GSIC - Global Service Information Center

# ENGINE ASSEMBLY > INSTALLATION

## for Preparation Click here

1. INSTALL OIL DIPSTICK GUIDE

1. Remove the oil dipstick.

1. Remove the bolt and pull out the oil dipstick guide.

1. Remove the O-ring from the oil dipstick guide.

2. INSTALL SPARK PLUG

3. INSTALL IGNITION COIL

1. Install the ignition coil with the bolt.

   Torque:
     10 N*m{ 102 kgf*cm , 7 ft.*lbf }

4. INSTALL OIL FILLER CAP HOUSING

1. Install a new gasket and oil filler cap housing with the 2 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

5. INSTALL OIL FILLER CAP

6. INSTALL WATER BY-PASS JOINT REAR

1. Install a new O-ring to the water outlet pipe.

1. Install 2 new gaskets and water by-pass joint with the 2 bolts and 4 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Connect the heater hose.

1. Connect the engine coolant temperature sensor connector.

7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

1. Inset the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

8. INSTALL INTAKE MANIFOLD

1. Set a new gasket on each cylinder head.

   NOTICE:
   1. Align the port holes of the gasket and cylinder head.
   2. Be careful of the installation direction.

1. Set the intake manifold on the cylinder heads.

1. Install and uniformly tighten the 10 bolts in several passes.

   Torque:
     26 N*m{ 265 kgf*cm , 19 ft.*lbf }

1. Connect the 6 fuel injector connectors.

9. INSTALL OIL FILTER BRACKET

1. Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts.

10. INSTALL WATER INLET HOUSING

1. Install a new gasket to the water inlet housing with thermostat.

1. Install the water inlet housing with thermostat with the 3 nuts.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

11. INSTALL V-RIBBED BELT TENSIONER

1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

1. Install the V-ribbed belt tensioner by tightening bolt 1 and then bolt 2.

   Torque:
     36 N*m{ 367 kgf*cm , 27 ft.*lbf }

1. Tighten the other bolts.

   Torque:
     36 N*m{ 367 kgf*cm , 27 ft.*lbf }

   HINT:
     Each bolt length is as follows:
     A = 70 mm (2.76 in.)
     B = 33 mm (1.30 in.)

12. INSTALL IDLER PULLEY

1. Install the idler pulley with the 3 bolts.

   Torque:
     25 N*m{ 255 kgf*cm , 18 ft.*lbf }

13. INSTALL NO. 1 IDLER PULLEY

1. Install the idler pulley with the bolt.

   Torque:
     54 N*m{ 551 kgf*cm , 40 ft.*lbf }

   HINT:
     "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No.2 idler pulley.

14. INSTALL NO. 2 IDLER PULLEY

1. Install the 2 idler pulleys with the 2 bolts.

   Torque:
     39 N*m{ 398 kgf*cm , 29 ft.*lbf }

15. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH

1. Install the engine mounting bracket with engine mounting insulator with the 3 bolts.

   Torque:
     43 N*m{ 438 kgf*cm , 32 ft.*lbf }

16. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH

1. Install the engine mounting bracket with engine mounting insulator with the 4 bolts.

   Torque:
     43 N*m{ 438 kgf*cm , 32 ft.*lbf }

17. INSTALL NO. 2 VENTILATION HOSE

18. INSTALL VENTILATION HOSE

19. INSTALL HEATER WATER HOSE TO ENGINE ASSEMBLY

20. INSTALL NO. 2 RADIATOR HOSE

21. INSTALL NO. 1 RADIATOR HOSE

22. INSTALL ENGINE WIRE TO ENGINE ASSEMBLY

23. INSTALL ENGINE ASSEMBLY

1. Attach the engine sling device and chain block to the engine hangars.

1. Slowly lower the engine assembly into the engine compartment.

1. Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts.

   Torque:
     38 N*m{ 387 kgf*cm , 28 ft.*lbf }

1. Remove the 4 bolts and 2 engine hangers.

24. INSTALL FLYWHEEL (for Manual Transmission)

1. Using SST, hold the crankshaft.

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

1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent

1. Install the flywheel.

1. Install and tighten the 8 mounting bolts uniformly in several steps.

   Torque:
     83 N*m{ 846 kgf*cm , 61 ft.*lbf }

25. INSTALL CLUTCH DISC (for Manual Transmission)

1. Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.

   SST
     09301-00110

   NOTICE:
     Take care not to insert the clutch disc facing the wrong direction.

26. INSTALL CLUTCH COVER (for Manual Transmission)

1. Align the matchmarks on the clutch cover and flywheel.

1. Tighten the 6 bolts as described below.

   1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.

   2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.

