Installation

1UR-FSE ENGINE MECHANICAL: ENGINE (for AWD): INSTALLATION

1. INSTALL IGNITION COIL ASSEMBLY Installation

2. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Installation

3. INSTALL ENGINE OIL LEVEL SENSOR Installation

4. INSTALL WATER INLET HOUSING

(a) Install a new gasket and inlet housing with the 3 bolts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(b) Using needle-nose pliers, grip the claws of the clips and slide the clips to connect the water by-pass hoses and water inlet hose.

5. INSTALL WATER PUMP PULLEY Installation

6. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley with the bolt.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

HINT
Install the No. 1 idler pulley in the direction shown in the illustration.

7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley with the bolt.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

8. INSTALL KNOCK SENSOR Installation

9. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY

(a) Install the engine cover.

10. INSTALL ENGINE WIRE

(a) Install the engine wire with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for bolt A

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) for bolt B

(b) Connect the 4 knock sensor connectors and attach the 5 clamps.

11. INSTALL SEPARATOR CASE Installation

12. INSTALL FUEL INJECTOR SEAL (for Direct Injection) Installation

13. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) Installation

14. INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection) Installation

15. INSTALL FUEL DELIVERY PIPE (for Direct Injection) Installation

16. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY Installation

17. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH Installation

18. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY Installation

19. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

20. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection) Installation

21. INSTALL FUEL DELIVERY PIPE (for Port Injection) Installation

22. INSTALL FUEL PUMP ASSEMBLY (for Bank 1) Installation

23. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Installation

24. INSTALL ENGINE COVER SUB-ASSEMBLY LH (for Bank 1) Installation

25. INSTALL FUEL PUMP ASSEMBLY (for Bank 2) Installation

26. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

27. INSTALL ENGINE COVER SUB-ASSEMBLY (for Bank 2) Installation

28. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Installation

29. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

30. INSTALL INTAKE MANIFOLD Installation

31. INSTALL THROTTLE BODY ASSEMBLY Installation

32. INSTALL VENTILATION HOSE

33. INSTALL PURGE VSV Installation

34. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY Installation

35. INSTALL NO. 1 ENGINE COVER

36. INSTALL INJECTOR DRIVER Installation

37. INSTALL ENGINE WIRE

(a) Install the engine wire with the 4 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Connect the 2 clamps and 2 clamp brackets with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for bolt A

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf) for bolt B

(c) Connect the intake air control valve actuator connector.

(d) Connect the purge VSV connector.

(e) Connect the 8 injector driver connectors and 2 clips as shown in the illustration.

(f) for Engine Rear Side:

(1) Install the ground wire with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(2) Attach the 8 wire harness clamps.

(3) Connect the fuel relief valve connector.

(4) Connect the engine wire connector.

(g) for Engine RH Side:

(1) Connect the engine oil level sensor connector.

(2) Connect the crankshaft position sensor connector. Then install the wire harness with the 2 bolts.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(3) Attach the 4 clamps.

(4) Connect the camshaft position sensor connector.

(5) Connect the fuel pump connector (for high pressure).

(6) Connect the 2 VVT sensor connectors.

(7) Connect the 4 ignition coil connectors.

(8) Connect the camshaft timing control valve connector.

(h) for Engine Front Side:

(1) Install the clamp bracket with the bolt.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(2) Attach the clamp and install the 3 ground wire with the 3 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(3) Connect the 2 camshaft timing control motor connectors (for Bank 2).

(4) Connect the 2 camshaft timing control motor connectors (for Bank 1).

(5) Connect the engine coolant temperature sensor connector.

(i) for Engine LH Side:

(1) Attach the 4 wire harness clamps.

(2) Connect the No. 8 engine wire connector.

(3) Connect the fuel pump connector (for high pressure).

(4) Connect the 2 VVT sensor connectors.

(5) Connect the 4 ignition coil connectors.

(6) Connect the camshaft timing control valve connector.

(j) Connect the throttle body connectors.

