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Engine Assembly: Installation

  1. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT:

    Perform this procedure only when replacement of the engine mounting insulator is necessary.

    1. Temporarily install the engine mounting insulator with the 4 bolts.
    2. Tighten the 4 bolts in the sequence shown in the illustration.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

    3. Install the air cleaner bracket with the bolt.

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

      Fig 1: Locating Engine Mounting Insulator With Bolts
      G05997911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ENGINE MOUNTING SPACER 

    HINT:

    Perform this procedure only when replacement of the engine mounting spacer is necessary.

    1. Temporarily install the engine mounting spacer with the 2 bolts.
    2. Tighten the 2 bolts in the sequence shown in the illustration.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 2: Locating Engine Mounting Spacer With Bolts
      G05997912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT:

    Perform this procedure only when replacement of the engine mounting insulator is necessary.

    1. Temporarily install the engine mounting insulator with the 3 bolts.
    2. Tighten the 3 bolts in the sequence shown in the illustration.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

    3. Install the radiator reservoir bracket with the bolt.

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

      Fig 3: Locating Engine Mounting Insulator With Bolts
      G05997913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT:

    Perform this procedure only when replacement of the engine mounting insulator is necessary.

    1. Temporarily install the engine mounting insulator with the 2 bolts and 2 nuts.
    2. Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 4: Locating Engine Mounting Insulator With Bolts And Nuts
      G05997914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE ENGINE STAND 
    1. Install the No. 1 and No. 2 engine hangers with the 2 bolts as shown in the illustration.

      Engine Hanger 

      ENGINE HANGER REFERENCE CHART

      Item Part No.
      No. 1 engine hanger 12281-36020
      No. 2 engine hanger 12282-36020
      Bolt 91552-81040, 91552-81025

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT:

      Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

    2. Attach an engine sling device and hang the engine with a chain block.
    3. Lift the engine and remove it from the engine stand.
      Fig 5: Locating No. 1 And No. 2 Engine Hangers With Bolts
      G05997905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY  (See INSTALLATION  )
  7. INSTALL AUTOMATIC TRANSAXLE 
    1. for 2WD:

      Install the automatic transaxle (See INSTALLATION ).

    2. for 4WD:

      Install the automatic transaxle (See INSTALLATION ).

  8. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  9. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the suspension crossmember to the engine with the bolt.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      HINT:

      When installing the suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

      Fig 6: Locating Suspension Crossmember To Engine With Bolt
      G05997916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See POWER STEERING ECU )
  11. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine.
  12. INSTALL ENGINE AND TRANSAXLE 
    1. Place the engine on an engine lifter.

      HINT:

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. Remove the 2 bolts and No. 1 and No. 2 engine hangers.
    3. Operate the engine lifter and install the engine to the vehicle.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
      Fig 7: Locating No. 1 And No. 2 Engine Hangers Bolts
      G05997917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporarily install the front suspension crossmember with the 2 bolts.
    5. Temporarily install the member brace rear RH and LH with the 6 bolts.
      Fig 8: Locating Member Brace Rear RH And LH With Bolts
      G05997904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the engine mounting insulator LH with the bolt and nut.

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

      NOTE: While holding the bolt in place, tighten the nut.
      Fig 9: Locating Engine Mounting Insulator LH With Bolt And Nut
      G05997903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the engine mounting insulator RH with the bolt and 2 nuts.

      Torque: for bolt and nut A 

      95 N*m (969 kgf*cm, 70 ft.*lbf) 

      for nut B 

      52 N*m (530 kgf*cm, 38 ft.*lbf) 

      Fig 10: Locating Engine Mounting Insulator RH With Bolt And Nuts
      G05997920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Tighten the front suspension member bolts.

      Torque: for bolt A 

      145 N*m (1479 kgf*cm, 107 ft.*lbf) 

    9. Tighten the member brace rear bolts.

      Torque: for bolt B 

      145 N*m (1479 kgf*cm, 107 ft.*lbf) 

      for bolt C 

      93 N*m (948 kgf*cm, 69 ft.*lbf) 

      Fig 11: Locating Front Suspension Member Bolts
      G05997921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR 
    1. Temporarily install the engine mounting insulator with the bolt and nut.
      Fig 12: Locating Engine Mounting Insulator With Bolt And Nut
      G05997901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY 
    1. Install the crossmember with the 6 bolts.

      Torque: for bolt A 

      96 N*m (979 kgf*cm, 71 ft.*lbf) 

      for bolt B 

      95 N*m (969 kgf*cm, 70 ft.*lbf) 

    2. Tighten the bolt and nut holding the engine mounting insulator.

      Torque: 145 N*m (1479 kgf*cm, 107 ft.*lbf) 

      Fig 13: Identifying Crossmember With Bolts Tightening Sequence
      G05997923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH 
    1. Install the reinforcement with the 4 bolts.

      Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) 

      Fig 14: Locating Reinforcement LH With Bolts
      G05997899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH 
    1. Install the reinforcement with the 4 bolts.

      Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) 

  17. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See POWER STEERING ECU )
  18. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See POWER STEERING ECU )
  19. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See POWER STEERING ECU )
    Fig 15: Locating Reinforcement RH With Bolts
    G05997898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL TORQUE CONVERTER SETTING BOLT 
    1. Apply a few drops of adhesive to 2 or 3 threads at the tip of the 6 torque converter clutch mounting bolts.

      Adhesive: 

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

      Fig 16: Applying Drops Of Adhesive To Threads
      G04961658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 6 torque converter clutch setting bolts while holding the crankshaft pulley bolt with a wrench.

      Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) 

      HINT:

      First install the black colored bolt, and then the 5 remaining silver colored bolts.

