Installation

4GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, install the temperature sensor.

Torque : 20 Nm (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 Nm (153 kgf-cm, 11 ft-lbf)

NOTICE:
Do not start the engine within 1 hour after installation for prevent oil leaks.

3. INSTALL ENGINE OIL LEVEL SENSOR

(a) Install the engine oil level sensor and a new gasket with the 4 bolts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

4. INSTALL IGNITION COIL ASSEMBLY

(a) Install the 6 ignition coils with the 6 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

5. INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY

(a) Install the V-bank cover bracket with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

6. INSTALL WIRING HARNESS CLAMP BRACKET

(a) Install the wiring harness clamp bracket with the bolt

Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)

7. INSTALL KNOCK SENSOR Installation

8. INSTALL FUEL INJECTOR ASSEMBLY

HINT
Installation.

9. INSTALL FUEL PUMP

HINT
Installation.

10. INSTALL INTAKE MANIFOLD Installation

11. INSTALL WATER HOSE JOINT

(a) Connect the 2 hoses, and install the bolt and water hose joint.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

12. INSTALL NO. 2 SURGE TANK STAY

(a) Install the bolt and No. 2 surge tank stay.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

13. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

HINT
Installation.

14. INSTALL INJECTOR DRIVER

(a) Install the injector driver with the bolt and 2 nuts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

15. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine assembly.

16. INSTALL WATER PUMP PULLEY Installation

17. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.(2WD)

(b) Temporarily install the V-ribbed belt tensioner with the 4 bolts.(4WD)

Each bolt length is as follows:

(c) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

(d) Tighten the other bolts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

19. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the mounting bracket with the 4 bolts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

(b) Connect the 2 clamps.

20. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the mounting bracket with the 4 bolts.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

21. INSTALL COOLER COMPRESSOR ASSEMBLY (for 2WD) Installation

22. TEMPORARILY TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD) Installation

23. INSTALL OIL FILTER BRACKET (for 4WD) Installation

24. INSTALL COOLER COMPRESSOR ASSEMBLY (for 4WD) Installation

25. INSTALL GENERATOR ASSEMBLY Installation

26. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the plate and idler pulley with the bolt.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

27. INSTALL NO. 1 ENGINE COVER

(a) Install the No. 1 engine cover with the 3 clips.

28. INSTALL NO. 2 ENGINE COVER

(a) Install the No. 2 engine cover with the 3 clips.

(b) Connect the clamp.

29. INSTALL V-RIBBED BELT Installation

30. INSTALL ENGINE HANGERS

Torque : 33 Nm (336 kgf-cm, 24 ft-lbf)

31. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

(a) Hold the crankshaft with SST.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Using several steps, install and tighten 8 new bolts uniformly in the sequence shown in the illustration.

Torque : 73 Nm (741 kgf-cm, 54 ft-lbf)

NOTICE:
* Do not reuse the flywheel installation bolts. Be sure to check the tightening torque within 5 minutes after tightening.
* Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
* Make sure that the seating surface of the flywheel installation bolts and installation surfaces of the crankshaft and flywheel are free of oil or foreign matter.

32. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

(a) Using SST, hold the crankshaft.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Apply adhesive to 2 or 3 threads of the mounting bolts ends.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the front spacer, drive plate and rear spacer on the crankshaft.

(d) Install and tighten the 8 mounting bolts uniformly in several steps.

Torque : 83 Nm (846 kgf-cm, 61 ft-lbf)

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

33. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)

(a) Install the front suspension crossmember sub-assembly with the 2 bolts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

34. INSTALL FRONT FRAME ASSEMBLY (for 4WD)

(a) Install the front frame assembly with the 2 bolts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

35. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)

36. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

37. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

HINT
Installation.

38. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

HINT
* A960E Installation.
* A760H .

39. INSTALL STARTER ASSEMBLY Installation

40. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

(b) Install the exhaust manifold with 6 new nuts.

LH:

(b) Install the exhaust manifold with 6 new nuts.

