Installation
1UR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
1. INSTALL ENGINE HANGER Removal
2. REMOVE ENGINE STAND
(a) Attach an engine sling device and hang the engine with a chain block.
Text in Illustration
(b) Lift the engine and remove it from the engine stand.
(c) Place the engine onto a workbench.
3. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Connect the 2 water hoses and install the No. 1 water by-pass pipe.
Text in Illustration
HINT
* When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
* The direction of the hose clamp is indicated in the illustration.
4. INSTALL ENGINE ASSEMBLY
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Slowly lower the engine into the engine compartment.
(c) Install the front engine mounting insulator LH and RH with the 2 nuts and 4 bolts.
for nut - Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)
for bolt - Torque : 57 Nm (581 kgf-cm, 42 ft-lbf)
Text in Illustration
(d) Remove the 2 bolts and 2 engine hangers.
5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST : 09213-70011
09213-70020
SST : 09330-00021
(b) Install the crankshaft angle sensor rotor.
Text in Illustration
HINT
* Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.
* As the crankshaft angle sensor rotor is not reversible, be sure to install it so that it is facing in the direction shown in the illustration.
(c) Install the drive plate and ring gear and the rear drive plate spacer to the crankshaft.
Text in Illustration
HINT
As the rear drive plate spacer and the drive plate and ring gear are not reversible, be sure to install them so that they are facing in the directions shown in the illustration.
(d) Install the drive plate and ring gear and bolts.
HINT
The bolts are tightened in 2 progressive steps.
(1) Clean the bolts and bolt holes.
(2) Apply adhesive to 2 or 3 threads at the end of each of the 10 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Text in Illustration
(3) Step 1:
Uniformly install and tighten the 10 new bolts in several steps in the sequence shown in the illustration.
Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)
(4) Mark the top of each drive plate installation bolt with paint.
(5) Step 2:
Tighten the drive plate installation bolts 90°.
(6) Check that the painted marks are now at a 90° angle to the top.
NOTICE:
Do not start the engine for at least an hour after installing the drive plate.
6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
(a) Install the rear No. 1 engine mounting insulator to the transmission with the 4 bolts.
Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)
(b) Install the rear engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) Install the automatic transmission assembly Installation.
8. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Installation
9. INSTALL PROPELLER SHAFT ASSEMBLY
(a) Install the propeller shaft assembly Installation.
10. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
(a) Install the front propeller shaft assembly Installation.
11. CONNECT OIL COOLER TUBE SUB-ASSEMBLY
(a) Connect the oil cooler tube with the bolt.
Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)
12. CONNECT ENGINE WIRE
(a) Connect the ECM connector.
(1) Attach the grommet to the wire harness support.
Text in Illustration
(2) Pass the wire harness into the vehicle and install the wire harness support.
(3) Connect the 6 connectors and attach the clamp.
(b) Install the lower instrument panel Installation.
(c) for Engine Room RH Side:
(1) Attach the 3 wire harness clamps to connect the engine wire and connect the connector.
Text in Illustration
(2) Connect the ground wire with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(d) for Engine Room LH Side:
(1) Attach the wire harness clamp.
Text in Illustration
(2) Connect the No. 2 engine wire and ground wire with the 2 bolts.
for bolt A - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
for bolt B - Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)
(3) Attach the 2 claws and connect the engine wire to the engine room relay block.
Text in Illustration
(4) Install the nut to the engine room relay block.
Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)
(5) Connect the connector.
(6) Connect the ground wire with the bolt.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
13. CONNECT FUEL HOSE AND NO. 2 FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel hose and No. 2 fuel tube Service Precautions.
(b) Install the 2 fuel pipe clamps to the fuel tube connector.
14. INSTALL FLYWHEEL HOUSING SIDE COVER
15. INSTALL STARTER ASSEMBLY Installation
16. INSTALL STARTER COVER Installation
17. INSTALL EXHAUST MANIFOLD ASSEMBLY RH Installation
18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
19. INSTALL EXHAUST MANIFOLD ASSEMBLY LH Installation
20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
21. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY Installation
22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY Installation
25. INSTALL EXHAUST PIPE STOPPER BRACKET Installation
26. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
27. INSTALL SUCTION HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the suction hose.
(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the 2 O-rings to the suction hose.
(d) Install the suction hose with the 2 bolts and nut.
for bolt A - Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
for bolt B and nut - Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
28. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the discharge hose.
(b) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor.
Compressor oil:
ND-OIL 8 or equivalent
(c) Install the 2 O-rings to the discharge hose.