      Torque:
        19 N*m{ 195 kgf*cm , 14 in.*lbf }

1. Lightly move SST up and down, and right and left.

   SST
     09301-00110

1. Check that the disc is in the center, and then tighten the bolts.

27. INSTALL DRIVE PLATE AND RING GEAR ASSEMBLY (for Automatic Transmission)

1. Using SST, hold the crankshaft.

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

1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive:
     Part No. 08833-00070, THREE BOND 1324 or equivalent

1. Install the front spacer, drive plate and rear spacer on the crankshaft.

1. Install and uniformly tighten the 8 mounting bolts in several passes in the sequence as shown in the illustration.

   Torque:
     83 N*m{ 846 kgf*cm , 61 ft.*lbf }

28. INSTALL MANUAL TRANSMISSION

1. 2WD:
   Install the manual transmission to the vehicle (Click here).

1. 4WD:
   Install the manual transmission to the vehicle (Click here).

29. INSTALL AUTOMATIC TRANSMISSION

1. 2WD:
   Install the automatic transmission to the vehicle (Click here).

1. 4WD:
   Install the automatic transmission to the vehicle (Click here).

30. INSTALL STARTER

1. Install the starter with the 2 bolts.

   Torque:
     37 N*m{ 377 kgf*cm , 27 ft.*lbf }

1. Install the starter wire to terminal 30 with the nut.

   Torque:
     9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

1. Connect the starter connector.

31. INSTALL EXHAUST MANIFOLD LH

1. Set a new gasket to the LH cylinder head with the oval shape facing backward.

   NOTICE:
     Be careful of the installation direction.

   Torque:
     30 N*m{ 306 kgf*cm , 22 ft.*lbf }

1. Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

1. Connect the A/F sensor connector.

32. INSTALL EXHAUST MANIFOLD RH

1. Set a new gasket to the RH cylinder head with the oval shape facing forward.

   NOTICE:
     Be careful of the installation direction.

1. Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

1. Connect the A/F sensor connector.

33. INSTALL FRONT FENDER APRON SEAL UPPER

1. Install the RH and LH fender seals with the 10 clips.

34. INSTALL FRONT FENDER SEAL

1. Install the RH and LH fender seals with the 10 clips.

1. Install the front tires.

35. INSTALL FRONT EXHAUST PIPE

1. Install the front pipe to the pipe support.

1. Install a new gasket and the front pipe to the exhaust manifold.

1. Install the front pipe with the 2 nuts.

   Torque:
     62 N*m{ 632 kgf*cm , 46 ft.*lbf }

36. INSTALL NO. 2 ENGINE WIRE

1. Install the ground cable to the cylinder block.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

37. INSTALL ENGINE WIRE

1. Connect the 2 engine room junction block connectors and connect the wire clamp.

1. Connect the cable to the engine room junction block with the nut.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

1. Install the engine room relay block cover (side).

1. Install the engine room relay block cover (upper).

1. Connect the ground wire with the bolt and clamp.

   Torque:
     31 N*m{ 316 kgf*cm , 23 ft.*lbf }

1. Connect the ground wire to the frame with the bolt so that it is within the range shown in the illustration.

   Torque:
     13 N*m{ 133 kgf*cm , 18 ft.*lbf }

1. Push the engine wire through the dash panel into the cabin. The wire should be within the range shown in the illustration.

1. Connect the 2 A/F sensor connectors.

   Torque:
     13 N*m{ 133 kgf*cm , 10 ft.*lbf }

1. Connect the A.D.D. connector.

1. Connect the ECM connectors.

   1. Install the glove compartment door.

   2. Connect the 4 ECM connectors.

   3. Connect the 4WD control ECU connector.

1. Connect the wire clamp to the engine mounting bracket front LH with the bolt.

38. INSTALL INTAKE AIR SURGE TANK

1. Install a new gasket to the intake air surge tank.

1. Using an 8 mm socket hexagon wrench, install the intake air surge tank with the 4 bolts and 2 nuts.

   Torque:
     28 N*m{ 286 kgf*cm , 21 ft.*lbf }

1. Install the 2 surge tank stays with the 4 bolts.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

1. Install the oil baffle plate with the bolt.

   Torque:
     9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

1. Install the throttle body bracket with the 2 bolts.

   Torque:
     21 N*m{ 214 kgf*cm , 15 ft.*lbf }

1. Install the 3 wire harness clamps and hose clamp.

1. Connect the throttle body with motor connector.

1. Connect the 2 VSV connectors.

1. Connect the ventilation hose.

1. Connect the fuel vapor feed hose.

1. Connect the 2 water by-pass hoses.

39. INSTALL HEATER HOSE

1. Connect the hater water inlet hose.

1. Connect the heater water outlet hose.

40. INSTALL NO. 2 FUEL PIPE

1. Connect the fuel pipe.

   1. Check that there is no damage or contamination in the connected part of the 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 little amount of fresh engine oil on the tip of the pipe.

