Installation

ENGINE ASSEMBLY

COMPONENTS (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):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Using a 19 mm deep socket wrench, remove the temperature sensor.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

2. INSTALL OIL PRESSURE SWITCH ASSEMBLY

(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)

NOTICE: Do not start the engine within 1 hour after installation.

3. INSTALL ENGINE OIL LEVEL SENSOR
(a) Install the engine oil level sensor and new gasket with the 4 bolts.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

4. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

5. INSTALL BANK COVER BRACKET
(a) Install the bracket with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

6. INSTALL RADIO SETTING CONDENSER
(a) Install the 2 condensers with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

7. INSTALL KNOCK SENSOR
8. INSTALL FUEL INJECTOR ASSEMBLY
(a) for Port: Install the injector assembly.
(b) for Direct: Install the injector assembly.

9. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
10. INSTALL NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY
11. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY
12. INSTALL HIGH PRESSURE SIDE FUEL PUMP
13. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

14. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Install the pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Connect the 2 hoses.

15. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

16. INSTALL FUEL TUBE SUB-ASSEMBLY
(a) Install the tube with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

17. INSTALL INTAKE MANIFOLD

18. INSTALL NO. 3 WATER BY-PASS PIPE
(a) Connect the 2 hoses.
(b) Install the pipe with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

19. INSTALL NO. 2 INTAKE AIR SURGE TANK BRACKET

NOTICE: Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them.

(a) Install the bracket with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

20. INSTALL INTAKE AIR SURGE TANK SUB-ASSEMBLY

21. INSTALL INJECTOR DRIVER
(a) Install the injector driver with the bolt and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

22. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine assembly.

23. INSTALL WATER PUMP PULLEY

24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.

Each bolt length is as follows:

(b) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(c) Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

25. INSTALL ENGINE MOUNTING BRACKET LH
(a) Install the bracket with the 4 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(b) Connect the 2 clamps.

26. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the bracket with the 4 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

27. INSTALL COOLER COMPRESSOR ASSEMBLY

28. INSTALL NO. 1 ENGINE COVER
(a) Install the cover with the 3 clamps.

29. INSTALL NO. 2 ENGINE COVER
(a) Install the cover with the 3 clamps.
(b) Connect the clamp.

30. INSTALL FAN AND GENERATOR V BELT

31. REMOVE ENGINE STAND
(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Part No.:

Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
(b) Attach an engine sling device and hang the engine with a chain block.
(c) Remove the engine assembly from the engine stand.

32. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Install the front suspension crossmember subassembly with the 2 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

33. INSTALL FLYWHEEL SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
(b) Apply adhesive to 2 or 3 threads of the mounting bolts end.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(c) Install and tighten the 8 mounting bolts uniformly in several steps.
Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf)

NOTICE: Do not start the engine for at least 1 hour after installing.

(d) Install the transmission input damper cover with the 9 bolts.
Torque: 49 N*m (504 kgf*cm, 36 ft.*lbf)

34. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY
35. INSTALL WATER PIPE AND HOSE ASSEMBLY

(a) for LH Side: Connect the hose.
(b) Install the pipe with the 2 bolts.
Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf)

(c) for RH Side: Connect the hose.
(d) Install the pipe with the 2 bolts.
Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf)

36. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Install a new gasket as shown in the illustration.

(b) Install exhaust manifold to the cylinder head with the 6 nuts in the order shown in the illustration.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

NOTICE: Do not damage the stud bolt when installing the exhaust manifold.

37. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Install a new gasket as shown in the illustration.

(a) Install a new O-ring to the guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the No. 1 guide end into the guide hole.
(d) Install the No. 1 guide with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(e) Connect the harness clamp.

(f) Install a new O-ring to the guide.
(g) Apply a light coat of engine oil to the O-ring.
(h) Push in the No. 2 guide end into the No. 1 guide hole.
(i) Install the No. 2 guide with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(j) Install the dipstick.

39. INSTALL ENGINE AND TRANSMISSION

(a) Remove the 4 bolts and 2 engine hangers.
(b) Set an engine lifter.
(c) Operate the engine lifter, then install the engine to the vehicle.

(d) Install the engine and transmission with crossmember sub-assembly with the 12 bolts.
Torque:
167 N*m (1,700 kgf*cm, 123 ft.*lbf) for bolt A
204 N*m (2,080 kgf*cm, 150 ft.*lbf) for bolt B
50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt D

(e) Install the engine rear mounting member with the 4 bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)

40. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
41. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH
42. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH
43. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH
44. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH

45. CONNECT HEIGHT CONTROL SENSOR LINK
(a) Connect the height control sensor link and install it with the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

46. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
(a) Install the protector with the 4 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

47. CONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY
(a) Connect the fuel hose to the pipe.

48. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) for RH Side: Connect the fuel tube.
(b) for LH Side: Connect the fuel tube.