38. INSTALL NO. 6 ENGINE COVER SUB-ASSEMBLY Installation

39. INSTALL NO. 5 ENGINE COVER SUB-ASSEMBLY Installation

40. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY Installation

41. CONNECT COOLER COMPRESSOR ASSEMBLY

(a) Connect the cooler compressor with the 2 stud bolts, 2 nuts and 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf) for stud bolts

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf) for nuts

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf) for bolts

42. REMOVE ENGINE STAND

(a) Install the 2 engine hangers with the 2 bolts as shown in the illustration.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

HINT

(b) Attach an engine sling device and hang the engine with a chain block.

NOTICE:
When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

(c) Remove the bolts and engine assembly from the engine stand.

43. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.

SST : 09213-54015

90119-08216

SST : 09330-00021

(b) Clean the installation holes.

(c) Install the sensor rotor.

HINT
Align the pin of the front spacer with the pin hole of the crankshaft.

(d) Install the drive plate and rear spacer plate on the crankshaft.

(e) Apply a few drops of adhesive to 2 or 3 threads of the bolt end.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(f) Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.

Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)

NOTICE:
* Do not reuse the drive plate installation bolts.
* Do not impact or damage the drive plate installation bolts. Be sure to handle them carefully.

(g) Mark the upside of each drive plate installation bolt with paint.

(h) Retighten the drive plate installation bolts by 90° as shown.

(i) Check that the painted marks are now at a 90° angle to the upside.

44. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Installation

45. CONNECT WIRE HARNESS AND CONNECTOR Installation

46. INSTALL NO. 3 COVER SUB-ASSEMBLY Installation

47. INSTALL OIL COOLER TUBE Installation

48. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

(a) Align the matchmarks on the transfer companion flange and the front propeller shaft.

(b) Temporarily install the front propeller shaft with 6 new bolts and the 2 constant velocity universal joint washers.

(c) Align the matchmarks on the differential companion flange and the front propeller shaft.

(d) Temporarily install the front propeller shaft with 6 new bolts and the 2 constant velocity universal joint washers.

(e) Using a screwdriver or equivalent, hold the transfer companion flange.

(f) Using a 6 mm socket hexagon wrench, tighten the 6 bolts.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Be careful not to damage the front propeller shaft.

(g) Using a screwdriver or equivalent, hold the differential companion flange.

(h) Using a 6 mm socket hexagon wrench, tighten the 6 bolts.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

NOTICE:
Be careful not to damage the front propeller shaft.

49. INSTALL STARTER ASSEMBLY Installation

50. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR Installation

51. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH

(a) Temporarily install the No. 2 mounting bracket with the 2 nuts.

(b) Temporarily install the No. 1 mounting bracket with the 5 bolts.

(c) Tighten the 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(d) Remove the 5 bolts and No. 1 mounting bracket.

52. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET RH

(a) Temporarily install the No. 2 mounting bracket with the 2 nuts.

(b) Temporarily install the No. 1 mounting bracket with the 5 bolts.

(c) Tighten the 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(d) Remove the 5 bolts and No. 1 mounting bracket.

53. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

54. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

55. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Install the mounting bracket with the 5 bolts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

56. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

(a) Install the mounting bracket with the 5 bolts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

57. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the 2 spacers and 2 mounting insulators with the 2 nuts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

58. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

59. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

60. INSTALL GENERATOR ASSEMBLY Installation

61. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the O-ring to the guide.

(c) Install the dipstick guide with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(d) Install the dipstick.

62. INSTALL FRONT FRAME ASSEMBLY

(a) Slowly lower the engine and set it to the front frame.

(b) Install the 4 nuts.

Torque : 70 Nm (714 kgf-cm, 52 ft-lbf)

63. INSTALL ENGINE AND TRANSMISSION

(a) Place the engine on an engine lifter.

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

(b) Remove the 2 bolts and 2 engine hangers.

(c) Operate the engine lifter and install the engine to the vehicle.

NOTICE:
Make sure that the engine is clear of all wiring and hoses.

(d) Align the front frame to the marks on the vehicle, and temporarily install the front frame with the 4 bolts.

NOTICE:
Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.

(e) Install the 4 rear engine mounting member's bolts.

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

(f) Tighten the 4 front frame bolts.

Torque : 188 Nm (1917 kgf-cm, 139 ft-lbf)

64. INSTALL FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH

(a) Connect the absorber and absorber bracket. Then install the bolt.

Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)

65. INSTALL FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH

(a) Connect the absorber and absorber bracket. Then install the bolt.

Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)

66. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY Installation

67. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

(a) Install the propeller shaft Installation.

68. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install the front exhaust pipe Installation.

69. INSTALL FRONT DRIVE SHAFT ASSEMBLY

(a) Install the front drive shaft Installation.

70. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

71. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY

(a) Attach the 2 claws to install the air duct with the bolt.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

72. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY

(a) Install the driver side knee airbag Installation.

73. CONNECT HOSES AND CONNECTORS

(a) Connect the purge line hose.

(b) Connect the 2 heater hoses.

(d) Connect the ground wire with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(e) Connect the 2 power steering ECU connectors and attach the 2 clamps.

HINT
Refer to the following procedures to connect A the power steering ECU connector Installation.

(f) Connect the 3 connectors with front controller with the clamp.

(g) Connect the wires with No. 1 engine room junction block with the 2 nuts. Then attach the 2 clamps.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(h) Lift up the wiring harness support and connect the 4 ECM connectors.

(i) Install the wiring harness support to the ECM box.

(j) Attach the clip of connector A to the ECM box.

(k) Connect the 4 TCM connectors and 2 wiring harness support connectors.

(l) Install the ECM box cover (upper).

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

74. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

75. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

76. CONNECT NO. 1 FUEL HOSE Installation

77. CONNECT NO. 3 FUEL HOSE Installation

78. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Installation

79. INSTALL V-RIBBED BELT Installation

80. INSTALL RESONATOR BRACKET SUB-ASSEMBLY Replacement

81. CONNECT NO. 2 RADIATOR HOSE

82. CONNECT NO. 1 RADIATOR HOSE

83. INSTALL RADIATOR RESERVOIR ASSEMBLY Installation

84. INSTALL ENGINE ROOM ECU OUTLET DUCT

(a) Install the outlet duct to the fan shroud and ECM box.

85. INSTALL AIR CLEANER ASSEMBLY RH Installation

86. INSTALL AIR CLEANER ASSEMBLY LH Installation

87. INSTALL INTAKE AIR CONNECTOR PIPE Installation

88. INSTALL REAR FRAME SIDE RAIL

(a) Install the side rail with the 6 bolts and 4 nuts.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

89. INSTALL FRONT BUMPER COVER

(a) Install the front bumper cover Installation.

90. CONNECT NO. 1 OIL COOLER OUTLET HOSE

(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.

91. CONNECT NO. 1 OIL COOLER INLET HOSE

(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.

92. INSTALL NO. 1 AIR CLEANER INLET Installation

93. ADD ENGINE OIL Replacement

94. ADD ENGINE COOLANT Service and Repair

95. ADD DIFFERENTIAL OIL Testing and Inspection

96. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

97. 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.

98. CHARGE REFRIGERANT Service and Repair

99. INSPECT FOR REFRIGERANT Service and Repair

100. INSPECT FOR OIL LEAK Installation

101. INSPECT FOR COOLANT LEAK Component Tests and General Diagnostics

102. INSPECT FOR FUEL LEAK Fuel System

103. INSPECT FOR EXHAUST GAS LEAK Installation

104. INSTALL FRONT WHEEL

105. CHECK SHIFT LEVER POSITION Installation

106. CHECK IGNITION TIMING On-Vehicle Inspection

107. CHECK IDLE SPEED On-Vehicle Inspection

108. CHECK CO/HC On-Vehicle Inspection

109. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER

(a) Install the suspension member protector with the 9 bolts.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf) for bolt A

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf) for other bolt

110. INSTALL NO. 1 ENGINE UNDER COVER Service and Repair

111. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH Installation

112. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH Installation

113. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the under cover with the 4 screws and 2 clips.

114. INSTALL FRONT FLOOR COVER CENTER

(a) Install the floor cover with the 3 screws, 2 bolts and clip.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

115. CHECK ENGINE OIL LEVEL Testing and Inspection

116. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

117. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

(a) Check and adjust the front wheel alignment Front Wheel Alignment.

118. INSTALL ENGINE ROOM SIDE COVER RH

(a) Install the side cover with the 4 clips.

119. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the side cover with the 4 clips.

120. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY Installation

121. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

122. INSTALL COWL TOP VENTILATOR LOUVER RH Installation