Installation
ENGINE ASSEMBLYCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9) (w/ Active Stabilizer System):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
COMPONENTS (Part 12):
COMPONENTS (Part 13):
COMPONENTS (Part 14):
COMPONENTS (Part 15):
COMPONENTS (Part 16):
INSTALLATION
1. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a) Install the mounting bracket with the 4 bolts.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
HINT: The LH mounting bracket is marked with an "L".
2. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH
(a) Install the mounting bracket with the 4 bolts.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
HINT: The RH mounting bracket is marked with an "L".
3. INSTALL ENGINE OIL LEVEL SENSOR
4. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
(a) Install a new gasket to the bracket.
(b) Install the oil filter bracket with the stud bolt and 2 nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
5. INSTALL OIL PRESSURE SWITCH
(a) Install the oil pressure switch.
(1) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the oil pressure switch connector.
6. INSTALL IGNITION COIL
7. INSTALL KNOCK SENSOR
8. INSTALL CRANKSHAFT POSITION SENSOR
9. INSTALL VVT SENSOR
(a) Install the 2 sensors with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(b) Connect the 2 sensor connectors.
10. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(b) Connect the 2 sensor connectors.
11. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Install a new O-ring to the oil control valve.
(b) Install the oil control valve with the bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
12. INSTALL OIL FILLER CAP HOUSING
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
13. INSTALL STARTER ASSEMBLY
14. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install a new O-ring to the water by-pass pipe.
(b) Apply soapy water to the O-ring.
(c) Push in the water by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the bolt.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(e) Install the wire clamp to the bracket of the water bypass pipe.
COMPONENTS (Part 13):
15. INSTALL REAR WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
16. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(b) Connect the ECT sensor connector.
17. INSTALL WATER INLET HOUSING
(a) Install a new O-ring to the inlet housing.
(b) Apply soapy water on the O-ring.
(c) Apply seal packing to the sealing groove of inlet housing as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
Seal width: 2 to 3 mm (0.08 to 0.12 in.)
NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.
(d) Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
18. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY RH
(a) Install the gasket to the cover.
(b) Install the cover with the cap nut and 3 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
19. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH
(a) Install the gasket to the cover.
(b) Pass the camshaft position sensor wire through the cover hole.
(c) Install the cover with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(d) Install the wire grommet to the cover.
(e) Install the sensor connector to the sensor holder.
(f) Connect the sensor connector.
(g) Install the sensor wire to the wire clamp on the cover.
(h) Install the engine wire to the 2 wire clamps on the cover.
(i) Connect the 2 water by-pass hoses as shown in the illustration.
(j) Install the No. 3 water by-pass pipe to the cover with the cap nut.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
RH Bank:
20. INSTALL NO. 2 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
LH Bank:
21. INSTALL NO. 1 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
22. INSTALL GENERATOR ASSEMBLY
23. INSTALL NO. 1 IDLER PULLEY BRACKET SUBASSEMBLY
24. INSTALL INTAKE MANIFOLD ASSEMBLY
(a) Install the manifold.
25. REMOVE ENGINE STAND
26. INSTALL NO. 2 WIRING HARNESS HEAT INSULATOR
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
27. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts.
Uniformly tighten the nuts in several passes.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
28. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
29. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts.
Uniformly tighten the nuts in several passes.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
30. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
31. INSTALL ENGINE MOUNTING INSULATOR FRONT
(a) Install the front suspension crossmember subassembly with the 2 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
32. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install a new O-ring to the guide.
(b) Install the guide with the bolt.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
33. INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY
HINT: If any one of the mounting bolts is broken or deformed, replace it.
(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the front spacer, drive plate and rear spacer on the crankshaft.
(c) Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown in the illustration.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.
(d) Mark the mounting bolt with paint.
(e) Retighten the mounting bolt by 90° in the numerical order shown.
(f) Check that the painted mark is now at a 90° angle.
34. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) Install the automatic transmission to the engine with the 9 bolts.
Torque:
37 N*m (377 kgf*cm, 27 ft.*lbf) for 14 mm head bolt A
71 N*m (724 kgf*cm, 52 ft.*lbf) for 17 mm head bolt B
HINT: Bolt (B) is tightened to the wire harness clamp.
(b) Install the 6 torque converter clutch mounting bolts.
Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)
HINT: First install the black colored bolt and then the remaining 5 bolts.
35. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the under cover with the 2 bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
36. INSTALL WIRE HARNESS AND CONNECTORS
(a) Connect the 2 speed sensor connectors.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch connector.
(d) Install the wire harness clamps with the 5 bolts.
Torque:
71 N*m (724 kgf*cm, 52 ft.*lbf) Bolt (A)
10 N*m (102 kgf*cm, 7 ft.*lbf) Bolt (B)
HINT: Bolt (A) is tightened to the transmission housing.
37. INSTALL NO. 1 OIL COOLER OUTLET TUBE
(a) Temporarily install the oil cooler outlet tube.
(b) Temporarily install the oil cooler inlet tube.
(c) Install the 2 clamps with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(d) Tighten the oil cooler outlet tube No.1.
Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf)
NOTICE: Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
38. INSTALL NO. 1 OIL COOLER INLET TUBE
(a) Tighten the oil cooler inlet tube.
Torque: 42 N*m (428 kgf*cm, 31 ft.*lbf)
NOTICE: Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
39. INSTALL ENGINE WIRE
40. INSTALL ENGINE WITH TRANSMISSION ASSEMBLY
(a) Set the engine lifter.
(b) Operate the engine lifter, then install the engine to the vehicle.
(c) Install the 12 bolts.
Torque:
204 N*m (2,080 kgf*cm, 150 ft.*lbf) for bolt A
167 N*m (1,700 kgf*cm, 123 ft.*lbf) for bolt B
50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt C
49 N*m (500 kgf*cm, 36 ft.*lbf) for bolt D
(d) Install the engine rear mounting member with the 4 bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
(e) Install the earth bolt with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
41. INSTALL FRONT ACTIVE STABILIZER CONTROL ACTUATOR ASSEMBLY (w/Active Stabilizer System)
(a) Install the front active stabilizer control actuator assembly.
42. INSTALL POWER STEERING LINK WIRE HARNESS
(a) Install the power steering ground wire to the power steering link with bolt (B).
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect wire harness connector (E) to the power steering link and securely lock the connector.
(c) Connect 2 wire harness connectors (C) and (D) to the power steering.
(d) Install the 2 wire harness clamps to the power steering link.
(e) Connect the ground wire to the bracket with bolt (A).
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
43. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) Align the matchmarks on the intermediate shaft assembly No. 2 and the power steering link.
(b) Install bolt (A) and tighten the 2 bolts.
Torque: 35 N*m (360 kgf*cm, 26 ft.*lbf)
44. INSTALL LOWER BALL JOINT ASSEMBLY FRONT LH
(a) Install the steering knuckle to the lower ball joint with the 2 bolts.
Torque: 120 N*m (1220 kgf*cm, 89 ft.*lbf)
45. INSTALL LOWER BALL JOINT ASSEMBLY FRONT RH
(a) Install the steering knuckle to the lower ball joint with the 2 bolts.
Torque: 120 N*m (1220 kgf*cm, 89 ft.*lbf)
46. INSTALL SHOCK ABSORBER ASSEMBLY FRONT LH
(a) Fully tighten the bolt on the lower side of the front shock absorber while holding the nut.
Torque: 157 N*m (1,600 kgf*cm, 116 ft.*lbf)
47. INSTALL HEIGHT CONTROL SENSOR LINK
(a) Connect the height control sensor link with the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
48. INSTALL SHOCK ABSORBER ASSEMBLY FRONT RH
(a) Fully tighten the bolt on the lower side of the front shock absorber while holding the nut.
Torque: 157 N*m (1,600 kgf*cm, 116 ft.*lbf)
49. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUBASSEMBLY
50. ADJUST SHIFT LEVER POSITION
51. INSPECT SHIFT LEVER POSITION
52. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET
53. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
(a) Install the support bracket with the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
54. INSTALL FRONT TWC
(a) Install 2 new gaskets to the 2 TWCs.
