Engine Assembly, Intake Manifold, Exhaust Manifold: Installation
- INSTALL ENGINE COOLANT TEMPERATURE SENSOR
- Using a 19 mm deep socket wrench, remove the temperature sensor.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
- Using a 19 mm deep socket wrench, remove the temperature sensor.
- INSTALL OIL PRESSURE SWITCH ASSEMBLY
- Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
NOTE: Do not start the engine within 1 hour after installation.
- Using a 24 mm deep socket wrench, install the oil pressure switch.
- INSTALL ENGINE OIL LEVEL SENSOR
- Install the engine oil level sensor and new gasket with the 4 bolts.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
- Install the engine oil level sensor and new gasket with the 4 bolts.
- INSTALL IGNITION COIL ASSEMBLY
- Install the 6 ignition coils with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the 6 ignition coils with the 6 bolts.
- INSTALL OIL FILLER CAP SUB-ASSEMBLY
- INSTALL ENGINE MOUNTING BRACKET RH
- Install the mounting bracket with the 4 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Install the mounting bracket with the 4 bolts.
- INSTALL ENGINE MOUNTING BRACKET LH
- Install the mounting bracket with the 4 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Install the mounting bracket with the 4 bolts.
- INSTALL KNOCK SENSOR
- Install the 2 knock sensors so that they are horizontal as shown in the illustration. Then install the 2 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
HINT:
It is acceptable for the sensor to be tilted +10° to - 5°.
- Install the 2 knock sensors so that they are horizontal as shown in the illustration. Then install the 2 bolts.
- INSTALL FUEL INJECTOR ASSEMBLY (See INSTALLATION )
- INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (See INSTALLATION )
- INSTALL NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY (See INSTALLATION )
- INSTALL HIGH PRESSURE SIDE FUEL PUMP (See INSTALLATION )
- INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
- INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (See INSTALLATION )
- INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See INSTALLATION )
- INSTALL INTAKE MANIFOLD
- Install a new gasket and the intake manifold with the 4 bolts and 2 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install a new gasket and the intake manifold with the 4 bolts and 2 nuts.
- INSTALL INTAKE AIR SURGE TANK SUB-ASSEMBLY
- Install a new gasket to the intake air surge tank.
- Install the intake air surge tank with the 2 nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
- Using a hexagon socket wrench 5, install the 7 bolts.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
- Install the 2 surge tank stays with the 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the intake manifold stay with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- INSTALL NO. 4 WATER BYPASS PIPE
- Install the water bypass pipe with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the water bypass pipe with the bolt.
- INSTALL NO. 3 WATER BYPASS PIPE
- Install the water bypass pipe with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the water bypass pipe with the bolt.
- INSTALL REAR ENGINE COVER SUB-ASSEMBLY
- Install the engine cover with the 3 clips.
- CONNECT NO. 2 WATER BYPASS HOSE
- CONNECT NO. 1 WATER BYPASS HOSE
- INSTALL INJECTOR DRIVER
- Install the injector driver with the bolt and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the injector driver with the bolt and 2 nuts.
- INSTALL WATER PUMP PULLEY (See INSTALLATION )
- INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
- Temporarily install the V-ribbed belt tensioner with the 5 bolts.
- Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
Each bolt length is as follows:
BOLT SPECIFICATIONSA 70 mm (2.76 in.) B 33 mm (1.30 in.) - Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)
- Temporarily install the V-ribbed belt tensioner with the 4 bolts.
- Install the V-ribbed belt tensioner by tightening the bolt 1in the order shown in the illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
Each bolt length is as follows:
BOLT SPECIFICATIONSA 70 mm (2.76 in.) B 33 mm (1.30 in.) - Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
- Install the plate and idler pulley with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Install the plate and idler pulley with the bolt.
- INSTALL FRONT DIFFERENTIAL ASSEMBLY (See INSTALLATION )
- INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
- INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
- Install a new gasket as shown in the illustration.
- Install the exhaust manifold with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
NOTE: Do not damage the stud bolt when installing the exhaust manifold.HINT:
First tighten either of the 2 nuts indicated by the arrows in the illustration.
- INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
- Install a new gasket as shown in the illustration.
- Install the exhaust manifold with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
NOTE: Do not damage the stud bolt when installing the exhaust manifold.HINT:
First tighten either of the 2 nuts indicated by the arrows in the illustration.
- INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
- Install a new O-ring to the oil level gauge guide.
- Apply a light coat of engine oil to the O-ring.
