Installation

1UR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. REMOVE ENGINE FROM 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.

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

2. INSTALL ENGINE ASSEMBLY

(a) Slowly lower the engine assembly into the engine compartment.

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

(b) Attach the engine mounting insulators to the vehicle.

(c) Install the 4 engine mounting insulator bolts.

Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)

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

3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.

SST : 09213-70011

SST : 09330-00021

(b) Install the crankshaft angle sensor rotor.

HINT
Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.

(d) Apply adhesive to 2 or 3 threads of the 8 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(e) Install and uniformly 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 strike or damage the drive plate installation bolts. Be sure to handle them carefully.

(f) Mark the top of each drive plate installation bolt with paint.

(g) Tighten the drive plate installation bolts 90° as shown in the illustration.

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

4. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for 4WD)

5. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for 2WD)

6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) for 2WD:

Refer to the following procedures .

(b) for 4WD:

Refer to the following procedures Installation.

7. INSTALL STARTER ASSEMBLY Installation

8. INSTALL STARTER COVER Installation

9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

10. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

12. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

13. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY Installation

14. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

15. CONNECT NO. 1 WATER BY-PASS PIPE

(a) Connect the No. 1 water by-pass pipe with the 3 bolts.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

16. INSTALL EXHAUST PIPE ASSEMBLY

(a) Install the exhaust pipe Installation.

17. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

(a) Install the front propeller shaft Installation.

18. INSTALL PROPELLER SHAFT ASSEMBLY

(a) for 2WD:

Refer to the following procedures Installation.

(b) for 4WD:

Refer to the following procedures Installation.

19. INSTALL GENERATOR ASSEMBLY Installation

20. CONNECT VANE PUMP ASSEMBLY Installation

21. CONNECT COOLER COMPRESSOR ASSEMBLY Installation

22. CONNECT WIRE HARNESS AND HOSE

(a) Connect the 2 connectors and 2 clips to the engine room junction block.

(b) Install the engine wire with the nut. Then connect the 2 clips.

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

(c) Connect the 4 air injection control driver connectors.

(d) Install the ground wire with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(e) Connect the cable to the positive (+) battery terminal.

(f) Install the wire to the positive (+) battery cable with the nut.

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

(g) Connect the air injection system hose.

(h) Install the connector bracket with the nut.

Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

(i) Connect the 2 clamps and air pump connector.

(j) Connect the clamp and ground wire with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(k) Connect the 4 connectors to the connector holder block.

(l) Connect the 2 heater hoses.

(m) Connect the No. 4 water by-pass hose.

(n) Connect the ECM connector and clamp.

HINT
Refer to the following procedures to connect the ECM connector Installation.

23. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

(a) Connect the No. 2 fuel tube Service Precautions.

24. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Connect the No. 1 fuel pipe Service Precautions.

(b) Install the fuel pipe clamp.

25. INSTALL INTAKE MANIFOLD Installation

26. INSTALL AIR TUBE SUB-ASSEMBLY LH Installation

27. INSTALL VENTILATION HOSE ASSEMBLY Installation

28. INSTALL EGR VALVE BRACKET Installation

29. INSTALL EGR VALVE ASSEMBLY Installation

30. CONNECT NO. 13 WATER BY-PASS HOSE Installation

31. CONNECT NO. 12 WATER BY-PASS HOSE Installation

32. INSTALL RADIATOR ASSEMBLY Installation

33. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL (for RH Side) Installation

34. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL (for LH Side) Installation

35. INSTALL FAN SHROUD Installation

36. INSTALL FAN AND GENERATOR V BELT Installation

37. INSTALL RADIATOR SIDE DEFLECTOR LH Installation

38. INSTALL RADIATOR SIDE DEFLECTOR RH Installation

39. CONNECT OUTLET RADIATOR HOSE Installation

40. INSTALL INLET RADIATOR HOSE Installation

41. INSTALL FRONT BUMPER COVER

(a) Install the front bumper cover Installation.

42. INSTALL FRONT FENDER APRON SEAL REAR LH Installation

43. INSTALL FRONT FENDER APRON SEAL LH Installation

44. INSTALL FRONT FENDER APRON SEAL REAR RH Installation

45. INSTALL FRONT FENDER APRON SEAL RH Installation

46. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY Installation

47. INSTALL AIR CLEANER ASSEMBLY

(a) Install the air cleaner case with the 2 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(b) Install the air cleaner element to the air cleaner case.

(c) Install the air cleaner cap.

(1) Install the air cleaner cap and fasten the 4 hook clamps.

(2) Connect the MAF meter connector.

(3) Attach the wire harness clamp.

48. INSTALL AIR CLEANER HOSE ASSEMBLY

(a) Install the air cleaner hose with the 2 clamps.

Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)

(b) Connect the ventilation hose and vacuum sensing hose.

49. ADD ENGINE OIL Replacement

50. ADD ENGINE COOLANT Service and Repair

51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

52. INSPECT FOR OIL LEAK Replacement

53. INSPECT FOR COOLANT LEAK Testing and Inspection

54. INSPECT FOR EXHAUST GAS LEAK Installation

55. INSPECT FOR FUEL LEAK Installation

56. INSPECT SHIFT LEVER POSITION

(a) Inspect the shift lever position .

57. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins, and press down on the V-bank cover to attach the pins.

58. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood with the 4 bolts.

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

(b) Attach the lower part of the 2 hood supports to the hood support bolt ball joints.

CAUTION:
Install the hood support while supporting the hood by hand.

(c) Attach the hood support clips.

NOTICE:
Check that the hood support is engaged in the ball joint and that it cannot be pulled out.

59. ADJUST HOOD SUB-ASSEMBLY Adjustments

60. INSTALL NO. 1 ENGINE UNDER COVER Replacement

61. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

(a) Install the front wiper motor and link Installation.

62. INSPECT IGNITION TIMING Engine

63. INSPECT ENGINE IDLE SPEED Engine

64. INSPECT CO/HC Engine

65. CHECK ENGINE OIL LEVEL Testing and Inspection

66. CHECK ENGINE COOLANT LEVEL Testing and Inspection