RH:

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

NOTICE:
* Do not damage the stud bolt when installing the exhaust manifold.
* Be sure to tighten either of nuts A first as shown in the illustration.

42. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD)

(a) Install a new O-ring to the oil dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push in the oil dipstick guide end into the guide hole.

(d) Install the No. 1 oil dipstick guide with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(e) Connect the clamp.

(f) Install the No. 2 oil dipstick guide with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(g) Install the oil dipstick.

43. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD)

(a) Install a new O-ring to the oil dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push in the oil dipstick guide end into the guide hole.

(d) Install the No. 1 oil dipstick guide with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(e) Install the No. 2 oil dipstick guide with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(f) Install the oil dipstick.

44. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

45. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)

(a) Set the engine lifter.

(b) Operate the engine lifter, then install the engine to the vehicle.

(c) Install the engine and transmission assembly with crossmember with the 2 nuts and 10 bolts.

Torque : 154 Nm (1570 kgf-cm, 114 ft-lbf) for nut

Torque : 188 Nm (1917 kgf-cm, 139 ft-lbf) for bolt A

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf) for bolt B

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf) for bolt C

(d) Install the engine rear mounting member with the 4 bolts.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

46. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 4WD)

(a) Set the engine lifter.

(b) Operate the engine lifter, then install the engine to the vehicle.

(c) Install the engine and transmission assembly with crossmember with the 2 nuts and 6 bolts.

Torque : 154 Nm (1570 kgf-cm, 114 ft-lbf) for nut

Torque : 154 Nm (1570 kgf-cm, 114 ft-lbf) for bolt A

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf) for bolt B

(d) Install the engine rear mounting member with the 4 bolts.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

47. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) Installation

48. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD)

49. CONNECT POWER STEERING LINK WIRE HARNESS (for 2WD)

(a) Install the power steering earth wire to the power steering link assembly with bolt (B).

Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)

(b) Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.

(c) Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.

(d) Install the 2 wire harness clamps to the power steering link assembly.

(e) Connect the earth wire to the bracket with bolt (A).

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

50. CONNECT POWER STEERING LINK WIRE HARNESS (for 4WD)

(a) Install the power steering earth wire to the power steering link assembly with bolt (A).

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(b) Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.

(c) Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.

(d) Install the 2 wire harness clamps to the front frame.

(e) Connect the earth wire to the bracket with bolt (B).

Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)

(f) Install the bolt (F) to connect the bracket to the front frame.

Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)

51. INSTALL FRONT AXLE ASSEMBLY LH (for 4WD)

52. INSTALL FRONT AXLE ASSEMBLY RH (for 4WD)

HINT
Install the RH side following the same procedures as for the LH side.

53. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)

(a) Install the front lower ball joint with the 2 bolts.

Torque : 120 Nm (1,224 kgf-cm, 89 ft-lbf)

54. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)

HINT
Install the RH side following the same procedures as for the LH side.

55. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)

(a) Install the front lower ball joint with the 2 bolts.

Torque : 120 Nm (1,224 kgf-cm, 89 ft-lbf)

56. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)

HINT
Install the RH side following the same procedures as for the LH side.

57. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)

(a) Install the bolt on the lower side of the front shock absorber while holding the nut.

Torque : 157 Nm (1,600 kgf-cm, 116 ft-lbf)

58. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT
Install the RH side following the same procedures as for the LH side.

59. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)

(a) Install the bolt on the lower side of the front absorber bracket lower.

Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)

60. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT
Install the RH side following the same procedures as for the LH side.

61. CONNECT HEIGHT CONTROL SENSOR LINK (for 2WD)

(a) Connect the height control sensor link and install it with the nut.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

62. CONNECT HEIGHT CONTROL SENSOR LINK (for 4WD)

(a) Connect the height control sensor link and install it with the bolt.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

63. INSTALL TIE ROD ASSEMBLY LH (for 4WD) Installation

64. INSTALL TIE ROD ASSEMBLY RH (for 4WD)

HINT
Install the RH side following the same procedures as for the LH side.

