Installation
2UZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:
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 (Installation)
3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (Installation)
4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (Installation)
5. INSTALL NO. 2 AIR TUBE (Installation)
6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (Installation)
7. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (Installation)
8. INSTALL NO. 3 AIR TUBE (Installation)
9. INSTALL ENGINE ASSEMBLY
(a) Slowly lower the engine assembly into the engine compartment.
NOTE: Make sure that the engine is clear of all wiring and hoses.
(b) Attach the engine mounting insulators to the vehicle.
(c) Install the 4 engine mounting insulator's bolts.
Torque: 79 Nm (806 kgf-cm, 58 ft-lbf)
10. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST: 09213-70011
09213-70020
SST: 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 Nm (306 kgf-cm, 22 ft-lbf)
- 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 (Installation).
(b) for 4WD, refer to the following procedures (Installation).
12. INSTALL PROPELLER SHAFT ASSEMBLY
(a) for 2 joint type, refer to the following procedures (Service and Repair).
(b) for 3 joint type, refer to the following procedures (Service and Repair).
13. INSTALL EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures (Installation).
(b) except Regular cab standard deck, refer to the following procedures (Installation).
14. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install the water by-pass pipe with the 2 bolts.
15. INSTALL GENERATOR ASSEMBLY (Installation)
16. CONNECT VANE PUMP ASSEMBLY (Installation)
17. CONNECT COOLER COMPRESSOR ASSEMBLY (Installation)
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 Nm (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 Nm (82 kgf-cm, 71 in-lbf)
(e) Connect the positive (+) battery terminal and install the engine wire with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(f) Connect the air injection system hose.
(g) Install the ground wire with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(h) Connect the air pump connector and install the connector bracket with the bolt.
Torque: 4.0 Nm (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 (Installation).
(l) Connect the vacuum hose assembly.
19. CONNECT FUEL MAIN AND RETURN HOSE
(a) Connect the fuel main and return hoses (Technician Safety Information).
(b) Install the fuel pipe clamp.
20. INSTALL RADIATOR ASSEMBLY (Installation)
21. INSTALL OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Install the oil cooler (Installation).
22. INSTALL FLUID COUPLING ASSEMBLY (Installation)
23. INSTALL FAN AND GENERATOR V BELT (Installation)
24. INSTALL RADIATOR HOSE OUTLET
25. INSTALL RADIATOR HOSE INLET
26. INSTALL RADIATOR SIDE DEFLECTOR LH (Installation)
27. INSTALL RADIATOR SIDE DEFLECTOR RH (Installation)
28. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Install the air cleaner element onto the air cleaner case.
(c) Install the air cleaner cap.
(1) Fasten the 4 hook clamps.
(2) Connect the MAF meter connector.
(3) Attach the wire harness clamp.
29. INSTALL NO. 2 VENTILATION HOSE
(a) Install the No. 2 ventilation hose and vacuum hose.
30. INSTALL AIR CLEANER HOSE ASSEMBLY
(a) Install the air cleaner hose.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
HINT: Make sure that the clamp band end is aligned with the limit mark when the hose clamp is tightened, as indicated by A and B in the illustration.
(b) Connect the vacuum hose.
(c) Connect the No. 2 ventilation hose.
31. ADD ENGINE OIL (Replacement)
32. ADD ENGINE COOLANT (Service and Repair)
33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).
34. INSPECT FOR OIL LEAK
(a) Inspect the engine oil leak (Replacement).
35. INSPECT FOR COOLANT LEAK (Testing and Inspection)
36. INSPECT FOR EXHAUST GAS LEAK (Installation)
37. INSPECT FOR FUEL LEAK (Fuel System)
38. INSPECT SHIFT LEVER POSITION (Shift Lever Assembly (for Column Shift Type))
39. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY (Installation)
40. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY (Installation)
41. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor (Installation).
42. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Attach the lower part of the 2 food supports to the hood support bolt ball joints.
NOTE: Install the hood support while supporting the hood by hand.
(c) Attach the hood support clips.
NOTE: Check that the hood support is engaged in the ball joint and it cannot be pulled out.
43. ADJUST HOOD SUB-ASSEMBLY (Adjustments)
44. INSTALL NO. 1 ENGINE UNDER COVER (Replacement)
45. CHECK IGNITION TIMING (Engine)
46. CHECK ENGINE IDLE SPEED (Engine)
47. CHECK CO/HC (Engine)
48. CHECK ENGINE OIL LEVEL (Testing and Inspection)
49. CHECK ENGINE COOLANT LEVEL (Testing and Inspection)