ДВИГАТЕЛЬ В СБОРЕ УСТАНОВКА

PROCEDURE


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 front engine mounting insulators with the 2 nuts.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  2. INSTALL ENGINE HANGER

    Click here

  3. REMOVE ENGINE FROM ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  4. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Install the engine with the 4 bolts and 4 nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      For RHD vehicles only:

      B001I7ZE02

      When tightening the nut closer to the rear of the vehicle for the engine mounting bracket on the right side, make sure that the claw (stopper) of the bolt does not protrude past the rear edge of the bracket.

      Text in Illustration
      *1 Claw (Stopper)
      *2 Bracket
      *a Correct
      *b Incorrect

    3. Remove the 2 bolts and 2 engine hangers.

  5. INSTALL FLYWHEEL HOUSING DUST SEAL

  6. INSTALL REAR END PLATE


    1. Install the rear end plate with the 2 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  7. INSTALL FLYWHEEL SUB-ASSEMBLY

    B001HUZE05

    1. Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and bolt holes.

    3. Apply adhesive to 2 or 3 threads of each of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the flywheel to the crankshaft.

    5. Temporarily install the flywheel with the 8 bolts.

    6. B001CPEE03

      Tighten the 8 bolts uniformly in several steps in the order shown in the illustration.

      Torque:
      123 N*m  { 1249 kgf*cm, 90 ft.*lbf }

      Note

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

  8. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  9. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator to the transmission with the 4 bolts.

      Note

      Perform this procedure when replacement of the engine mounting insulator is necessary.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  11. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. Install the manual transmission Click here.

  12. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  13. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  16. INSTALL STARTER ASSEMBLY

    Click here

  17. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  18. INSTALL VANE PUMP ASSEMBLY


    1. Temporarily install the vane pump with the 2 bolts and nut.

    2. B001GC0E05

      Install the pulley to the pump shaft.

    3. Using SST, hold the pulley and install the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      43 N*m  { 443 kgf*cm, 31 ft.*lbf }

  19. CONNECT FUEL HOSE


    1. Connect the 2 fuel hoses.

  20. CONNECT HEATER WATER HOSE ASSEMBLY


    1. Connect the 2 water hoses.

    2. Install the heater water hose clamp with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  21. INSTALL WIRING HARNESS CLAMP BRACKET (for LHD)


    1. Install the wiring harness clamp bracket with the bolt.

      Torque:
      22 N*m  { 219 kgf*cm, 16 ft.*lbf }

  22. CONNECT ENGINE WIRE


    1. Connect the ECM connector.


      1. B001EQ8E09
        Text in Illustration
        *1 Grommet
        *2 Wire Harness Support

        Attach the grommet to the wire harness support.

      2. Pass the wire harness into the vehicle and install the wire harness support.

    2. B001HB2E03
      Text in Illustration
      *A for LHD
      *B for RHD

      Connect the 5 ECM connectors and attach the clamp.

    3. B001IF8

      for LHD:

      Connect the 4 wire harness clamps.

    4. B001EUY

      Attach the 2 clamps and connect the connector.

    5. Attach the 2 claws and install the nut.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    6. Install the No. 1 relay block cover.

    7. B001CNEE03

      Attach the clamp and install the 3 bolts.

      Torque:
      for bolt A
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      for bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt C
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  23. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY


    1. Install the glove compartment door Click here.

  24. INSTALL GENERATOR ASSEMBLY

    Click here

  25. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. B001DZYE03

      Temporarily install the cooler compressor with the 2 bolts.

    2. Temporarily install the idle pulley bracket with the 4 bolts.

    3. Tighten the 6 bolts in the sequence shown in the illustration.

      Torque:
      for bolt A
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      except bolt A
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Connect the wire harness with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

    5. Connect the cooler compressor connector.

  26. INSTALL INTAKE PIPE ASSEMBLY

    Click here

  27. INSTALL RADIATOR ASSEMBLY

    Click here

  28. INSTALL FAN SHROUD

    Click here

  29. INSTALL NO. 2 RADIATOR HOSE

    Click here

  30. INSTALL NO. 1 RADIATOR HOSE

    Click here

  31. INSTALL RADIATOR SIDE DEFLECTOR RH

    Click here

  32. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

  33. INSTALL UPPER FRONT BUMPER RETAINER

    Click here

  34. INSTALL FRONT BUMPER COVER

    Click here

  35. INSTALL AIR CLEANER CASE ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  36. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  37. INSTALL RESONATOR WITH AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  38. INSTALL NO. 1 FRONT FENDER APRON TO FRAME SEAL LH


    1. Install the No. 1 front fender apron to frame seal with the 5 clips.

  39. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal with the 5 clips.

  40. INSTALL NO. 1 FRONT FENDER APRON TO FRAME SEAL RH


    1. Install the No. 1 front fender apron to frame seal with the 5 clips.

  41. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal with the 4 clips.

  42. INSTALL REAR ENGINE UNDER COVER ASSEMBLY


    1. Install the rear engine under cover with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  43. INSTALL TRANSMISSION UNDER COVER


    1. Install the transmission under cover with the 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

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


    1. B001IJW

      Hook the engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  45. INSTALL FRONT BUMPER COVER LOWER


    1. Install the front bumper cover lower with the 5 bolts and clip.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  46. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  47. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Install the cowl top ventilator louver Click here.

  48. INSTALL HOOD SUB-ASSEMBLY


    1. B001CHC

      Install the hood with the 8 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Text in Illustration
      B001CHY Bolt A
      B001DEF Bolt B

    2. Connect the washer nozzle hose.

  49. ADJUST HOOD SUB-ASSEMBLY

    Click here

  50. INSTALL BATTERY TRAY

  51. INSTALL BATTERY

  52. INSTALL BATTERY HOLD DOWN CLAMP


    1. B001I3ZE03

      Install the battery hold down clamp with the 2 nuts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Connect the engine wire with the nut labeled A.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  54. ADD ENGINE OIL

    Click here

  55. ADD ENGINE COOLANT

    Click here

  56. TIGHTEN FUEL TANK CAP ASSEMBLY

  57. BLEED AIR FROM FUEL SYSTEM

    Click here

  58. INSPECT FOR FUEL LEAK

    Click here

  59. INSPECT FOR ENGINE OIL LEAK

    Click here

  60. INSPECT FOR COOLANT LEAK

    Click here

  61. ADD MANUAL TRANSMISSION OIL

  62. INSPECT FOR GAS LEAK

    Click here

  63. INSPECT ENGINE IDLE SPEED

    Click here

  64. INSPECT MAXIMUM ENGINE SPEED

    Click here