Installation
3UZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
1. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a) Install the mounting bracket with the 4 bolts.
Torque : 36 Nm (370 kgf-cm, 27 ft-lbf)
HINT
The LH mounting bracket is marked with an "L".
2. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH
(a) Install the mounting bracket with the 4 bolts.
Torque : 36 Nm (370 kgf-cm, 27 ft-lbf)
HINT
The RH mounting bracket is marked with an "R".
3. INSTALL NO. 2 WIRING HARNESS HEAT INSULATOR
4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE:
Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE:
Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)
7. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
8. INSTALL ENGINE WIRE
9. INSTALL ENGINE OIL LEVEL SENSOR [1][2]Installation
10. INSTALL CRANKSHAFT POSITION SENSOR [1][2]Installation
11. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY [1][2]Installation
12. INSTALL IGNITION COIL
(a) Install the 8 ignition coils with the 8 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
13. INSTALL NO. 2 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
14. INSTALL NO. 1 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)
15. INSTALL VVT SENSOR
(a) Install the 2 sensors with the 2 bolts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
16. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH
(a) Install a new O-ring to the oil control valve.
(b) Install the oil control valve with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Connect the oil control valve connector.
18. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH
(a) Install a new O-ring to the oil control valve.
(b) Install the oil control valve with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Connect the oil control valve connector.
19. INSTALL OIL DIPSTICK AND GUIDE [1][2]Installation
20. INSTALL STARTER ASSEMBLY Installation
21. INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(b) Connect the 2 knock sensor connectors.
22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install a new O-ring to the water by-pass pipe.
(b) Apply soapy water to the O-ring.
(c) Push in the water by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the bolt.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(e) Install the wire clamp to the bracket of the water by-pass pipe.
23. INSTALL REAR WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
24. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(b) Connect the ECT sensor connector.
25. INSTALL WATER INLET HOUSING Installation
26. INSTALL GENERATOR ASSEMBLY Installation
27. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH Installation
28. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH Installation
29. INSTALL INTAKE MANIFOLD
(a) Place 2 new gaskets on the cylinder heads with the white mark facing outward.
NOTICE:
Be careful of the installation direction.
(b) Install the intake manifold assembly with the 6 bolts and 4 nuts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(c) Connect the 8 injector connectors.
(d) Install the engine wire protector (rear side) with the 2 bolts.
(e) Install the engine wire protector (LH side) with the 4 bolts.
(f) Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
(g) Install the No. 4 V-bank cover with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(h) Install the No. 1 V-bank cover bracket with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(i) Connect the VSV connector for ACIS.
(j) Install the No. 3 V-bank cover bracket with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(k) Install the No. 2 V-bank cover bracket with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(l) Install the purge VSV to the intake manifold with the bolt.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(m) Connect the purge hose to the purge VSV.
(n) Connect the purge VSV connector.
30. INSTALL THROTTLE BODY ASSEMBLY
(a) Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
(b) Connect the water by-pass hoses.
31. REMOVE ENGINE STAND
32. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
HINT
If any one of the mounting bolts is broken or deformed, replace it.
(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the front spacer, drive plate and rear spacer on the crankshaft.
(c) Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
(c) If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.
(d) Mark the mounting bolt with paint.
(e) Retighten the mounting bolt by 90° in the numerical order shown.
(f) Check that the painted mark is now at a 90° angle.
33. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) Check the torque converter clutch installation Installation.
(b) Install the automatic transmission to the engine with the 9 bolts.
Torque : 37 Nm (377 kgf-cm, 27 ft-lbf for bolt A)
Torque : 71 Nm (724 kgf-cm, 52 ft-lbf for bolt B)
HINT
* Make sure that the mark is positioned as shown in the illustration.
* Bolt head size:
* 14 mm for bolt A
* 17 mm for bolt B
* Bolt (B) will be tightened with the wire harness clamp.
(c) Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch mounting bolts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
HINT
First install the black colored bolt and then the remaining 5 bolts.
34. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover with the 2 bolts.
Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)
35. INSTALL OIL COOLER TUBE
(a) Temporarily install the oil cooler outlet tube.
(b) Temporarily install the oil cooler inlet tube.
(c) Install the 3 clamps with the 3 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(d) Using a union nut wrench, tighten the oil cooler outlet tube.
Torque : 44 Nm (449 kgf-cm, 32 ft-lbf for use without union nut wrench)
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf for use with union nut wrench)
HINT
* Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
* Make sure a union nut wrench and a wrench are connected in a straight line.
(e) Using a union nut wrench, tighten the oil cooler inlet tube.
Torque : 44 Nm (449 kgf-cm, 32 ft-lbf for use without union nut wrench)
Torque : 39 Nm (398 kgf-cm, 29 ft-lbf for use with union nut wrench)
HINT
* Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
* Make sure a union nut wrench and a wrench are connected in a straight line.
36. CONNECT WIRE HARNESS
(a) Connect the 2 speed sensor connectors.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch connector.
(d) Install the wire harness clamps with the 5 bolts.
Torque : 71 Nm (724 kgf-cm, 52 ft-lbf for bolt A)
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf for bolt B)
HINT
Bolt (A) is tightened to the transmission housing.
37. CONNECT ENGINE WIRE
(a) Connect the engine wire to the transmission.
(1) Connect the VSV connector.
(2) Connect the engine wire to the 3 wire clamps.
(3) Connect the oil level sensor connector.
38. INSTALL ENGINE WITH TRANSMISSION ASSEMBLY
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine and transmission assembly into the engine compartment.
