2 new gaskets and the No. 2 front exhaust pipe with the 4 bolts.
    2. Tighten the 2 bolts holding the WU-TWC to the No. 2 front exhaust pipe.
      • Torque: 56 N.m (560 kgf.cm, 41 ft.lbf) 
    3. Tighten the 2 bolts holding the No. 2 front exhaust pipe to the front exhaust pipe.
      • Torque: 56 N.m (560 kgf.cm, 41 ft.lbf) 
      Fig 20: Tightening Bolts Holding Front Exhaust Pipe To Front Exhaust Pipe
      G01331879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. CONNECT A/T SHIFT CONTROL CABLE TO TRANSAXLE 
  27. INSTALL A/C COMPRESSOR (See  COMPRESSOR AND MAGNETIC CLUTCH  ) 
  28. INSTALL GENERATOR (See  CHARGING SYSTEM  ) 
  29. CONNECT ENGINE WIRE TO CABIN 
    1. Push in the engine wire through the cowl panel.
    2. Install the 2 nuts holding the engine wire retainer to the cowl panel.
    3. Install the ECM. (See FUEL SYSTEM )
  30. CONNECT ACCELERATOR CABLE TO THROTTLE BODY 
  31. CONNECT HOSES 
    • Brake booster vacuum hose to air intake chamber
    • Heater hose to intake manifold
    • Heater hose to water inlet housing
    • Fuel inlet hose to fuel pipe
      CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions (See FUEL SYSTEM ).
    • Purge hose to pipe on emission control valve set
    • 2 vacuum hoses to vacuum tank for ACIS
    • Upper radiator hose to water outlet
    • Lower radiator hose to water inlet pipe
    • 2 A/T cooler hoses to 2 pipes on transaxle
  32. CONNECT CONNECTORS AND CLAMP 
    • Generator wire, connector and clamp
    • 2 ground strap connectors to RH fender apron
    • Ground strap to LH fender apron
    • Noise filter connector on LH fender apron
    • Battery negative (-) cable
  33. INSTALL FRONT UPPER SUSPENSION BRACE 
    1. Install the front upper suspension brace with the 4 nuts.
      • Torque: 80 N.m (810 kgf.cm, 59 ft.lbf) 
    2. Connect the 2 heater hoses.
    3. Connect the engine wire clamp.
    4. Install the brake master cylinder reservoir with the bolt.
  34. INSTALL CRUISE CONTROL ACTUATOR 
  35. INSTALL AIR CLEANER CAP AND AIR CLEANER CASE 
    Fig 21: Installing Air Cleaner Caps And Air Cleaner Case
    G01331880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL V-BANK COVER 
  37. INSTALL BATTERY TRAY AND BATTERY 
  38. INSTALL OUTER COWL TOP PANEL ASSEMBLY 
    1. Install the outer cowl top panel with the 9 bolts.
    2. Install the wiper motor with the wiper link with the 5 bolts.
    3. Connect the wiper motor wire and connector.
    4. Install the cowl top ventilator louver with the clip. Install the RH and LH ventilator louvers.
    5. Install the head to cowl top seal.
    6. Install the wiper arm and blade assemblies with the 3 nuts.
      • Torque: 24 N.m (245 kgf.cm, 18 ft.lbf) 
  39. INSTALL HOOD 
  40. INSTALL ENGINE UNDER COVER 
  41. FILL ENGINE WITH OIL 
  42. FILL WITH ENGINE COOLANT 
  43. START ENGINE AND CHECK FOR LEAKS 
  44. BLEED POWER STEERING SYSTEM (See  DRIVE BELT  ) 
  45. PERFORM ROAD TEST 

    Check for abnormal noise, shock, slippage, correct shift points and smooth operation.

  46. RECHECK ENGINE COOLANT AND OIL LEVELS 
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