49. INSTALL HEATER WATER PUMP ASSEMBLY
(a) Connect the 2 hoses and install the water pump.

50. CONNECT ENGINE WIRE

(a) w/Front Active Stabilizer Control Actuator: Using the procedures below, connect the connector to the front active stabilizer control ECU.
(1) Connect the connector to the front active stabilizer control (*1).
(2) Rotate the lever in the direction of the arrow until a "click" sound is heard (*2).
(3) Lock the lever's lock (*3).
(b) Install the wire clamp to the bracket.
(c) Install the ground wire to the front active stabilizer control ECU with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

(d) Install the front fender liner RH with the 8 bolts.

(e) Connect the clamp and connector to the heater water pump.

(f) Install the ground wire with the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

(g) Install the power steering ground wire to the power steering link assembly with bolt (B).
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(h) Connect wire harness connector (E) to the power steering link assembly and securely lock the connector.
(i) Connect 2 wire harness connectors (C) and (D) to the power steering link assembly.
(j) Install the 2 wire harness clamps to the power steering link assembly.
(k) Connect the earth wire to the bracket with bolt (A).
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

(l) Install the No. 3 engine wire with the bolt.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
(m) Connect the clamp to the body.

(n) Install the No. 2 wire with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(o) Connect the 2 connectors to the compressor assembly.
(p) Connect the 2 clamps.

(q) Install the No. 4 engine wire with the nut.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(r) Connect the clamp to the body.

51. INSTALL ECM
52. INSTALL HYBRID VEHICLE CONTROL ECU
53. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
54. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

55. CONNECT NO. 2 INVERTER COOLING HOSE
(a) Connect the cooling hose.

56. CONNECT NO. 1 INVERTER COOLING HOSE
(a) Connect the cooling hose.

57. CONNECT HEATER WATER OUTLET HOSE A
(a) Connect the outlet hose.

58. CONNECT HEATER WATER INLET HOSE A
(a) Connect the inlet hose.

59. CONNECT RADIATOR RESERVE TANK HOSE
60. CONNECT RADIATOR HOSE INLET
61. CONNECT RADIATOR HOSE OUTLET

62. CONNECT NO. 2 FUEL VAPOR FEED HOSE
(a) Connect the feed hose.

63. INSTALL OIL PUMP MOTOR CONTROLLER

64. INSTALL AIR CLEANER CASE
(a) Install the case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the 2 clamps.

65. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
66. INSTALL NO. 2 VENTILATION HOSE

67. INSTALL NO. 1 AIR CLEANER INLET
(a) Install the air cleaner inlet with the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

68. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
69. INSTALL FRONT EXHAUST PIPE ASSEMBLY
70. INSTALL FRONT FLOOR BRACE CENTER
71. ADD ENGINE OIL
72. ADD ENGINE COOLANT
73. CHARGE REFRIGERANT
74. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
75. INSTALL SERVICE PLUG GRIP
76. 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.

77. CHECK FOR ENGINE OIL LEAKS
78. CHECK FOR ENGINE COOLANT LEAKS
79. CHECK FOR FUEL LEAKS
80. CHECK FOR LEAKAGE OF REFRIGERANT
81. CHECK FOR EXHAUST GAS LEAKS
82. INSTALL REAR ENGINE UNDER COVER LH
(a) Install the under cover with the bolt.

83. INSTALL REAR ENGINE UNDER COVER RH
(a) Install the under cover with the bolt.

84. INSTALL FRONT WHEELS
85. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
86. CHECK SHIFT LEVER POSITION
87. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
(a) Check and adjust the front wheel alignment.

88. CHECK IGNITION TIMING
89. CHECK IDLE SPEED
90. CHECK CO/HC
91. CHECK ENGINE OIL LEVEL
92. CHECK ENGINE COOLANT LEVEL
93. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the 4 screws, 2 grommets and 2 spacers.

94. INSTALL ENGINE UNDER COVER

95. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Attach the 3 clips to install the engine cover.

NOTICE:
^ Be sure to engage the clips securely.
^ Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.

96. INSTALL ENGINE ROOM COVER SIDE RH
(a) Install the side cover with the 4 clips.

97. INSTALL ENGINE ROOM SIDE COVER LH
(a) Install the side cover with the 3 clips.

98. INSTALL COOL AIR INTAKE DUCT SEAL
(a) Install the intake duct seal with the 7 clips.