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 EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation
3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
4. 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.
5. 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)
6. 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.
7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD:
Refer to the following procedures .
(b) for 4WD:
Refer to the following procedures Installation.
8. INSTALL STARTER ASSEMBLY Installation
9. INSTALL STARTER COVER Installation
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation
11. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
12. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
13. INSTALL FRONT FENDER APRON SEAL REAR RH Installation
14. INSTALL FRONT FENDER APRON SEAL RH Installation
15. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
(a) Install the front propeller shaft Installation.
16. INSTALL PROPELLER SHAFT ASSEMBLY
(a) for 2WD:
Refer to the following procedures Installation.
(b) for 4WD:
Refer to the following procedures Installation.
17. 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.
18. INSTALL GENERATOR ASSEMBLY Installation
19. CONNECT VANE PUMP ASSEMBLY Installation
20. CONNECT COOLER COMPRESSOR ASSEMBLY Installation
21. CONNECT WIRE HARNESS AND HOSE
(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.
(l) Connect the ECM connector and clamp.
HINT
Refer to the following procedures to connect the ECM connector Installation.
(m) Connect the union to check valve hose.
(n) Connect the purge line hose.
22. CONNECT FUEL MAIN AND RETURN HOSE
(a) Connect the fuel main and return hoses Service Precautions.
(b) Install the fuel pipe clamp.
23. INSTALL RADIATOR ASSEMBLY Installation
24. INSTALL FAN SHROUD Installation
25. INSTALL FAN & GENERATOR V BELT Installation
26. INSTALL RADIATOR SIDE DEFLECTOR LH Installation
27. INSTALL RADIATOR SIDE DEFLECTOR RH Installation
28. INSTALL OUTLET RADIATOR HOSE
29. INSTALL INLET RADIATOR HOSE
30. 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.
31. INSTALL AIR CLEANER HOSE ASSEMBLY
(a) Install the air cleaner hose with the 2 clamps.
Torque : 4.0 Nm (41 kgf-cm, 35 in-lbf)
(b) Connect the vacuum hose.
(c) Connect the ventilation hose.
32. ADD ENGINE OIL Replacement
33. ADD ENGINE COOLANT Service and Repair
34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
35. INSPECT FOR OIL LEAK
(a) Inspect for engine oil leak Replacement.
36. INSPECT FOR COOLANT LEAK Testing and Inspection
37. INSPECT FOR EXHAUST GAS LEAK Installation
38. INSPECT FOR FUEL LEAK Installation
39. INSPECT SHIFT LEVER POSITION
(a) for Column shift:
Refer to the following procedures .
(b) for Floor shift:
Refer to the following procedures .
40. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins, and press down on the V-bank cover to attach the pins.
41. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY Installation
42. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor Installation.
43. 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.
44. ADJUST HOOD SUB-ASSEMBLY Adjustments
45. INSTALL NO. 1 ENGINE UNDER COVER Replacement
46. INSPECT IGNITION TIMING Engine
47. INSPECT ENGINE IDLE SPEED Engine
48. INSPECT CO/HC Engine
49. CHECK ENGINE OIL LEVEL Testing and Inspection
50. CHECK ENGINE COOLANT LEVEL Testing and Inspection