   3. After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.

1. Install the fuel pipe clamp.

41. INSTALL NO. 1 FUEL PIPE

1. Connect the fuel pipe.

   1. Check that there is no damage or contamination in the connected part of the 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 little amount of fresh engine oil on the tip of the pipe.

   3. After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.

1. Install the fuel pipe clamp.

42. INSTALL COOLER COMPRESSOR

43. INSTALL GENERATOR

1. Install the generator and adjusting bar with the 2 bolts.

   Torque:
     43 N*m{ 438 kgf*cm , 32 ft.*lbf }

1. Install the generator wire with the nut.

   Torque:
     9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

1. Connect the generator connector.

44. INSTALL VANE PUMP

1. Install the vane pump with the 2 bolts.

   Torque:
     43 N*m{ 438 kgf*cm , 32 ft.*lbf }

   NOTICE:
     Do not hit other parts with the pulley when installing the vane pump.

1. Connect the oil pressure switch connector.

45. INSTALL FAN PULLEY

46. INSTALL FAN WITH FLUID COUPLING

1. Temporarily install the fan with fluid coupling with the 4 nuts.

47. INSTALL DRIVE BELT

1. While turning the belt tensioner counterclockwise, align its holes, and then insert a bar of 6 mm (0.24 in.) into the holes to fix the belt tensioner.

1. Install the V-ribbed belt.

1. While turning the belt tensioner counterclockwise, remove the bar.

1. If it is hard to install the V-ribbed belt, perform the following procedure.

   1. Put the V-ribbed belt on everything except the P/S pump as shown in the illustration.

   2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the P/S pump.

48. TIGHTEN FAN WITH FLUID COUPLING

49. INSTALL FAN SHROUD

1. Set the fan shroud into the engine compartment.

1. Connect the 2 oil cooler hoses with the hose clamp.

50. INSTALL RADIATOR

1. Install the radiator with the 4 bolts.

   Torque:
     12 N*m{ 122 kgf*cm , 9 ft.*lbf }

1. Attach the 4 clamps of the 2 front airbag sensors from harnesses to the radiator.

1. Connect the 2 front airbag sensor front connectors.

51. INSTALL RADIATOR SIDE DEFLECTOR RH

1. Install the deflector with the 2 clips and attach the claw.

52. INSTALL RADIATOR SIDE DEFLECTOR LH

1. Install the deflector with the 2 clips and attach the claw.

53. INSTALL AIR CLEANER

Torque:
  8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

54. INSTALL RADIATOR GRILLE

1. Push the radiator grille in the direction indicated by the arrow in the illustration. Attach the 5 claws to install the radiator grille.

1. Install the 2 screws and 2 clips.

55. CONNECT NO. 2 VENTILATION HOSE

56. INSTALL HOOD

1. Install the hood with the 4 bolts and adjust the hood to the correct position.

   Torque:
     11.5 N*m{ 117 kgf*cm , 8.5 ft.*lbf }

1. Connect the windshield washer hose.

57. INSTALL BATTERY

58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

59. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

60. ADD ENGINE OIL

1. Clean and install the oil drain plug with a new gasket.

   Torque:
     40 N*m{ 408 kgf*cm , 30 ft.*lbf }

1. Add fresh engine oil.

   Standard capacity:

     Item | Capacity
     Drain and refill with oil filter change | 5.5 liters (5.8 US qts, 4.8 Imp. qts)
     Drain and refill without oil filter change | 5.2 liters (5.5 US qts, 4.6 Imp. qts)
     Dry fill | 6.6 liters (7.0 US qts, 5.8 Imp. qts)

1. Install the oil filler cap.

61. ADD ENGINE COOLANT

1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

   Torque:
     24.5 N*m{ 250 kgf*cm , 18 ft.*lbf } for cylinder block drain cock plug

   Standard capacity:

     Item | Specified Condition
     A/T | 9.8 liters (10.4 US qts, 8.6 lmp. qts)
     M/T | 8.5 liters (9.0 US qts, 7.5 lmp. qts)

   HINT:
   1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic and technology consists of a combination of low phosphates and organic acids).
   2. Please contact your TOYOTA dealer for further details.

   NOTICE:
     Never use water as a substitute for engine coolant.

1. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

1. Install the radiator cap.

1. Bleed air from the cooling system.

   1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

   2. Maintain the engine speed at 2,000 to 2,500 rpm.

   3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

      CAUTION:
      When pressing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

1. Stop the engine and wait until the coolant cools down to ambient temperature.

   CAUTION:
     Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. Check the coolant level in the radiator reservoir.
   If the coolant level is low, add SLLC to the reservoir F line.

62. CHECK FOR ENGINE COOLANT LEAKS

CAUTION:

  Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. Fill the radiator with coolant and attach a radiator cap tester.

1. Warm up the engine.

1. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.
   If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the cylinder block and head.

63. CHECK FOR FUEL LEAKS

1. Connect the intelligent tester to the DLC3.

   1. Turn the ignition switch ON.

      NOTICE:
        Do not start the engine.

   2. Push the intelligent tester main switch ON.

   3. Select Active Test and enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

1. Check for fuel leaks.

   1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.

64. CHECK FOR ENGINE OIL LEAKS

1. Start the engine, and check that there are no oil leaks after performing maintenance.

65. INSTALL V-BANK COVER

1. Install the V-bank cover with the 2 nuts.

   Torque:
     7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

66. INSPECT IGNITION TIMING

1. When using intelligent tester:
   Check the ignition timing.

   1. Connect the intelligent tester to the DLC3.

      HINT:
        Please refer to the intelligent tester operator's manual for further details.

      Ignition timing:
        7 to 24°BTDC @ idle
        (Transmission in neutral position)

   2. Disconnect the intelligent tester from the DLC3.

1. When not using intelligent tester.
   Check the ignition timing.

   1. Remove the air cleaner cap.

   2. Connect the tester probe of a timing light to the green-red read wire of the ignition coil connector for the No.1 cylinder.

   3. Using SST, connect terminals TC and CG of the DLC3.

      SST
        09843-18040

   4. Using the timing light, check the ignition timing.

      Ignition timing:
        10 +- 2° BTDC @ idle
        (Transmission in neutral position)

   5. Remove the SST from the DLC3.

   6. Check the ignition timing.

      Ignition timing:
        7 to 24° BTDC @ idle
        (Transmission in neutral position)

   7. Disconnect the timing light from the engine.

   8. Install the air cleaner cap.

67. INSPECT ENGINE IDLE SPEED

1. When using intelligent tester:
   Check the idle speed.

   1. Connect the intelligent tester to the DLC3.

      HINT:
        Please refer to the intelligent tester operator's manual for further details.

   2. Switch the air conditioning OFF.

   3. Race the engine at 2,500 rpm for approximately 90 seconds.

   4. Check the idle speed.

      Idle speed:
        700 +- 50 rpm
        (Transmission in neutral position)
      If the idle speed is not as specified, check the air intake system

   5. Disconnect the intelligent tester from the DLC3.

1. When not using intelligent tester:
   Check the idle speed.

   1. Using SST, connect tachometer probe to terminal TAC of the DLC3.

      SST
        09843-18030

   2. Switch the air conditioning OFF.

   3. Race the engine speed at 2,500 rpm for approximately 90 seconds.

   4. Check the idle speed.

      Idle speed:
        700 +- 50 rpm
        (Transmission in neutral position)
      If the idle speed is not as specified, check the air intake system.

   5. Disconnect the tachometer from the DLC3.

68. INSPECT CO/HC

HINT:

  This check is for determining whether or not the idle CO/HC complies with regulations.

1. Start the engine.

1. Keep the engine speed at 2,500 rpm for approximately 180 seconds.

1. Insert CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idling.

1. Immediately check CO/HC concentration at idle and/or 2,500 rpm.

   HINT:
     When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
     If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

   1. Check the A/F sensor operation and heated oxygen sensor operation.

   2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.

      CO | HC | Symptom | Causes

      Normal

      High

      Rough idle

      1. Faulty ignitions:
      1. Incorrect timing
      2. Fouled, shorted or improperly gapped plugs
      2. Incorrect valve clearance
      3. Leaky intake and exhaust valves
      4. Leaky cylinder

      Low

      High

      Rough idle
      (Fluctuating HC reading)

      1. Vacuum leaks:
      1. PCV hose
      2. Intake manifold
      3. Throttle body
      2. Lean mixture causing misfire.

      High

      High

      Rough idle
      (Black smoke from exhaust)

      1. Restricted air filter
      2. Faulty SFI system:
      1. Faulty pressure regulator
      2. Defective ECT sensor
      3. Faulty ECM
      4. Faulty injector
      5. Faulty throttle position sensor
      6. Faulty MAF sensor

69. PERFORM INITIALIZATION

1. Perform initialization (Click here).

   NOTICE:
     Certain systems need to be initialized after disconnecting the cable from negative (-) battery terminal.