Engine Unit: Installation

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

HINT.

When viewed from the rear of the engine assembly, Bank 1 is on the left side and Bank 2 is on the right side.

Fig 1: Locating Oil Filler Cap Housing Bolts

INSTALL IGNITION COIL ASSEMBLY
1. Install the 8 ignition coils with the 8 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 2: Locating Ignition Coils Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KNOCK CONTROL SENSOR
1. Install the 4 knock control sensors with the 4 bolts so that the sensors are angled as shown in the illustration
  Torque: 20 N.m (204 kgf/cm, 15 ft.lbf)
  
  NOTE: The acceptable installation angle of the knock control sensors is between 10° above and below the horizontal position.
  
  Fig 3: Identifying Knock Control Sensor Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE WIRE
1. Install the engine wire with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
2. Connect the 5 clamps and 4 connectors.
  
  Fig 4: Locating Engine Wire Bolt And Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL SEPARATOR CASE
1. Install the separator case with the 4 bolts
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
INSTALL FUEL INJECTOR SEAL (See INSTALLATION )
INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) (See INSTALLATION )
INSTALL FUEL DELIVERY PIPE (See INSTALLATION )
INSTALL NO. 2 FUEL DELIVERY PIPE (See INSTALLATION ).
INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION ).
INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH (See INSTALLATION ).

Fig 5: Locating Separator Case Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY (See INSTALLATION ).
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See INSTALLATION ).
INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection) (See INSTALLATION ).
INSTALL FUEL DELIVERY PIPE ASSEMBLY (See INSTALLATION ).
INSTALL WATER INLET HOUSING (See INSTALLATION ).
INSTALL FUEL PUMP ASSEMBLY (for Bank 1) (See INSTALLATION ).
INSTALL FUEL PUMP ASSEMBLY (for Bank 2) (See INSTALLATION ).
INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION ).
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION ).
INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See INSTALLATION ).
INSTALL FUEL TUBE SUB-ASSEMBLY (See INSTALLATION ).
INSTALL INTAKE MANIFOLD ASSEMBLY
1. Install 2 new gaskets to the intake manifold.
2. Temporarily install the intake manifold with the 2 nuts and 8 bolts Then tighten the 2 nuts and 8 bolts uniformly in the order shown in the illustration.
  Torque: 21 N.m (214 kgf/cm, 15 ft.lbf)
  
  Fig 6: Locating Tightening Sequence Of Intake Manifold Nuts And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the No. 1 ventilation hose and 2 water bypass hoses as shown in the illustration.
  
  Fig 7: Locating Ventilation Hose And Water Bypass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Slide the clamp to connect the water inlet hose to the front water by-pass joint.
2. Install the water by-pass pipe with the 2 bolts.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 8: Locating Water By-Pass Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER WATER PUMP ASSEMBLY
1. Install the heater water pump with the bolt.
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
2. Slide the 2 clamps to connect the 2 hoses to the water by-pass pipe and water inlet housing.
  
  Fig 9: Locating Heater Water Pump Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PURGE VSV
1. Install the purge VSV with the bolt.
  Torque: 21 N.m (214 kgf/cm, 15 ft.lbf)
2. Connect the purge line hose to the intake manifold.
  
  Fig 10: Locating Purge VSV Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 ENGINE COVER
INSTALL INJECTOR DRIVER
NOTE:
- Be careful not to drop or strike the injector driver.
- The injector driver is grounded at the bolt and nut. To ensure that it is grounded, clean all oil and foreign matter from the installation areas of the injector driver and engine before installing the injector driver.
  
  Fig 11: Identifying Engine Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Temporarily install the 2 injector drivers with the 2 bolts and 2 nuts
2. Tighten the 2 bolts and 2 nuts in the order shown in the illustration
  Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  
  Fig 12: Locating Injector Drivers With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE WIRE
1. Engine Upper Side.
  1. Connect the engine wire with the 4 nuts.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  2. Install the 2 clamp brackets with the 2 bolts and connect the 2 clamps.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  3. Connect the intake air control valve actuator connector.
  4. Connect the purge VSV connector.
    
    Fig 13: Locating Clamp Brackets And Engine Wire Nuts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Connect the 2 clamps.
  6. Connect the 8 injector driver connectors as shown in the illustration.
    
    Fig 14: Connecting Injector Driver Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Engine Rear Side:
  1. Connect the 2 ground wires with the 2 bolts.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  2. Connect the 8 clamps.
  3. Connect the fuel relief valve connector.
  4. Connect the engine wire connector.
    
    Fig 15: Locating Ground Wires Bolts And Engine Wire Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Engine RH Side-
  1. Connect the 4 clamps.
  2. Connect the fuel injector connector
  3. Connect the camshaft position sensor connector
  4. Connect the engine wire connector.
  5. Connect the fuel pump connector (for high pressure).
  6. Connect the 2 VVT sensor connectors
  7. Connect the 4 ignition coil connectors
  8. Connect the camshaft timing control valve connector.
  9. Connect the 2 clamps and HC VSV1 connector
    
    Fig 16: Locating Fuel Injector Connector, Camshaft Position Sensor Connector And Engine Wire Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Engine Front Side:
  1. Connect the 3 ground wires with the 3 bolts.
    Torque: 10 N.m (102 kgf/cm, 7 ft.lbf)
  2. Connect the clamp.
  3. Connect the 2 camshaft timing control motor connectors (for Bank 2).
  4. Connect the 2 camshaft timing control motor connectors (for Bank 1).
  5. Connect the engine coolant temperature sensor connector.
    
    Fig 17: Locating Camshaft Timing Control Motor Connectors And Engine Coolant Temperature Sensor Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Engine LH Side:
  1. Connect the 4 clamps.
  2. Connect the fuel injector connector.
  3. Connect the fuel pump connector (for high pressure).
  4. Connect the 2 VVT sensor connectors
  5. Connect the 4 ignition coil connectors
  6. Connect the camshaft timing control valve connector
    
    Fig 18: Locating Camshaft Timing Control Valve Connector, Ignition Coil Connectors And VVT Sensor Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 5 COVER SUB-ASSEMBLY (See INSTALLATION ).
INSTALL ENGINE COVER SUB-ASSEMBLY RH (See INSTALLATION ).
INSTALL NO. 6 COVER SUB-ASSEMBLY (See INSTALLATION ).
INSTALL ENGINE COVER SUB-ASSEMBLY LH (See INSTALLATION ).
INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (See INSTALLATION ).
INSTALL WITH MOTOR COMPRESSOR ASSEMBLY (See INSTALLATION ).
INSTALL V-RIBBED BELT (See INSTALLATION )