Installation

ENGINE ASSEMBLY

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

COMPONENTS (Part 15):

INSTALLATION
1. REMOVE ENGINE STAND
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Remove the bolts and engine assembly from the engine stand.
2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
5. INSTALL NO. 2 AIR TUBE
6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
7. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
8. INSTALL NO. 3 AIR TUBE
9. INSTALL ENGINE ASSEMBLY
(a) Slowly lower the engine assembly into the engine compartment.

NOTICE: Make sure that the engine is clear of all wiring and hoses.

(b) Attach the engine mounting insulators to the vehicle.

10. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
(b) Install the front drive plate spacer, drive plate and rear drive plate spacer on the crankshaft.

(c) Install and uniformly tighten 8 new bolts in the sequence shown in the illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

NOTICE:
^ Do not reuse the flywheel installation bolts.
^ Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.

(d) Mark the upside of each flywheel installation bolt with paint.
(e) Retighten the flywheel installation bolts by 90° as shown.
(f) Check that the painted marks are now at a 90° angle to the upside.
11. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD, refer to the following procedures.
(b) for 4WD, refer to the following procedures.
12. INSTALL PROPELLER SHAFT ASSEMBLY
(a) for 2 joint type, refer to the following procedures.
(b) for 3 joint type, refer to the following procedures.
13. INSTALL EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures.
(b) except Regular cab standard deck, refer to the following procedures.

14. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install the water by-pass pipe with the 2 bolts.
15. INSTALL GENERATOR ASSEMBLY
16. CONNECT VANE PUMP ASSEMBLY
17. CONNECT COOLER COMPRESSOR ASSEMBLY

18. CONNECT WIRE HARNESS AND HOSE
(a) Connect the 3 connectors to the engine room junction block.
(b) Install the engine wire with the nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(c) Connect the 4 air injection control driver connectors.
(d) Install the ground wire with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(e) Connect the positive (+) battery terminal and install the engine wire with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

(f) Connect the air injection system hose.
(g) Install the ground wire with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(h) Connect the air pump connector and install the connector bracket with the bolt.
Torque: 4.0 N*m (41 kgf*cm, 35 in.*lbf)

(i) Connect the 4 connectors to the connector holder block.

(j) Connect the heater hoses.
(k) Connect the ECM connector and clamp.

HINT: Refer to the following procedures to connect the ECM connector.

(l) Connect the vacuum hose assembly.

19. CONNECT FUEL MAIN AND RETURN HOSE
(a) Connect the fuel main and return hoses.
(b) Install the fuel pipe clamp.
20. INSTALL RADIATOR ASSEMBLY
21. INSTALL OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Install the oil cooler.
22. INSTALL FLUID COUPLING ASSEMBLY
23. INSTALL FAN AND GENERATOR V BELT
24. INSTALL RADIATOR HOSE OUTLET
25. INSTALL RADIATOR HOSE INLET
26. INSTALL RADIATOR SIDE DEFLECTOR LH
27. INSTALL RADIATOR SIDE DEFLECTOR RH
28. INSTALL AIR CLEANER ASSEMBLY
29. INSTALL AIR CLEANER HOSE ASSEMBLY
30. ADD ENGINE OIL
31. ADD ENGINE COOLANT
32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE: Some systems need to be initialized after the cable is reconnected.

33. INSPECT FOR OIL LEAK
(a) Inspect the engine oil leak.
34. INSPECT FOR COOLANT LEAK
35. INSPECT FOR EXHAUST GAS LEAK
36. INSPECT FOR FUEL LEAK
37. INSPECT SHIFT LEVER POSITION
38. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY
39. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY
40. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor.
41. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

(b) Attach the lower part of the 2 food supports to the hood support bolt ball joints.

NOTICE: Install the hood support while supporting the hood by hand.

(c) Attach the hood support clips.

NOTICE: Check that the hood support is engaged in the ball joint and it cannot be pulled out.

42. ADJUST HOOD SUB-ASSEMBLY
43. INSTALL NO. 1 ENGINE UNDER COVER
44. CHECK IGNITION TIMING
45. CHECK ENGINE IDLE SPEED
46. CHECK CO/HC
47. CHECK ENGINE OIL LEVEL
48. CHECK ENGINE COOLANT LEVEL