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Home >> Toyota Truck >> 2011 >> FJ Cruiser 2WD V6-4.0L (1GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Installation

Installation





1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE WIRE

(a) Connect the connectors to the engine.

(b) Engage the clamps to the engine.

(c) Install the ground wire onto the bank 1 camshaft housing with the 2 bolts.

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

(d) Install the ground wire onto the bank 1 cylinder head cover with the bolt.

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

2. INSTALL ENGINE HANGER

(a) Install the 2 engine hangers with the 4 bolts.

Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

3. INSTALL ENGINE ASSEMBLY

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

(b) Lower the engine into the engine compartment carefully.

(c) Install the 2 front engine mounting insulators with the 6 nuts and 4 bolts.





Text in Illustration





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

for nut B - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

NOTICE:
For the rear bolt on the RH side only, make sure to install it so that the claw does not protrude past the edge of the mounting bracket.

(d) Remove the 4 bolts and 2 engine hangers.

(e) Install the fuel pipe clamp with the bolt.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(f) Install the wire harness clamp with the bolt.

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

4. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

(a) Using SST, hold the crankshaft.

SST : 09213-54015

91651-60855

SST : 09330-00021

(b) Temporarily install the flywheel with the 8 new bolts.

(c) Install and tighten the 8 mounting bolts uniformly in several steps.

Torque : 83 Nm (846 kgf-cm, 61 ft-lbf)

5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

(a) Using SST, hold the crankshaft.

SST : 09213-54015

91651-60855

SST : 09330-00021

(b) Install the front drive plate spacer, drive plate and ring gear and rear drive plate spacer onto the crankshaft.





Text in Illustration





NOTICE:
As the front drive plate spacer, drive plate and ring gear and rear drive plate spacer are not reversible, be sure to install it in the direction shown in the illustration.

(c) Apply adhesive to the 2 or 3 end threads of the bolts.





Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent.

(d) Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.





Torque : 83 Nm (846 kgf-cm, 61 ft-lbf)

NOTICE:
Do not start the engine for at least 1 hour after installing.

6. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission) Installation

7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) Installation

8. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission) Installation

9. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

(a) Install the manual transmission unit assembly Installation.

10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

(a) Install the automatic transmission assembly Installation or ).

11. CONNECT ENGINE WIRE (for Automatic Transmission 4WD)

(a) Install the wire harness clamp bracket with the bolt.

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

(b) Connect the front differential connector and clamp.

12. CONNECT ENGINE WIRE (for 2WD)





(a) Engage the grommet to the wire harness support.

Text in Illustration





(b) Pass the wire harness into the vehicle and install the wire harness support.

(c) Install the ground wire with the bolt and connect the connector.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(d) Connect the 3 connectors and clamp to the air conditioning unit.

(e) Connect the 6 connectors to the ECM.

(f) Install the glove compartment door Installation.

13. CONNECT ENGINE WIRE (for 4WD)





(a) Engage the grommet to the wire harness support.

Text in Illustration





(b) Pass the wire harness into the vehicle and install the wire harness support.

(c) Install the ground wire with the bolt and connect the connector.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(d) Connect the 3 connectors and clamp to the air conditioning unit.

(e) Connect the 6 connectors to the ECM.

(f) Connect the connector to the four wheel drive control ECU.

(g) Install the glove compartment door Installation.

14. CONNECT OUTLET HEATER WATER HOSE





(a) Connect the outlet heater water hose.

Text in Illustration





HINT
The direction of the hose clamp is indicated in the illustration.

15. CONNECT INLET HEATER WATER HOSE





(a) Connect the inlet heater water hose.

Text in Illustration





HINT
The direction of the hose clamp is indicated in the illustration.

16. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Connect the No. 2 fuel pipe Service Precautions.

(b) Install the No. 2 fuel pipe clamp.

17. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Connect the No. 1 fuel pipe Service Precautions.

(b) Install the No. 1 fuel pipe clamp.

18. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump with the 2 bolts.

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

(b) Connect the 2 clamps and vane pump connector.

19. INSTALL COOLER COMPRESSOR ASSEMBLY





(a) Temporarily install the cooler compressor with the 3 bolts.

(b) Using a E8 "TORX" socket wrench, install the stud bolt.

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

(c) Install the nut.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(d) Fully tighten the 3 bolts in the order shown in the illustration.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(e) Install the suction hose with the bolt.

Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

20. INSTALL STARTER ASSEMBLY

(a) Install the starter assembly Installation.

21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY

(a) Install the exhaust manifold sub-assembly Installation.

22. INSTALL GENERATOR ASSEMBLY

(a) Install the generator assembly Installation.

23. INSTALL INTAKE AIR SURGE TANK Installation

24. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

25. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

26. INSTALL AIR CLEANER CAP AND HOSE Installation

27. INSTALL RADIATOR ASSEMBLY

(a) Remove the radiator assembly Installation.

28. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood with the 4 bolts.

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

(b) Connect the windshield washer hose.

29. INSTALL HOOD SUPPORT Installation

30. ADJUST HOOD SUB-ASSEMBLY Adjustments

31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

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

32. ADD ENGINE COOLANT Service and Repair

33. ADD ENGINE OIL Replacement

34. PERFORM INITIALIZATION (for Automatic Transmission)

Programming and Relearning or )

35. INSPECT FOR COOLANT LEAK Testing and Inspection

36. INSPECT FOR ENGINE OIL LEAK Replacement

37. INSPECT FOR FUEL LEAK Fuel System

38. INSPECT FOR EXHAUST GAS LEAK

39. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

(a) Install the rear engine under cover with the 4 bolts.

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

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

(a) Hook the engine under cover to the frame.

(b) Install the 4 bolts.

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

41. CHECK ENGINE OIL LEVEL Testing and Inspection

42. INSPECT IGNITION TIMING Engine

43. INSPECT ENGINE IDLING SPEED Engine

44. INSPECT COMPRESSION Engine

45. INSPECT CO/HC Engine

46. INSTALL V-BANK COVER Installation

47. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Service and Repair.
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