Installation
ENGINE ASSEMBLYINSTALLATION
1. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
2. INSTALL OIL PRESSURE SWITCH
3. INSTALL IGNITION COIL
4. INSTALL KNOCK SENSOR
5. INSTALL CRANKSHAFT POSITION SENSOR
6. INSTALL VVT SENSOR (for Bank 1)
7. INSTALL VVT SENSOR (for Bank 2)
8. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1)
9. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2)
10. INSTALL STARTER ASSEMBLY
11. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
12. INSTALL REAR WATER BY-PASS JOINT
13. INSTALL FRONT WATER BY-PASS JOINT
14. INSTALL WATER INLET HOUSING
15. INSTALL OIL COOLER PIPE
16. INSTALL NO. 2 ENGINE HANGER
17. INSTALL NO. 1 ENGINE HANGER
18. INSTALL GENERATOR ASSEMBLY
19. INSTALL INTAKE MANIFOLD ASSEMBLY
20. INSTALL FRONT ENGINE MOUNTING BRACKET LH
(a) 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
(a) 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
23. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
24. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
25. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
26. INSTALL OIL DIPSTICK GUIDE
27. REMOVE ENGINE STAND
28. INSTALL DRIVE PLATE 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 in the illustration.
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.
(d) Mark the mounting bolts with paint.
(e) Tighten the mounting bolts another 90° in the same sequence shown in the step above.
(f) Check that the painted mark is now at a 90° angle.
29. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) 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
(b) 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.
30. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the under cover with the bolt.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
31. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine and the transmission assembly into the engine compartment.
(c) Attach the engine mounting brackets to the frame brackets.
(d) Keep the engine level with a jack.
(e) 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
(f) Install the transfer case protector with the 3 bolts.
(g) 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)
(h) Remove the engine chain hoist.
32. INSTALL REAR PROPELLER SHAFT
33. INSTALL FRONT PROPELLER SHAFT
34. INSTALL VANE PUMP
35. INSTALL COMPRESSOR ASSEMBLY
36. INSTALL FRONT EXHAUST PIPE ASSEMBLY LH
37. INSTALL FRONT EXHAUST PIPE ASSEMBLY RH
38. INSTALL HEATER HOSE
39. INSTALL NO. 2 FUEL HOSE
40. INSTALL NO. 1 FUEL HOSE
41. CONNECT ENGINE WIRE
(a) Connect the generator wire.
(b) Connect the generator connector.
(c) Connect the hose clamp for the PS air hose.
(d) Connect the engine wire clamp to the bracket on the cowl panel.
(e) Connect the engine wire grommet to the cowl panel.
(f) Connect the ground strap connector.
(g) Connect the clamp on negative (-) battery cable to the relay box.
(h) Connect the negative (-) battery cable to the right fender apron.
(i) Connect the positive (+) battery terminal cable.
(j) Connect the 3 ECM connectors.
42. INSTALL DRIVE BELT
43. INSTALL RADIATOR ASSEMBLY
44. INSTALL FAN SHROUD
45. INSTALL NO. 1 OIL COOLER OUTLET TUBE
46. INSTALL NO. 1 OIL COOLER INLET TUBE
47. INSTALL RADIATOR HOSE OUTLET
48. INSTALL RADIATOR HOSE INLET
49. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the MAF meter connector and clamp to the air cleaner.
50. INSTALL INTAKE AIR CONNECTOR PIPE
51. ADD AUTOMATIC TRANSMISSION FLUID
Add automatic transmission fluid.
52. ADD ENGINE COOLANT
53. ADD ENGINE OIL
54. INSTALL REAR ENGINE UNDER COVER
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL V-BANK COVER
57. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(b) Connect the hood damper.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Connect the windshield washer hose.
58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
59. CHECK FOR FUEL LEAKS
60. PERFORM INITIALIZATION Testing and Inspection
(a) Perform initialization.
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
61. CHECK IGNITION TIMING
62. CHECK ENGINE IDLE SPEED
63. CHECK CO/HC
64. CHECK FOR ENGINE OIL LEAKS
65. CHECK FOR ENGINE COOLANT LEAKS
66. CHECK ENGINE OIL LEVEL
67. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL