Installation

3UR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. REMOVE ENGINE STAND

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





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

HINT






(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 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.

3. INSTALL OIL COOLER TUBE

(a) Install the oil cooler tube with the bolt.

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

4. INSTALL NO. 1 WATER BY-PASS PIPE

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





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

5. 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 plate, drive gear 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 another 90° as shown.

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

6. INSTALL EXHAUST MANIFOLD

(a) Install the exhaust manifold Installation.

7. INSTALL GENERATOR ASSEMBLY

(a) Install the generator assembly Installation.

8. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

9. CONNECT NO. 2 AIR INJECTION SYSTEM HOSE Installation

10. CONNECT NO. 3 AIR INJECTION SYSTEM HOSE Installation

11. INSTALL ENGINE WIRE

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





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

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 cable to the positive (+) battery terminal.

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

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

(g) Connect the 2 air injection system hoses.





(h) Install the ground wire with the bolt.

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

(i) Connect the 2 air pump connectors and install the connector bracket with the nut.

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

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





(k) Connect the heater hoses.

12. INSTALL ECM

(a) Connect the ECM connector and clamp.





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

13. CONNECT FUEL MAIN AND RETURN HOSE

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





(b) Install the fuel pipe clamp.

14. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY

(a) Connect the purge line hose.





15. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the union to check valve hose.





16. CONNECT OUTLET HEATER WATER HOSE C Installation

17. CONNECT INLET HEATER WATER HOSE C Installation

18. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

19. INSTALL AIR CLEANER ASSEMBLY Installation

20. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD)

(a) Install the transmission assembly .

21. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD)

(a) Install the transmission assembly Installation.

22. INSTALL RADIATOR ASSEMBLY

(a) Install the radiator assembly Installation.

23. ADD ENGINE OIL Replacement

24. ADD ENGINE COOLANT Service and Repair

25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

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

26. INSPECT FOR OIL LEAK

27. INSPECT FOR COOLANT LEAK Testing and Inspection

28. INSPECT FOR EXHAUST GAS LEAK Installation

29. INSPECT FOR FUEL LEAK Installation

30. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY

(a) Install the outer panel with the 7 bolts.





Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)

(b) Connect the 2 washer hoses.

31. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

(a) Install the windshield wiper motor Installation.

32. 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 hood 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 that it cannot be pulled out.

33. ADJUST HOOD SUB-ASSEMBLY Adjustments

34. INSPECT IGNITION TIMING Engine

35. INSPECT ENGINE IDLE SPEED Engine

36. INSPECT CO/HC Engine

37. INSPECT FOR ENGINE OIL LEVEL Testing and Inspection

38. INSPECT FOR ENGINE COOLANT LEVEL Testing and Inspection

39. INSPECT SRS WARNING LIGHT

Diagnosis System