NOTICE: Do not reuse gasket.
(b) Install the 2 TWCs to the exhaust manifold with the 6 nuts.
Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)
55. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
56. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
57. INSTALL FRONT NO. 6 FLOOR HEAT INSULATOR
58. INSTALL FRONT NO. 5 FLOOR HEAT INSULATOR
59. INSTALL FRONT EXHAUST PIPE ASSEMBLY
60. INSTALL REAR NO. 1 FLOOR PANEL BRACE
61. INSTALL FRONT FLOOR BRACE CENTER
62. CONNECT HEATED OXYGEN SENSOR CONNECTOR
(a) Pass the sensor (bank 1 sensor 2) connector through the cabin and install the grommet.
(b) Connect the sensor connector.
(c) Pass the sensor connector through the cabin and install the grommet.
(d) Connect the sensor (bank 2 sensor 2) connector.
63. INSTALL INSTRUMENT PANEL FINISH PANEL END LH
64. INSTALL INSTRUMENT PANEL FINISH PANEL END RH
65. INSTALL CONSOLE UPPER PANEL ASSEMBLY
66. INSTALL FRONT CONSOLE UPPER PANEL GARNISH
67. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY
(a) Install the compressor with the 3 bolts, nut and bracket.
Torque:
49 N*m (500 kgf*cm, 36 ft.*lbf) for bolt
30 N*m (306 kgf*cm, 22 ft.*lbf) for nut
68. INSTALL UNION TO CHECK VALVE HOSE
(a) Connect the union to check valve hose with the clamp.
69. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
(a) Connect the heater water outlet hose A with the clamp.
70. INSTALL HEATER WATER INLET HOSE A
(a) Connect the heater water inlet hose A with the clamp.
71. CONNECT ENGINE WIRE
(a) Connect the ground wire and install it with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(c) Install the engine room No. 1 relay block cover.
(d) Connect the positive (+) battery cable and install it with the nut.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(e) Connect the ECM connectors.
(f) Connect the engine wire to the connector holder.
72. INSTALL FAN AND GENERATOR V-BELT
73. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY
(a) Connect the connector of the fuel tube connected to the fuel main tube, then pinch the connector.
74. INSTALL RADIATOR ASSEMBLY
(a) Installation procedure.
75. INSTALL NO. 1 OIL COOLER OUTLET TUBE
76. INSTALL NO. 1 OIL COOLER INLET TUBE
77. INSTALL RADIATOR HOSE OUTLET
78. INSTALL RADIATOR HOSE INLET
79. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the MAF meter connector and clamp to the air cleaner.
80. INSTALL INTAKE AIR CONNECTOR PIPE
81. ADD AUTOMATIC TRANSMISSION FLUID
82. ADD ENGINE COOLANT
83. ADD ENGINE OIL
84. INSTALL ENGINE UNDER COVER REAR LH
85. INSTALL ENGINE UNDER COVER REAR RH
86. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the clips.
87. INSTALL ENGINE UNDER COVER
(a) Install the under cover with the 10 screws and 3 clips.
88. INSTALL FRONT WHEELS
89. INSTALL ECM COVER
(a) Install the ECM cover with the 3 bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
90. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
NOTICE: Make sure that the wire harness does not get caught between parts.
91. INSTALL NO. 1 AIR CLEANER INLET
(a) Install the air cleaner inlet and bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
92. INSTALL ENGINE ROOM SIDE COVER LH
93. INSTALL ENGINE ROOM SIDE COVER RH
94. INSTALL COOL AIR INTAKE DUCT SEAL
95. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
96. INSTALL FRONT WHEELS
97. CHECK FOR FUEL LEAKS
98. RESET MEMORY
99. PERFORM INITIALIZATION
(a) Perform initialization. Repair Instruction - Initialization
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
100. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
101. CHECK IGNITION TIMING
102. CHECK ENGINE IDLE SPEED
103. CHECK CO/HC
104. CHECK FOR ENGINE OIL LEAKS
105. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks.
106. CHECK ENGINE OIL LEVEL