(c) Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
(d) Keep the engine level.
(e) Install the engine rear mounting member with the 4 bolts and 4 nuts.
Torque : 25.5 Nm (260 kgf-cm, 19 ft-lbf for bolts)
Torque : 13.5 Nm (137 kgf-cm, 10 ft-lbf for nuts)
NOTICE:
Be careful of installation direction.
(f) Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.
Torque : 68 Nm (693 kgf-cm, 50 ft-lbf)
(g) Install the 2 hole plugs.
(h) Remove the engine chain hoist.
(i) Install the No. 1 V-bank cover bracket to the No. 2 engine hanger with the nut.
39. INSTALL POWER STEERING GEAR HOUSING ASSEMBLY
(a) Connect the sliding yoke to the PS gear housing and intermediate shaft.
(b) Install the PS gear housing with the 4 bolts.
Torque : 65 Nm (662 kgf-cm, 48 ft-lbf)
(c) Install the 2 PS oil tube with the bolt.
40. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
(a) Tighten the 2 bolts for sliding yoke.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
41. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
(a) Connect the floor shift gear shifting rod with the nut.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
42. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation
43. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
(a) Install the insulator with the 4 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
44. INSTALL NO. 1 FRONT FLOOR HEAT INSULATOR
(a) Install the insulator with the 4 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
45. INSTALL CATALYST CONVERTER ASSEMBLY
(a) Install 2 new gaskets and 2 converters with 6 new nuts.
Torque : 62 Nm (632 kgf-cm, 46 ft-lbf)
46. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
(a) Install the bracket with the 2 bolts.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
47. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH
(a) Install the front suspension member brace with the 2 nuts and 4 bolts.
Torque : 56 Nm (571 kgf-cm, 41 ft-lbf for bolt)
Torque : 58 Nm (591 kgf-cm, 43 ft-lbf for nut)
48. INSTALL CENTER EXHAUST PIPE ASSEMBLY
(a) Install a new 2 gaskets and the exhaust pipe with the 4 nuts, 4 bolts and 2 rings.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
49. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install 3 new gaskets and the exhaust pipe with the 6 nuts and 6 bolts.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
50. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) Installation
51. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) Installation
52. INSTALL FRONT FLOOR BRACE CENTER
(a) Install the floor brace with the 4 bolts.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
53. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf for bolts)
Torque : 29 Nm (296 kgf-cm, 21 ft-lbf for nut)
(b) Connect the compressor connector.
(c) Install the wire clamp.
54. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque : 39.2 Nm (400 kgf-cm, 29 ft-lbf for bolts)
Torque : 43.1 Nm (439 kgf-cm, 32 ft-lbf for nut)
(b) Connect the PS oil pressure switch connector.
(c) Install the RH engine under cover with the 2 screws.
(d) Connect the 2 PS air hoses to the vane pump.
55. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
56. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
57. CONNECT HEATER WATER HOSE INLET A
58. CONNECT NO. 2 FUEL VAPOR FEED HOSE
59. CONNECT NO. 5 AIR HOSE
60. CONNECT ENGINE WIRE
(a) Connect the engine wire from the ECM box.
(b) Install the nut, and connect the generator wire to the generator.
(c) Connect the wire for generator wire to the wire clamp on generator.
(d) Connect the ground cable to the stay on generator with the bolt.
(e) Connect the PS oil hose to the No. 1 oil pan with the 2 bolts.
(f) Connect the ground strap to the body with the 2 bolts.
61. INSTALL FAN & GENERATOR V BELT Installation
62. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
(a) Using a union nut wrench, install the fuel pipe.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf for use with union nut wrench)
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf for use without union nut wrench)
HINT
* Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
* Make sure a union nut wrench and a wrench are connected in a straight line.
63. INSTALL RADIATOR ASSEMBLY Installation
64. CONNECT NO. 1 OIL COOLER OUTLET TUBE Installation
65. CONNECT NO. 1 OIL COOLER INLET TUBE Installation
66. CONNECT NO. 2 RADIATOR HOSE Installation
67. CONNECT NO. 1 RADIATOR HOSE Installation
68. INSTALL ECM COVER
(a) Install the cover with the 3 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
69. INSTALL NO. 2 ENGINE UNDER COVER
70. INSTALL ENGINE UNDER COVER RH
71. INSTALL ENGINE UNDER COVER
72. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Connect the MAF meter connector and clamp to the air cleaner.
73. INSTALL INTAKE AIR CONNECTOR PIPE
(a) Install the connector pipe with the bolt and hose clamp.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf for hose clamp)
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf for bolt)
(b) Connect the air hose and No. 1 ventilation hose.
74. INSTALL NO. 1 AIR CLEANER INLET Installation
75. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
NOTICE:
Make sure that the wire harness does not get caught between parts.
76. INSTALL HOOD SUB-ASSEMBLY
(a) Temporarily tighten the 4 bolts.
77. ADJUST HOOD SUB-ASSEMBLY Adjustments
78. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
79. PERFORM INITIALIZATION
NOTICE:
Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
80. ADD AUTOMATIC TRANSMISSION FLUID Installation
81. ADD ENGINE COOLANT Service and Repair
82. ADD ENGINE OIL Replacement
83. CHECK FOR ENGINE COOLANT LEAKS Testing and Inspection
84. CHECK FOR FUEL LEAKS Installation
85. ADJUST AUTOMATIC TRANSMISSION FLUID Installation
86. CHECK FOR ENGINE OIL LEAKS
87. DRIVING TEST
88. ADJUST ENGINE