    3. Install the flywheel housing under cover.
      Fig 17: Locating Crankshaft Pulley Bolt
      G05388182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) 
    1. Install the propeller shaft assembly (See INSTALLATION ).
  22. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See EXHAUST PIPE )
  23. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See FLOOR SHIFT ASSEMBLY )
  24. INSTALL DRIVE SHAFT 
    1. for 2WD:

      Install the front drive shafts (See INSTALLATION ).

    2. for 4WD:

      Install the front drive shafts (See INSTALLATION ).

  25. INSTALL FRONT AXLE SHAFT NUT  (See INSTALLATION )
  26. CONNECT WIRE HARNESS AND HOSE 
    1. Connect the heater hoses.
      Fig 18: Locating Heater Hoses
      G05997894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the vacuum hose.
      Fig 19: Locating Vacuum Hose
      G05997895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the ground wire with the bolt and clamp.

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

      Fig 20: Locating Ground Wire With Bolt And Clamp
      G05997930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the engine wire and install the nut.

      Torque: 13 N*m (130 kgf*cm, 9 in.*lbf) 

    5. Connect the 3 junction connectors.
      Fig 21: Locating Engine Wire Nut With Junction Connectors
      G05997893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the engine wire with the 3 clamps and install the bolt.

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

      Fig 22: Locating Engine Wire With Clamps And Bolt
      G05997932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the starter wire harness with the clamp, and then install the terminal nut and cover the nut with the cap.

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

      Fig 23: Identifying Terminal Nut And Cap
      G05997891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Push the tube connector onto the pipe until the tube connector makes a "click" sound.
      NOTE:
      • Before connecting the connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.
      • After connecting the fuel tube connector and pipe, check that they are securely connected by trying to pull them apart.
    2. Install the No. 1 fuel pipe clamp.
      Fig 24: Pushing Tube Connector Onto Pipe
      G05997934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See COMPRESSOR AND PULLEY (FOR 2GR-FE) )
  29. CONNECT SUCTION HOSE SUB-ASSEMBLY  (See COMPRESSOR AND PULLEY (FOR 2GR-FE) )
  30. CONNECT NO. 2 RADIATOR HOSE  (See INSTALLATION )
  31. CONNECT NO. 1 RADIATOR HOSE  (See INSTALLATION )
  32. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  33. INSTALL WIRE HARNESS CLAMP BRACKET  (See INSTALLATION )
  34. INSTALL FAN AND GENERATOR V BELT  (See INSTALLATION  )
  35. INSTALL RADIATOR RESERVOIR  (See THERMOSTAT )
  36. INSTALL ECM  (See INSTALLATION )
  37. INSTALL AIR CLEANER CASE  (See INSTALLATION )
  38. INSTALL AIR CLEANER ASSEMBLY  (See INSTALLATION )
  39. INSTALL BATTERY BRACKET REINFORCEMENT  (See INSTALLATION )
  40. INSTALL FRONT BATTERY BRACKET  (See INSTALLATION )
  41. INSTALL BATTERY TRAY 
  42. INSTALL BATTERY 
  43. INSTALL BATTERY INSULATOR 
  44. INSTALL BATTERY CLAMP SUB-ASSEMBLY  (See STARTER RELAY )
  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  46. CHARGE REFRIGERANT  (See REPLACEMENT )
  47. ADD TRANSFER OIL (for 4WD)  (See TRANSFER OIL )
  48. ADD AUTOMATIC TRANSAXLE FLUID 
    1. for 2WD:

      Add automatic transmission fluid (See TORQUE CONVERTER AND DRIVE PLATE ).

    2. for 4WD:

      Add automatic transmission fluid (See TORQUE CONVERTER AND DRIVE PLATE ).

  49. ADD ENGINE OIL  (See OIL PRESSURE SWITCH )
  50. ADD ENGINE COOLANT  (See COOLANT )
  51. INSPECT SHIFT LEVER POSITION  (See FLOOR SHIFT ASSEMBLY )
  52. INSPECT FOR FUEL LEAK  (See FUEL PRESSURE REGULATOR )
  53. INSPECT FOR OIL LEAK  (See OIL PRESSURE SWITCH )
  54. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  55. INSPECT FOR REFRIGERANT LEAK  (See REFRIGERANT LINE )
  56. INSPECT IGNITION TIMING  (See ON-VEHICLE INSPECTION  )
  57. INSPECT ENGINE IDLE SPEED  (See ON-VEHICLE INSPECTION  )
  58. INSPECT CO/HC  (See ON-VEHICLE INSPECTION  )
  59. INSTALL FRONT WHEEL 
  60. ADJUST WHEEL ALIGNMENT 
    1. Adjust the front wheel alignment (See FRONT WHEEL ALIGNMENT ).
  61. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the under cover with the 3 clips.
      Fig 25: Locating Under Cover With Clips
      G05997889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL REAR ENGINE UNDER COVER RH 
    1. Install the under cover with the 3 clips.
      Fig 26: Locating Under Cover With Clips
      G05997887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the under cover with the 2 clips.
      Fig 27: Locating Under Cover With Clips
      G05997888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the under cover with the 8 screws and 8 clips.
  65. INSTALL RADIATOR SUPPORT OPENING COVER  (See INSTALLATION  )
  66. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY  (See ECM )
  67. RESET MEMORY 
    1. When replacing the engine assembly, perform the Reset Memory procedure (A/T initialization) for U241E (2WD) (See INITIALIZATION ) or for U140F (4WD)(See INITIALIZATION ).
      Fig 28: Locating Under Cover With Screws And Clips
      G05997886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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