Installation
1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
1. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH
(a) Install the front No. 2 engine mounting bracket LH with the bolt.
Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)
2. INSTALL ENGINE HANGER
(a) Install 2 engine hangers with 4 bolts as shown in the illustration.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
Text in Illustration
HINT
3. REMOVE ENGINE FROM ENGINE STAND
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Lift the engine and remove it from the engine stand.
NOTICE:
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
* Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
4. INSTALL ENGINE ASSEMBLY
(a) Slowly lower the engine into the engine compartment.
Install the front engine mounting insulator LH with the nut and 2 bolts.
for nut - Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)
for bolt - Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)
Text in Illustration
(b) Install the front engine mounting insulator RH with the nut and 2 bolts.
for nut - Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)
for bolt - Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)
(c) Remove the 2 engine hangers and 4 bolts.
5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft.
SST : 09213-54015
91651-60855
SST : 09330-00021
Install the front spacer, drive plate and rear spacer to the crankshaft.
Text in Illustration
HINT
As the front spacer, the drive plate and ring gear and the rear spacer are not reversible, be sure to install them so that they are facing in the direction shown in the illustration.
(a) Clean the bolts and bolt holes.
Apply adhesive to 2 or 3 threads at the end of each of the 8 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Text in Illustration
Install and uniformly 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 installation.
6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.
(a) Install the rear engine mounting insulator to the transmission with the 4 bolts.
Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)
7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
Installation
8. INSTALL PROPELLER SHAFT ASSEMBLY
Installation
9. CONNECT NO. 1 AND NO. 2 FUEL PIPES
(a) Connect the No. 1 and No. 2 fuel pipes Service Precautions.
(b) Install the No. 2 fuel pipe clamp to the fuel tube connector.
10. CONNECT HEATER WATER HOSE ASSEMBLY
Connect the heater water inlet and outlet hoses.
Text in Illustration
HINT
The direction of the hose clamp is indicated in the illustration.
(a) Attach the wire harness clamp.
11. CONNECT COOLER COMPRESSOR ASSEMBLY
(a) Install the cooler compressor with the 2 stud bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Install the 2 bolts and 2 nuts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
HINT
Tighten the bolts and nuts in the order shown in the illustration to install the cooler compressor.
(b) Connect the cooler compressor connector.
12. CONNECT ENGINE WIRE
(a) Attach the 2 claws and connect the 2 connectors to connect the engine room junction block connector to the engine room junction block.
(b) Attach the claw and install the bolt to connect the engine wire harness.
Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)
(c) Attach the clamp and connect the air pump connector.
(d) Install the ground cable with the 2 bolts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(e) Attach the clamp and connect the ECM connector Installation.
(f) Attach the 2 clamps and connect the 7 connectors to connect the junction block connector to the junction block.
(g) Install the junction block cover.
(h) Attach the 2 wire harness clamps.
(i) Connect the 2 air injection control driver connectors.
13. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT Installation
14. INSTALL STARTER ASSEMBLY (for 1.6 kW Type) Installation
15. INSTALL STARTER ASSEMBLY (for 1.4 kW Type) Installation
16. INSTALL STARTER COVER (for 1.4 kW Type) Installation
17. INSTALL GENERATOR ASSEMBLY Installation
18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation
19. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
20. INSTALL NO. 2 AIR TUBE Installation
21. INSTALL MANIFOLD STAY Installation
22. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation
23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
24. INSTALL AIR TUBE Installation
25. INSTALL NO. 2 MANIFOLD STAY Installation
26. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install a new gasket and the exhaust pipe to the exhaust manifold RH with 3 new nuts.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(b) Install a new gasket and the exhaust pipe to the center exhaust pipe with the 2 bolts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
(c) Connect the air fuel ratio sensor connector.
(d) Connect the heated oxygen sensor connector and attach the 2 clamps.
27. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)
(a) Connect the front No. 2 exhaust pipe to the exhaust pipe support.
(b) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(c) Install a new gasket and the front No. 2 exhaust pipe to the center exhaust pipe with the 2 bolts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
(d) Connect the air fuel ratio sensor connector.
(e) Connect the heated oxygen sensor connector.
28. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck)
(a) Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 3 new nuts.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
(b) Connect the air fuel ratio sensor connector.
(c) Connect the heated oxygen sensor connector and attach the 2 clamps.
29. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for Regular Cab Standard Deck)
(a) Install a new gasket to the front No. 2 exhaust pipe.
(b) Install a new gasket to the front No. 3 exhaust pipe.
(c) Connect the front No. 3 exhaust pipe to the exhaust pipe support.
(d) Install the front No. 3 exhaust pipe with the 4 bolts and 2 new nuts.
Torque : 48 Nm (489 kgf-cm, 35 ft-lbf)
30. CONNECT VANE PUMP ASSEMBLY Installation
31. INSTALL FAN AND GENERATOR V BELT Installation
32. INSTALL INTAKE AIR SURGE TANK Installation
33. INSTALL AIR TUBE ASSEMBLY Installation
34. INSTALL RADIATOR ASSEMBLY Installation
35. INSTALL FAN SHROUD Installation
36. INSTALL RADIATOR HOSE OUTLET Installation
37. INSTALL RADIATOR HOSE INLET Installation
38. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
39. INSTALL AIR CLEANER CAP AND HOSE Installation
40. ADD ENGINE COOLANT Service and Repair
41. ADD ENGINE OIL Replacement
42. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY Installation
43. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY
Installation
44. 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.
45. INSPECT FOR FUEL LEAK Installation
46. INSPECT FOR ENGINE OIL LEAK Replacement
47. INSPECT FOR EXHAUST GAS LEAK Installation
48. CHECK ENGINE OIL LEVEL Testing and Inspection
49. INSTALL FRONT FENDER APRON SEAL REAR RH
(a) Install the fender apron seal with the 5 clips.
50. INSTALL FRONT FENDER APRON SEAL REAR LH
(a) Install the fender apron seal with the 5 clips.
51. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the front fender apron seal with the 6 clips.
52. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the front fender apron seal with the 6 clips.
53. INSTALL NO. 1 ENGINE UNDER COVER Replacement
54. PERFORM RESET MEMORY
Programming and Relearning
55. INSPECT IGNITION TIMING Engine
56. INSPECT ENGINE IDLE SPEED Engine
57. INSPECT CO/HC Engine
58. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts and 2 clips.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
59. ADJUST HOOD SUB-ASSEMBLY Adjustments