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Partial Engine: Replacement

  1. INSTALL ENGINE STAND

    REMOVE THROTTLE BODY ASSEMBLY, see REMOVAL (GS430, LS430 & SC430) .

  2. REMOVE INTAKE MANIFOLD ASSEMBLY
    1. Disconnect the VSV connector for EVAP.
    2. Disconnect the EVAP hose from the VSV for EVAP.
    3. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
    4. Remove the bolt and V-bank cover bracket No. 2.
    5. Remove the bolt and V-bank cover bracket No. 3.
    6. Disconnect the VSV connector for ACIS.
    7. Remove the bolt and V-bank cover bracket No. 1.
    8. Remove the bolt and V-bank cover fastener.
    9. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from upper intake manifold and camshaft bearing cap.
    10. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
    11. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water bypass joint and RH cylinder head.
    12. Disconnect the 8 injector connectors.
    13. Remove the 6 bolts, 4 nuts, the intake manifold assembly and 2 gaskets.
  3. REMOVE STARTER ASSEMBLY, see REMOVAL & INSTALLATION .
  4. REMOVE GENERATOR ASSEMBLY, see REPLACEMENT .

    REMOVE TIMING BELT COVER SUB-ASSEMBLY N0. 3 LH, see REPLACEMENT .

    1. Remove the cap nut and disconnect the water by-pass pipe No. 3 from the timing belt cover.
    2. Disconnect the 2 water by-pass hoses from the water by-pass pipe No. 3.
    3. Disconnect the engine wire from the 2 wire clamps.
    4. Disconnect the camshaft position sensor connector.
    5. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
    6. Remove the wire grommet from the timing belt cover.
    7. Remove the 4 bolts.
    8. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
    9. Disconnect the wire clamp for the sensor from the timing belt cover.
    10. Remove the connector holder from the sensor connector.
    11. Remove the timing belt cover.
  5. REMOVE TIMING CHAIN OR BELT COVER NO. 2
    1. Disconnect the 2 PS air hoses from the clamp on the timing belt cover No. 2.
    2. Remove the cap nut, 3 bolts, timing belt cover No. 2 and gasket.
  6. REMOVE WATER INLET HOUSING, see REPLACEMENT .
  7. REMOVE WATER BY-PASS JOINT FR
    1. Disconnect the ECT sensor connector.
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  8. REMOVE WATER BY-PASS JOINT RR
    1. Disconnect the heater inlet hose from the water by-pass joint.
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  9. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
    1. Disconnect the heater outlet hose from the water by-pass pipe.
    2. Disconnect the wire clamp (for knock sensor 1, 2) from bracket of the water by-pass pipe.
    3. Remove the bolt.
    4. Pull out the water by-pass pipe from the water pump.
    5. Remove the O-ring from the water by-pass pipe.
  10. REMOVE OIL LEVEL GAGE GUIDE
  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
  13. REMOVE CAM POSITION SENSOR ASSEMBLY
  14. REMOVE VVT SENSOR
  15. REMOVE KNOCK CONTROL SENSOR
  16. REMOVE ENGINE HANGER NO. 1
  17. REMOVE ENGINE HANGER NO. 2
  18. REMOVE IGNITION COIL ASSEMBLY
  19. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
    1. Disconnect the oil pressure switch connector.
    2. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.
  20. REMOVE CRANK POSITION SENSOR
  21. REMOVE ENGINE OIL LEVEL SENSOR
  22. REMOVE ENGINE WIRE
  23. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
  24. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
  25. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
  26. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
  27. REMOVE WIRING HARNESS HEAT INSULATOR NO. 2
  28. REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 RH
  29. REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 LH
  30. INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 LH
    1. Install the mounting bracket with the 4 bolts
      Fig 1: Installing Engine Mounting Bracket Front No. 1 (LH)
      G03387247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

    NOTE: The LH mounting bracket is marked with "L".
  31. INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 RH
    1. Install the mounting bracket with the 4 bolts

      Torque: 36 N.m (370 kgf.cm, 27 ft.lbf) 

    NOTE: The RH mounting bracket is marked with "R".
    Fig 2: Installing Engine Mounting Bracket Front No. 1 (RH)
    G03387248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL WIRING HARNESS HEAT INSULATOR NO. 2
  33. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
    1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
      Fig 3: Identifying White Mark Position On Exhaust Manifold Gasket
      G03387249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Be careful of the installation direction.
    2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

  34. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
  35. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
    1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
      NOTE: Be careful of the installation direction.
    2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.

      Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

    Fig 4: Identifying White Mark Position On Exhaust Manifold Gasket
    G03387250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
  37. INSTALL ENGINE WIRE
  38. INSTALL ENGINE OIL LEVEL SENSOR
  39. INSTALL CRANK POSITION SENSOR, see CRANKSHAFT POSITION (CKP) SENSOR .
  40. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

    Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

  41. INSTALL IGNITION COIL ASSEMBLY

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  42. INSTALL ENGINE HANGER NO. 2

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  43. INSTALL ENGINE HANGER NO. 1

    Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 

  44. INSTALL KNOCK CONTROL SENSOR

    Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) 

  45. INSTALL VVT SENSOR
  46. INSTALL CAM POSITION SENSOR ASSEMBLY

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  47. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
  48. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY 
  49. INSTALL OIL LEVEL GAGE GUIDE
  50. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
    1. Install a new O-ring to the water by-pass pipe.
    2. Apply soapy water to the O-ring.
    3. Push in the water by-pass pipe end into the pipe hole of the water pump.
    4. Install the water by-pass pipe with the bolt.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    5. Install the wire clamp to the bracket of the water by-pass pipe.
  51. INSTALL WATER BY-PASS JOINT RR
    1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

  52. INSTALL WATER BY-PASS JOINT FR
    1. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    2. Connect the ECT sensor connector.
  53. INSTALL WATER INLET HOUSING, see REPLACEMENT .
  54. INSTALL TIMING CHAIN OR BELT COVER NO. 2
    1. Install the gasket to the timing belt cover.
    2. Install the timing belt cover with the cap nut and 3 bolts.
    3. Connect the 2 PS air hoses to the clamp on the timing belt cover.
  55. INSTALL TIMING BELT COVER SUB-ASSEMBLY N0. 3 LH
    1. Install the gasket to the timing belt cover.
    2. Run the camshaft position sensor wire through the timing belt cover hole.
    3. Install the timing belt cover with the 4 bolts.
    4. Install the wire grommet to the timing belt cover.
    5. Install the sensor connector to the sensor holder.
    6. Connect the sensor connector.
    7. Install the sensor wire to the wire clamp on the timing belt cover.
    8. Install the engine wire to the 2 wire clamps on the timing belt cover.
    9. Connect the 2 water by-pass hoses to the water by-pass pipe No. 3.
    10. Install the No. 3 water by-pass pipe to the timing belt cover No. 3 LH with the cap nut.
    Fig 5: Installing Timing Belt Cover Sub-Assembly No. 3 LH
    G03387251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL GENERATOR ASSEMBLY, see  REPLACEMENT  . 
  57. INSTALL STARTER ASSEMBLY, see  REMOVAL & INSTALLATION  . 
  58. INSTALL INTAKE MANIFOLD ASSEMBLY 
    1. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
      NOTE: Be careful of the installation direction.
      Fig 6: Identifying White Mark Position On Intake Manifold Gasket
      G03387252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the intake manifold assembly with the 6 bolts and 4 nuts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    3. Connect the 8 injector connectors.
      Fig 7: Installing Intake Manifold Assembly
      G03387253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire protector (rear side) with the 2 bolts.
    5. Install the engine wire protector (LH side) with the 4 bolts.
    6. Install the 2 wire clamps on the engine wire (RH side the brackets on the RH delivery pipe.
      Fig 8: Installing Wire Clamp On Engine Wire (RH Side)
      G03387254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the V-bank cover fastener with bolt.
    8. Install the V-bank cover bracket No. 1 with bolt.
    9. Connect the VSV connector for ACIS.
      Fig 9: Connecting VSV Connector For ACIS
      G03387255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the V-bank cover bracket No. 3 with bolt.
    11. Install the V-bank cover bracket No. 2 with bolt.
    12. Connect the VSV for EVAP to the intake manifold with the bolt.
    13. Connect the EVAP hose to the VSV for EVAP.
    14. Connect the VSV connector for EVAP.
    Fig 10: Installing V-Bank Cover Bracket
    G03387256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL THROTTLE BODY ASSEMBLY, see REMOVAL (GS430, LS430 & SC430) .
  60. REMOVE ENGINE STAND
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