65. INSTALL FRONT AXLE HUB LH NUT (for 4WD)

66. INSTALL FRONT AXLE HUB RH NUT (for 4WD)

HINT
Install the RH side following the same procedures as for the LH side.

67. INSTALL FRONT SPEED SENSOR LH (for 4WD) Installation

68. INSTALL FRONT SPEED SENSOR RH (for 4WD)

HINT
Install the RH side following the same procedures as for the LH side.

69. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD) Installation

70. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) Installation

71. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD)

(a) Install the protector with the 4 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

72. CONNECT NO. 3 FUEL HOSE

(a) Connect the No. 3 fuel hose and clamp.

73. CONNECT FUEL MAIN TUBE

HINT
Service Precautions.

74. CONNECT ENGINE WIRE

(a) Install the bolt, clamp and engine wire No. 3.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(b) Connect the ground cable and install it with the bolt.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(c) Connect the connector and install the 4 clamps to the body.

(d) Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.

Torque : 12 Nm (124 kgf-cm, 9 ft-lbf)

(e) Install the engine room No. 1 relay block cover.

(f) Connect the battery positive (+) cable and install it with the nut.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(g) Connect the ECM connectors.

(h) Connect the connector holder.

75. INSTALL ECM COVER Installation

76. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

77. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

78. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

79. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.

80. CONNECT INLET RADIATOR HOSE

(a) Install the clamp and connect the inlet radiator hose.

81. CONNECT OUTLET RADIATOR HOSE

(a) Install the clamp and connect the outlet radiator hose.

82. CONNECT RADIATOR RESERVOIR TANK HOSE

(a) Install the clamp and connect the reservoir tank hose.

83. CONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 2 fuel vapor feed hose.

84. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the hose to the surge tank.

85. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case, clamp and 2 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

86. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation

87. INSTALL NO. 1 INLET AIR CLEANER

(a) Install the inlet air cleaner with the bolt.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

88. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

HINT
Installation.

89. INSTALL FRONT EXHAUST PIPE ASSEMBLY

HINT
Installation.

90. ADD FRONT DIFFERENTIAL OIL (for 4WD) Adjustments

91. ADD ENGINE OIL (for 2WD) Replacement

92. ADD ENGINE OIL (for 4WD) Replacement

93. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

94. ADD ENGINE COOLANT Testing and Inspection

95. CHARGE REFRIGERANT Service and Repair

96. INSPECT FOR FUEL LEAK Fuel System

97. INSPECT COOLANT LEAK Testing and Inspection

98. INSPECT OIL LEAK

99. INSPECT EXHAUST GAS LEAK

100. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair

101. INSTALL FRONT WHEEL

Torque : 103 Nm (1,050 kgf-cm, 76 ft-lbf)

102. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

103. ADJUST SHIFT LEVER POSITION Adjustments

104. CHECK SHIFT LEVER POSITION Initial Inspection and Diagnostic Overview

105. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

106. CHECK IGNITION TIMING On-Vehicle Inspection

107. CHECK ENGINE IDLE SPEED On-Vehicle Inspection

108. CHECK CO / HC On-Vehicle Inspection

109. CHECK ENGINE OIL LEVEL Testing and Inspection

110. CHECK FRONT DIFFERENTIAL OIL LEVEL (for 4WD) Adjustments

111. INSTALL ENGINE UNDER COVER REAR LH (for 2WD)

(a) Install the engine under cover rear LH with the bolt.

112. INSTALL ENGINE UNDER COVER REAR RH (for 2WD)

HINT
Install the RH side following the same procedures as for the LH side.

113. INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)

114. INSTALL ENGINE UNDER COVER

115. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 2 clips on the front of the cover, and then engage the clip on the rear to install the V-bank 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.

116. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the side cover with the 5 clips.

117. INSTALL ENGINE ROOM SIDE COVER RH

(a) Install the side cover with the 2 clips.

118. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 11 clips.