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.
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 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.
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)
(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
09213-70020
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)
- 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 (Installation).
(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 ().
16. INSTALL PROPELLER SHAFT ASSEMBLY
(a) for 2WD:
Refer to the following procedures (Service and Repair).
(b) for 4WD:
Refer to the following procedures (Service and Repair).
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 (Technician Safety Information).
(b) Install the fuel pipe clamp.
23. INSTALL RADIATOR ASSEMBLY (Installation)
24. INSTALL FAN SHROUD (Installation)
25. INSTALL FAN AND GENERATOR V BELT (Installation)
26. INSTALL OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Install the oil cooler (Installation).
27. INSTALL RADIATOR SIDE DEFLECTOR LH (Installation)
28. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Trailer Towing System) (Installation)
29. INSTALL OUTLET RADIATOR HOSE
30. INSTALL INLET RADIATOR HOSE
31. 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.
32. 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 shown in the illustration.
(b) Connect the vacuum hose.
(c) Connect the ventilation hose.
33. ADD ENGINE OIL (Replacement)
34. ADD ENGINE COOLANT (Service and Repair)
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected (Repair Instruction - Initialization).
36. INSPECT FOR OIL LEAK
(a) Inspect for engine oil leak (Replacement).
37. INSPECT FOR COOLANT LEAK (Testing and Inspection)
38. INSPECT FOR EXHAUST GAS LEAK (Installation)
39. INSPECT FOR FUEL LEAK (Installation)
40. INSPECT SHIFT LEVER POSITION
(a) for Column shift:
Refer to the following procedures (On-Vehicle Inspection).
(b) for Floor shift:
Refer to the following procedures (On-Vehicle Inspection).
41. 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.
42. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY (Installation)
43. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor (Installation).
44. 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.
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 that it cannot be pulled out.
45. ADJUST HOOD SUB-ASSEMBLY (Adjustments)
46. INSTALL NO. 1 ENGINE UNDER COVER (Replacement)
47. INSPECT IGNITION TIMING (Engine)
48. INSPECT ENGINE IDLE SPEED (Engine)
49. INSPECT CO/HC (Engine)
50. CHECK ENGINE OIL LEVEL (Testing and Inspection)
51. CHECK ENGINE COOLANT LEVEL (Testing and Inspection)