Installation

1UR-FSE ENGINE MECHANICAL: ENGINE (for 2WD): INSTALLATION

1. INSTALL IGNITION COIL ASSEMBLY Installation

2. INSTALL KNOCK SENSOR Installation

3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Installation

4. INSTALL ENGINE OIL LEVEL SENSOR

(a) Install the oil level sensor with the 4 bolts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Installation

6. INSTALL WATER INLET HOUSING Installation

7. INSTALL WATER PUMP PULLEY Installation

8. 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.

9. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the idler pulley with the bolt.

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

10. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY

(a) Install the engine cover.

11. INSTALL ENGINE WIRE

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

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

(b) Connect the 4 knock sensor connectors.

12. INSTALL SEPARATOR CASE 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 FUEL PUMP ASSEMBLY (for High Pressure) Installation

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

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

20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Installation

21. INSTALL ENGINE COVER SUB-ASSEMBLY Installation

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

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

24. INSTALL FUEL TUBE SUB-ASSEMBLY Installation

25. INSTALL NO. 3 COVER SUB-ASSEMBLY Installation

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

27. INSTALL INTAKE MANIFOLD Installation

28. INSTALL THROTTLE BODY ASSEMBLY Installation

29. INSTALL VENTILATION HOSE

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

31. INSTALL NO. 1 ENGINE COVER

32. INSTALL INJECTOR DRIVER Installation

33. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

(a) Install the mounting bracket with the 6 bolts.

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

34. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Install the mounting bracket with the 6 bolts.

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

35. INSTALL ENGINE MOUNTING DAMPER

(a) Install the 2 mounting dampers with the 2 nuts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

36. INSTALL GENERATOR ASSEMBLY Installation

37. 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.

38. INSTALL FRONT ENGINE MOUNTING INSULATOR

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

(a) Install the 2 engine mounting insulators with the 2 nuts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

39. INSTALL ENGINE MOUNTING SPACER

(a) Install the 2 mounting spacers.

40. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the crossmember with the 2 nuts.

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

41. 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 their 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 spacer plate on the crankshaft.

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

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.

42. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Installation

43. INSTALL STARTER ASSEMBLY Installation

44. INSTALL ENGINE WIRE

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

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

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

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

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

(d) Connect the purge VSV connector.

(e) Connect the 4 injector driver connectors as shown in the illustration.

(f) for Engine RH Side:

(1) Connect the 2 clamps and install the 3 clamp brackets with the 3 bolts.

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

(2) Connect the engine oil level sensor connector.

(3) Connect the crankshaft position sensor connector.

(4) Connect the starter connector and starter wire with the nut.

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

(5) Connect the generator connector and generator wire with the nut.

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

(6) Connect the camshaft position sensor connector.

(7) Connect the engine wire connector.

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

Connect the fuel pump connector (for high pressure).

Connect the 2 VVT sensor connectors.

(11) Connect the 4 ignition coil connectors.

(12) Connect the camshaft timing control valve connector.

(g) for Engine LH Side:

(1) Install the clamp bracket with the bolt.

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

(2) Connect the 3 clamps and 3 ground wires with the 3 bolts.

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

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

(4) Connect the oil pressure sensor connector.

(5) Connect the engine coolant temperature sensor connector.

(6) Connect the clamp and install the 2 clamp brackets with the 2 bolts.

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

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

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

Connect the 2 VVT sensor connectors.

Connect the 4 ignition coil connectors.

(11) Connect the camshaft timing control valve connector.

(h) Connect the throttle body connectors.

45. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR Installation

46. INSTALL OIL COOLER TUBE Installation

47. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 2) Installation

48. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

49. 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.

50. 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 crossmember to the marks on the vehicle, and temporarily install the engine and transmission with crossmember 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) Tighten the 4 bolts.

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

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

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

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

52. CONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY

(a) Connect the front No. 2 lower suspension arm Installation.

53. 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 (255 kgf-cm, 18 ft-lbf) for nuts

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

54. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1) Installation

55. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

56. INSTALL POWER STEERING LINK ASSEMBLY (w/ VGRS) Installation

57. INSTALL POWER STEERING LINK ASSEMBLY (w/o VGRS) Installation

58. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/ VGRS) Installation

59. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS) Installation

60. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS) Installation

61. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS) Installation

62. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH Installation

63. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH Installation

64. INSTALL FRONT STABILIZER BAR

(a) Install the stabilizer bar Installation.

65. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

(a) Install the propeller shaft Installation.

66. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY Installation

67. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install the front exhaust pipe Installation.

68. CONNECT HOSES AND CONNECTORS

(a) Connect the purge line hose.

(b) Connect the 2 heater hoses.

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

(d) Connect the ground wire with the bolt.

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

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

(f) Attach the clamp and connect the cooler compressor connector.

(g) Connect the 3 ECT connectors and 4 ECM connectors.

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

69. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Installation

70. CONNECT NO. 3 FUEL HOSE Installation

71. INSTALL ENGINE ROOM ECU OUTLET DUCT

(a) Install the outlet duct.

72. CONNECT NO. 2 RADIATOR HOSE

73. CONNECT NO. 1 RADIATOR HOSE

74. INSTALL AIR CLEANER ASSEMBLY RH Installation

75. INSTALL AIR CLEANER ASSEMBLY LH Installation

76. INSTALL V-RIBBED BELT Installation

77. INSTALL INTAKE AIR CONNECTOR PIPE Installation

78. INSTALL NO. 1 AIR CLEANER INLET Installation

79. INSTALL FRONT SUSPENSION CROSSMEMBER LOWER

(a) Install the suspension crossmember lower with the 6 bolts and 4 nuts.

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

80. INSTALL FRONT BUMPER COVER

(a) Install the front bumper cover Installation.

81. 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.

82. 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.

83. ADD ENGINE OIL Replacement

84. ADD ENGINE COOLANT Service and Repair

85. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

86. 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.

87. INSPECT FOR OIL LEAK

(a) Inspect for engine oil leak Installation.

88. INSPECT FOR COOLANT LEAK Component Tests and General Diagnostics

89. INSPECT FOR FUEL LEAK Fuel System

90. INSPECT FOR EXHAUST GAS LEAK Installation

91. INSTALL FRONT WHEEL

92. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

93. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

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

94. CHECK SHIFT LEVER POSITION Installation

95. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER

(a) Install the suspension member protector with the 8 bolts.

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

96. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the under cover with the 8 bolts.

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

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf) for bolt B

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

98. CHECK IGNITION TIMING On-Vehicle Inspection

99. CHECK IDLE SPEED On-Vehicle Inspection

100. CHECK CO/HC On-Vehicle Inspection

101. CHECK ENGINE OIL LEVEL Testing and Inspection

102. INSTALL ENGINE ROOM SIDE COVER RH

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

103. INSTALL ENGINE ROOM SIDE COVER LH

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

104. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY Installation

105. INSTALL V-BANK COVER SUB-ASSEMBLY Installation

106. INSTALL COWL TOP VENTILATOR LOUVER RH Installation