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Engine Assembly: Installation

WARNING: This page is about a different car, the 2007 Toyota Land Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (See  INSTALLATION  ) 
  2. INSTALL OIL PRESSURE SWITCH (See  ON-VEHICLE INSPECTION  ) 
  3. INSTALL IGNITION COIL (See  INSTALLATION  ) 
  4. INSTALL KNOCK SENSOR (See  INSTALLATION  ) 
  5. INSTALL CRANKSHAFT POSITION SENSOR (See  INSTALLATION  ) 
  6. INSTALL VVT SENSOR (for Bank 1) (See  INSTALLATION  ) 
  7. INSTALL VVT SENSOR (for Bank 2) (See  INSTALLATION  ) 
  8. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) (See  INSTALLATION  ) 
  9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) (See  INSTALLATION  ) 
  10. INSTALL STARTER ASSEMBLY (See  INSTALLATION  ) 
  11. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See  INSTALLATION   ) 
  12. INSTALL REAR WATER BY-PASS JOINT (See  INSTALLATION   ) 
  13. INSTALL FRONT WATER BY-PASS JOINT (See  INSTALLATION   ) 
  14. INSTALL WATER INLET HOUSING (See  INSTALLATION   ) 
  15. INSTALL OIL COOLER PIPE (See  INSTALLATION   ) 
  16. INSTALL NO. 2 ENGINE HANGER (See  INSTALLATION   ) 
  17. INSTALL NO. 1 ENGINE HANGER (See  INSTALLATION   ) 
  18. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  19. INSTALL INTAKE MANIFOLD ASSEMBLY (See  INSTALLATION  ) 
  20. INSTALL FRONT ENGINE MOUNTING BRACKET LH 
    1. Install the mounting bracket with the 4 bolts.

      Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

      HINT:

      The LH mounting bracket is marked with an "L".

  21. INSTALL FRONT ENGINE MOUNTING BRACKET RH 
    1. Install the mounting bracket with the 4 bolts.

      Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

      HINT:

      The RH mounting bracket is marked with an "R".

  22. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See  INSTALLATION   ) 
  23. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See  INSTALLATION   ) 
  24. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See  INSTALLATION   ) 
  25. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See  INSTALLATION   ) 
  26. INSTALL OIL DIPSTICK GUIDE (See  INSTALLATION  ) 
  27. REMOVE ENGINE STAND 
  28. INSTALL DRIVE PLATE SUB-ASSEMBLY 

    HINT:

    If any one of the mounting bolts is broken or deformed, replace it.

    1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

      Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

      Fig 1: Applying Adhesive To Threads Of Mounting Bolt
      G04435856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front spacer, drive plate and rear spacer on the crankshaft.
    3. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown in Fig 2 .

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

      If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.

      Fig 2: Tightening Mounting Bolts In Sequence
      G04435857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the mounting bolts with paint.
      Fig 3: Marking Mounting Bolts With Paint
      G04435858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the mounting bolts another 90° in the same sequence shown in Fig 2 .
    6. Check that the painted mark is now at a 90° angle.
  29. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 
    1. Install the automatic transmission to the engine with the 10 bolts.

      Torque: 

      • 37 N*m (377 kgf*cm, 27 ft.*lbf) for 14 mm head 
      • 72 N*m (734 kgf*cm, 53 ft.*lbf) for 17 mm head 
      Fig 4: Installing Automatic Transmission To Engine With Bolts
      G04435859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 6 torque converter clutch mounting bolts.

      Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf) 

      HINT:

      First install the black colored bolt, then install the other bolts.

      Fig 5: Installing Torque Converter Clutch Mounting Bolts
      G04435860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the under cover with the bolt.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    Fig 6: Installing Under Cover
    G04435861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL ENGINE AND TRANSMISSION ASSEMBLY 
    1. Attach the engine chain hoist to the engine hangers.
    2. Slowly lower the engine and the transmission assembly into the engine compartment.
      Fig 7: Lowering Engine & Transmission Assembly Into Engine Compartment
      G04435862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach the engine mounting brackets to the frame brackets.
    4. Keep the engine level with a jack.
      Fig 8: Keeping Engine Level With Jack
      G04435863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the frame crossmember with the 8 bolts and 4 nuts.