- Push in the oil level gauge guide end into the guide hole.
- Install the oil level gauge guide No. 1 with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the oil level gauge guide No. 2 with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the oil level gauge.
- INSTALL ENGINE WIRE
- Install the engine wire to the engine assembly.
- REMOVE ENGINE ASSEMBLY
- Remove the bolts and engine from the engine stand.
- INSTALL FRONT ENGINE MOUNTING INSULATOR
- Install the front suspension crossmember subassembly with the 2 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
- Install the front suspension crossmember subassembly with the 2 bolts.
- INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY
- Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
- Apply adhesive to 2 or 3 threads of the mounting bolts end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent
- Install the front spacer, drive plate and rear spacer on the crankshaft.
- Install and tighten the 8 mounting bolts uniformly in several steps.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf)
NOTE: Do not start the engine for at least 1 hour after installing.
- Using SST, hold the crankshaft.
- INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) (See INSTALLATION )
- INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) (See INSTALLATION )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) (See INSTALLATION )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD) (See INSTALLATION )
- INSTALL ENGINE AND TRANSMISSION (for 2WD)
- Remove the engine hanger No. 1 and No. 2.
- Set the engine lifter.
- Operate the engine lifter, then install the engine to the vehicle.
- Install the engine and transmission with crossmember sub-assembly with the 12 bolts.
Torque: 167 N*m (1,700 kgf*cm, 123 ft.*lbf) for bolt A
204 N*m (2,080 kgf*cm, 150 ft.*lbf) for bolt B
50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt C 49 N*m (500 kgf*cm, 36 ft.*lbf) for bolt D
- Install the engine rear mounting member with the 4 bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
- INSTALL ENGINE AND TRANSMISSION (for 4WD)
- Remove the engine hanger No. 1 and No. 2.
- Set the engine lifter.
- Operate the engine lifter, then install the engine to the vehicle.
- Install the engine and transmission with crossmember sub-assembly with the 8 bolts.
Torque: 167 N*m (1,700 kgf*cm, 123 ft.*lbf) for bolt A
165 N*m (1,683 kgf*cm, 121 ft.*lbf) for bolt B
50 N*m (550 kgf*cm, 37 ft.*lbf) for bolt C
- Install the engine rear mounting member with the 4 bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
- CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) (See INSTALLATION )
- INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUBASSEMBLY (for 4WD) (See INSTALLATION )
- INSTALL POWER STEERING LINK WIRE HARNESS (for 2WD) (See INSTALLATION )
- INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) (See INSTALLATION )
- INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See INSTALLATION )
- INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD) (See INSTALLATION )
- INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD) (See INSTALLATION )
- INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) (See INSTALLATION )
- INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD) (See INSTALLATION )
- INSTALL SHOCK ABSORBER ASSEMBLY FRONT RH (for 4WD) (See INSTALLATION )
- INSTALL SHOCK ABSORBER ASSEMBLY FRONT LH (for 4WD) (See INSTALLATION )
- INSTALL TIE ROD ASSEMBLY RH (for 2WD) (See INSTALLATION )
- INSTALL TIE ROD ASSEMBLY LH (for 2WD) (See INSTALLATION )
- INSTALL TIE ROD ASSEMBLY RH (for 4WD) (See INSTALLATION )
- INSTALL TIE ROD ASSEMBLY LH (for 4WD) (See INSTALLATION )
- INSTALL FRONT AXLE HUB NUT RH (for 4WD) (See INSTALLATION )
- INSTALL FRONT AXLE HUB NUT LH (for 4WD) (See INSTALLATION )
- INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER (for 2WD)
- Install the protector with the 4 bolts.
Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)
- Install the protector with the 4 bolts.
- CONNECT HEIGHT CONTROL SENSOR LINK
- Connect the height control sensor link and install it with the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Connect the height control sensor link and install it with the nut.
- CONNECT WITH PULLEY COMPRESSOR ASSEMBLY (for 2WD)
- Using an E8 "Torx" socket, install the with pulley compressor with the stud bolt.
Torque: 10 N*m (102 kgf*cm, 89 ft.*lbf)
- Install the with pulley compressor with the 3 bolts and nut.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
- Using an E8 "Torx" socket, install the with pulley compressor with the stud bolt.
- CONNECT WITH PULLEY COMPRESSOR ASSEMBLY (for 4WD)
- Using an E8 "Torx" socket, install the with pulley compressor with the stud bolt.
