Installation

3UR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. REMOVE ENGINE STAND

(a) Install 2 engine hangers with 2 bolts as shown in the illustration.





Engine Hanger Part No.:





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

(b) Attach an engine sling device and hang the engine with a chain block.

(c) Remove the bolts and engine assembly from the engine stand.

2. INSTALL NO. 2 FRONT ENGINE MOUNTING BRACKET LH

(a) Install the No. 2 front engine mounting bracket LH with the bolt.





Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

3. INSTALL FRONT ENGINE MOUNTING INSULATOR RH





(a) Install the mounting insulator with the nut.

Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)

4. INSTALL FRONT ENGINE MOUNTING INSULATOR LH





(a) Install the mounting insulator with the nut.

Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)

5. 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.

(c) Install the 4 engine mounting insulator bolts.





Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)

(d) Remove the 2 bolts and 2 engine hangers.

6. INSTALL NO. 2 WATER BY-PASS PIPE





(a) Connect the 2 hoses and install the water by-pass pipe with the 2 bolts.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

7. CONNECT OIL COOLER PIPE ASSEMBLY





(a) Connect the oil cooler pipe with the 2 bolts.

Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.





SST : 09213-70011

SST : 09330-00021

(b) Install the crankshaft angle sensor rotor, drive plate and rear drive plate spacer to the crankshaft.

(c) Install and uniformly tighten 10 new bolts in the sequence shown in the illustration.





Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)

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

(d) Mark the upside of each flywheel installation bolt with paint.





(e) Tighten the flywheel installation bolts 90° as shown in the illustration.

(f) Check that the painted marks are now at a 90° angle to the upside.

9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

(a) Install the rear engine mounting insulator to the transmission with the 4 bolts.





Torque : 59 Nm (602 kgf-cm, 44 ft-lbf)

(b) Install the front engine mounting insulator RH with the 2 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) Install the automatic transmission Installation.

11. INSTALL STARTER ASSEMBLY Installation

12. INSTALL STARTER COVER Installation

13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

14. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

15. INSTALL NO. 1 MANIFOLD STAY Installation

16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

18. INSTALL NO. 2 MANIFOLD STAY Installation

19. INSTALL PROPELLER SHAFT HEAT INSULATOR Installation

20. INSTALL REAR PROPELLER SHAFT ASSEMBLY

(a) Install the rear propeller shaft Installation.

21. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

(a) Install the front propeller shaft Installation.

22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE





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

(b) Install the O-ring to the guide.

(c) Install the dipstick guide with the bolt.

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

(d) Install the dipstick.

(e) Connect the wire harness clamp.

23. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY Installation

25. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

26. INSTALL TAILPIPE ASSEMBLY Installation

27. INSTALL GENERATOR ASSEMBLY Installation

28. CONNECT VANE PUMP ASSEMBLY Installation

29. CONNECT COOLER COMPRESSOR ASSEMBLY Installation

30. CONNECT WIRE HARNESS AND HOSE

(a) Connect the clamp and 2 connectors.





(b) Connect the 2 connectors and 2 clips to the engine room junction block.

(c) Install the engine wire with the nut. Then connect the 2 clips.

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

(d) Connect the 4 air injection control driver connectors.

(e) Install the ground wire to the air injection control bracket with the bolt.

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

(f) Install the ground wire to the body with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(g) Connect the cable to the positive (+) battery terminal.

(h) Install the wire to the positive (+) battery cable with the nut.

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

(i) Connect the 2 air injection system hoses.





(j) Install the ground wire with the bolt.

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

(k) Connect the 3 clamps and 2 air pump connectors.

(l) Install the connector bracket with the nut.

Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

(m) Connect the clamp and 4 connectors to the connector holder block.





(n) Connect the 4 heater hoses.





(o) Connect the ECM connector and clamp.

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

(p) Connect the purge line hose.





31. CONNECT FUEL MAIN AND RETURN HOSE

(a) Connect the fuel main and return hoses Service Precautions.





(b) Install the fuel pipe clamp.

32. INSTALL RADIATOR ASSEMBLY Installation

33. INSTALL FAN SHROUD Installation

34. INSTALL NO. 2 RADIATOR HOSE

35. INSTALL NO. 1 RADIATOR HOSE

36. INSTALL AIR CLEANER ASSEMBLY





(a) Install the air cleaner with the 3 bolts.

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

37. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

38. ADD ENGINE OIL Replacement

39. ADD ENGINE COOLANT Service and Repair

40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

41. INSPECT FOR OIL LEAK Replacement

42. INSPECT FOR COOLANT LEAK Testing and Inspection

43. INSPECT FOR EXHAUST GAS LEAK Installation

44. INSPECT FOR FUEL LEAK Installation

45. INSPECT SHIFT LEVER POSITION On-Vehicle Inspection

46. INSTALL V-BANK COVER SUB-ASSEMBLY





(a) Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

47. INSTALL OIL PAN PROTECTOR ASSEMBLY Installation

48. INSTALL NO. 2 ENGINE UNDER COVER





(a) Install the No. 2 engine under cover with the 2 bolts.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

49. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY





(a) Install the No. 1 engine under cover with the 10 bolts.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

50. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH Installation

51. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH Installation

52. INSTALL FRONT FENDER APRON SEAL REAR RH Installation

53. INSTALL FRONT FENDER APRON SEAL FRONT RH Installation

54. INSTALL FRONT FENDER APRON SEAL REAR LH Installation

55. INSTALL FRONT FENDER APRON SEAL LH Installation

56. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

(a) Install the cowl top ventilator louver Installation.

57. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood with the 4 bolts.





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

(b) Connect the 2 hood supports with the 2 hood support bolts.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

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

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

58. ADJUST HOOD SUB-ASSEMBLY Adjustments

59. CONNECT RADIATOR SIDE DEFLECTOR LH Installation

60. CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) Installation

61. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler) Installation

62. INSTALL FRONT BUMPER COVER Installation

63. INSTALL RADIATOR GRILLE Installation

64. INSTALL UPPER RADIATOR SUPPORT SEAL Installation

65. INSPECT IGNITION TIMING Engine

66. INSPECT ENGINE IDLE SPEED Engine

67. INSPECT CO/HC Engine

68. INSPECT ENGINE OIL LEVEL Testing and Inspection

69. INSPECT ENGINE COOLANT LEVEL Testing and Inspection