(d) Install the discharge hose with the 3 bolts.
for bolt A - Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
for bolt B - Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
for bolt C - Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
29. INSTALL GENERATOR ASSEMBLY Installation
30. INSTALL VANE PUMP ASSEMBLY Installation
31. CONNECT PRESSURE FEED TUBE Installation
32. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE Installation
33. INSTALL INTAKE MANIFOLD Installation
34. INSTALL AIR TUBE SUB-ASSEMBLY Installation
35. INSTALL VENTILATION HOSE ASSEMBLY Installation
36. CONNECT NO. 4 WATER BY-PASS PIPE Installation
37. INSTALL EGR VALVE BRACKET Installation
38. INSTALL EGR VALVE ASSEMBLY Installation
39. CONNECT NO. 13 WATER BY-PASS HOSE Installation
40. CONNECT NO. 12 WATER BY-PASS HOSE Installation
41. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Single Air Conditioning System)
Text in Illustration
(a) Install the water pipe and hose with the 2 nuts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) Connect the 4 water hoses.
HINT
* When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
* The direction of each hose clamp is indicated in the illustration.
42. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Dual Air Conditioning System)
Text in Illustration
(a) Install the water pipe and hose with the 2 nuts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) Connect the 6 water hoses.
HINT
* When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
* The direction of each hose clamp is indicated in the illustration.
43. INSTALL RADIATOR ASSEMBLY Installation
44. CONNECT OIL COOLER ACCESSORY ASSEMBLY Installation
45. INSTALL NO. 2 RADIATOR HOSE Installation
46. INSTALL FAN SHROUD Installation
47. INSTALL NO. 1 RADIATOR HOSE Installation
48. INSTALL RADIATOR RESERVOIR ASSEMBLY Installation
49. INSTALL RADIATOR SIDE DEFLECTOR RH Installation
50. INSTALL RADIATOR SIDE DEFLECTOR LH Installation
51. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Install the air cleaner case with the 3 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
52. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
53. INSTALL AIR CLEANER CAP AND HOSE
(a) Attach the 4 clamps to install the air cleaner cap and hose.
Text in Illustration
HINT
When installing the air cleaner hose, align its groove with the protrusion of the throttle body as shown in the illustration.
(b) Tighten the hose clamp.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
HINT
Make sure the direction of the hose clamp is as shown in the illustration.
(c) Connect the mass air flow meter connector, No. 1 air hose and No. 2 ventilation hose and attach the wire harness clamp.
54. INSTALL FRONT BUMPER COVER
(a) Install the front bumper cover Installation.
55. INSTALL BATTERY TRAY
56. INSTALL BATTERY
(a) Install the battery.
(b) Install the battery hold down clamp with the 2 nuts.
Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)
(c) Install the No. 2 engine wire with the nut.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
57. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
(a) Install the cowl top ventilator louver sub-assembly Installation.
58. 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.
59. ADD ENGINE OIL Replacement
60. ADD ENGINE COOLANT Service and Repair
61. ADD POWER STEERING FLUID
62. BLEED POWER STEERING FLUID On-Vehicle Inspection
63. INSPECT FOR OIL LEAK Replacement
64. INSPECT FOR COOLANT LEAK Testing and Inspection
65. INSPECT FOR FUEL LEAK Installation
66. INSPECT ENGINE OIL LEVEL Testing and Inspection
67. INSPECT FOR POWER STEERING FLUID LEAK
68. INSPECT FOR EXHAUST GAS LEAK Installation
69. PERFORM RESET MEMORY
(a) Perform the Reset Memory procedures Programming and Relearning.
70. INSPECT IGNITION TIMING On-Vehicle Inspection
71. INSPECT ENGINE IDLE SPEED On-Vehicle Inspection
72. INSPECT CO/HC On-Vehicle Inspection
73. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 8 bolts.
for bolt A - Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
for bolt B - Torque : 18 Nm (178 kgf-cm, 13 ft-lbf)
(b) Connect the washer hose.
74. ADJUST HOOD SUB-ASSEMBLY Adjustments
75. CHARGE REFRIGERANT Service and Repair
76. WARM UP ENGINE Service and Repair
77. CHECK FOR REFRIGERANT GAS LEAK Service and Repair
78. INSTALL ENGINE ROOM SIDE COVER
(a) Install the engine room side cover with the 4 clips.
79. INSTALL ENGINE ROOM SIDE COVER LH
(a) Install the engine room side cover LH with the 4 clips.
80. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Attach the 2 V-bank cover hooks to the No. 1 V-bank cover 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.
Text in Illustration
81. INSTALL UPPER RADIATOR SUPPORT SEAL
(a) Install the upper radiator support seal with the 13 clips.
82. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH
(a) Install the front No. 1 fender apron to frame seal RH with the 5 clips.
83. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH
(a) Install the front No. 1 fender apron to frame seal LH with the 5 clips.
84. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the front fender apron seal RH with the 4 clips.
85. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the front fender apron seal LH with the 7 clips.
86. INSTALL REAR ENGINE UNDER COVER ASSEMBLY
(a) Install the rear engine under cover with the 4 bolts.
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
87. INSTALL TRANSMISSION UNDER COVER
(a) Install the transmission under cover with the 2 bolts.
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
88. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
(a) Hook the No. 1 engine under cover to the vehicle body as shown in the illustration.
(b) Install the 4 bolts.
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)
89. INSTALL LOWER FRONT BUMPER COVER
(a) Install the lower front bumper cover with the 5 bolts and clip.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)