Torque: 10 N*m (102 kgf*cm, 89 ft.*lbf)
- Temporarily install the 2 bolts and nut to the pulley compressor.
- Install the bracket with the bolt and nut.
- Tighten the 3 bolts and 2 nuts of the compressor and bracket.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
- Connect the magnetic clutch connector.
- Using an E8 "Torx" socket, install the with pulley compressor with the stud bolt.
- INSTALL FAN AND GENERATOR V BELT (See INSTALLATION )
- CONNECT ENGINE WIRE
- Connect the ground cable and install it with the bolt.
Torque: 10 N*m (102 kgf*cm, 89 ft.*lbf)
- Connect the wire to the engine room No. 1 relay block, junction block. Then, install it with the nut.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the engine room No. 1 relay block, junction block cover.
- Connect the battery positive cable (+) and install it with the nut.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Connect the ECM connectors.
- Connect the connector holder.
- Connect the ground cable and install it with the bolt.
- INSTALL ENGINE ROOM ECM COVER
- Install the engine room ECM cover with the 3 bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
- Install the engine room ECM cover with the 3 bolts.
- CONNECT FUEL MAIN TUBE (See INSTALLATION )
- CONNECT HEATER WATER OUTLET HOSE A
- Connect the outlet hose.
- CONNECT HEATER WATER INLET HOSE A
- Connect the inlet hose.
- CONNECT UNION TO CHECK VALVE HOSE
- Connect the hose to the surge tank.
- CONNECT RADIATOR RESERVE TANK HOSE
- CONNECT RADIATOR HOSE INLET (See INSTALLATION )
- CONNECT RADIATOR HOSE OUTLET (See INSTALLATION )
- INSTALL AIR CLEANER ASSEMBLY WITH HOSE
- Tighten the hose clamp.
- Install the air cleaner cap together with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the EVAP VSV to the air cleaner hose.
- Connect the MAF meter connector and clamp to the air cleaner.
- Connect the ventilation hose to the cylinder head cover with the clamp.
- INSTALL NO. 1 AIR CLEANER INLET
- Install the air cleaner inlet with the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the air cleaner inlet with the bolt.
- INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See INSTALLATION )
- INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See INSTALLATION )
- INSTALL FRONT EXHAUST PIPE ASSEMBLY (See INSTALLATION )
- INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)
- Install the under cover with the 4 screws, 2 grommets and 2 spacers.
- INSTALL ENGINE UNDER COVER (See INSTALLATION )
- INSTALL V-BANK COVER SUB-ASSEMBLY
- Install the V-bank cover with the 2 nuts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the V-bank cover with the 2 nuts.
- INSTALL ENGINE ROOM COVER SIDE RH
- Install the side cover with the 2 clip and nut.
- INSTALL ENGINE ROOM SIDE COVER LH
- Install the side cover with the 3 clips.
- INSTALL COOL AIR INTAKE DUCT SEAL
- Install the intake duct seal with the 7 clips.
- INSTALL FRONT WHEELS
- ADD ENGINE OIL (for 2WD) (See REPLACEMENT )
- ADD ENGINE OIL (for 4WD) (See REPLACEMENT )
- ADD AUTOMATIC TRANSMISSION FLUID (for 2WD) (See REMOVAL )
- ADD AUTOMATIC TRANSMISSION FLUID (for 4WD) (See REMOVAL )
- ADD FRONT DIFFERENTIAL OIL (for 4WD) (See ADJUSTMENT )
- ADD ENGINE COOLANT (See ON-VEHICLE INSPECTION )
- CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
- PERFORM INITIALIZATION
- Perform initialization procedure. (see INITIALIZATION
).NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
- Perform initialization procedure. (see INITIALIZATION
).
- CHECK SHIFT LEVER POSITION (for 2WD) (See REMOVAL )
- REMOVE CHECK SHIFT LEVER POSITION (for 4WD) (See REMOVAL )
- CHECK AND ADJUST FRONT WHEEL ALIGNMENT (See ADJUSTMENT )
- CHECK IGNITION TIMING (See ENGINE )
- CHECK IDLE SPEED (See ON-VEHICLE INSPECTION )
- CHECK CO / HC (See ON-VEHICLE INSPECTION )
- CHECK FOR ENGINE OIL LEAKS
- CHECK FOR ENGINE COOLANT LEAKS
- CHECK FOR FUEL LEAKS
- CHECK ENGINE OIL LEVEL
- CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
- CHECK ENGINE COOLANT LEVEL