      Torque:  

      • 50 N*m (510 kgf*cm, 37 ft.*lbf) for bolts 
      • 74 N*m (755 kgf*cm, 55 ft.*lbf) for nuts 
      Fig 9: Installing Frame Crossmember
      G04435864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the transfer case protector with the 3 bolts.
    7. Install the 2 nuts and the 4 bolts holding the engine mounting brackets to the frame brackets.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      Fig 10: Installing Engine Mounting Brackets To Frame Brackets
      G04435865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the engine chain hoist.
  32. INSTALL REAR PROPELLER SHAFT (See  INSTALLATION  ) 
  33. INSTALL FRONT PROPELLER SHAFT (See  INSTALLATION  ) 
  34. INSTALL VANE PUMP (See  REASSEMBLY  ) 
  35. INSTALL COMPRESSOR ASSEMBLY (See  INSTALLATION  ) 
  36. INSTALL FRONT EXHAUST PIPE ASSEMBLY LH (See  INSTALLATION  ) 
  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY RH (See  INSTALLATION  ) 
  38. INSTALL HEATER HOSE 
  39. INSTALL NO. 2 FUEL HOSE (See  INSTALLATION  ) 
  40. INSTALL NO. 1 FUEL HOSE (See  INSTALLATION  ) 
  41. CONNECT ENGINE WIRE 
    1. Connect the generator wire.
    2. Connect the generator connector.
    3. Connect the hose clamp for the PS air hose.
    4. Connect the engine wire clamp to the bracket on the cowl panel.
    5. Connect the engine wire grommet to the cowl panel.
    6. Connect the ground strap connector.
    7. Connect the clamp on negative (-) battery cable to the relay box.
    8. Connect the negative (-) battery cable to the right fender apron.
    9. Connect the positive (+) battery terminal cable.
    10. Connect the 3 ECM connectors.
  42. INSTALL DRIVE BELT (See  INSTALLATION   ) 
  43. INSTALL RADIATOR ASSEMBLY (See  INSTALLATION  ) 
  44. INSTALL FAN SHROUD (See  INSTALLATION  ) 
  45. INSTALL NO. 1 OIL COOLER OUTLET TUBE (See  INSTALLATION  ) 
  46. INSTALL NO. 1 OIL COOLER INLET TUBE (See  INSTALLATION  ) 
  47. INSTALL RADIATOR HOSE OUTLET (See  INSTALLATION  ) 
  48. INSTALL RADIATOR HOSE INLET (See  INSTALLATION  ) 
  49. INSTALL AIR CLEANER ASSEMBLY 
    1. Install the air cleaner assembly with the 3 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    2. Connect the MAF meter connector and clamp to the air cleaner.
  50. INSTALL INTAKE AIR CONNECTOR PIPE (See  INSTALLATION  ) 
  51. ADD AUTOMATIC TRANSMISSION FLUID 

    See AUTOMATIC TRANSMISSION FLUID .

  52. ADD ENGINE COOLANT (See  REPLACEMENT  ) 
  53. ADD ENGINE OIL (See  REPLACEMENT  ) 
  54. INSTALL REAR ENGINE UNDER COVER (See  INSTALLATION   ) 
  55. INSTALL NO. 1 ENGINE UNDER COVER (See  INSTALLATION   ) 
  56. INSTALL V-BANK COVER (See  INSTALLATION  ) 
  57. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood with the 4 bolts.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    2. Connect the hood damper.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    3. Connect the windshield washer hose.
  58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  59. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  60. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
  61. CHECK IGNITION TIMING (See  ON-VEHICLE INSPECTION   ) 
  62. CHECK ENGINE IDLE SPEED (See  ON-VEHICLE INSPECTION   ) 
  63. CHECK CO/HC (See  ON-VEHICLE INSPECTION   ) 
  64. CHECK FOR ENGINE OIL LEAKS 
  65. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  66. CHECK ENGINE OIL LEVEL (See  ON-VEHICLE INSPECTION  ) 
  67. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL (See  AUTOMATIC TRANSMISSION FLUID  ) 
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