ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

    Note


    • 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.

    • 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.


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

    2. Remove the engine assembly from the engine stand.

  3. INSTALL ENGINE ASSEMBLY

    Tech Tips

    Perform "Inspection After Repair" after replacing the engine assembly.

    Click here


    1. Slowly lower the engine assembly into the engine compartment.

    2. Install the engine assembly to the body with the 4 bolts and 4 nuts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Tech Tips


      • Make sure to tighten the side with the nut.

      • When installing a bolt with a claw (stopper), make sure to install the bolt with the claw (stopper) as shown in the illustration so that a clearance is maintained between the claw (stopper) and the intermediate shaft.

      B003QUPC01
      *a

      Front Engine Mounting Insulator

      (LH Side)
      *b Claw (Stopper)
      B003R2S Front

    3. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.

  4. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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  5. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


  6. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  7. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 4WD)


  8. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Pre-Runner)


  9. INSTALL PROPELLER SHAFT GUARD

    Click here

  10. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

    Click here

  11. INSTALL POWER STEERING LINK ASSEMBLY (for 4WD)

    Click here

  12. CONNECT STEERING SLIDING YOKE (for 4WD)

    Click here

  13. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING (for 4WD)

    Click here

  14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)

    Click here

  15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

    Tech Tips

    Use the same procedure described for the LH side.

  16. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (for 4WD)

    Click here

  17. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH (for 4WD)

    Tech Tips

    Use the same procedure described for the LH side.

  18. CONNECT TIE ROD END SUB-ASSEMBLY LH (for 4WD)

    Click here

  19. CONNECT TIE ROD END SUB-ASSEMBLY RH (for 4WD)

    Tech Tips

    Use the same procedure described for the LH side.

  20. CONNECT FRONT SPEED SENSOR LH (for 4WD)

    Click here

  21. CONNECT FRONT SPEED SENSOR RH (for 4WD)

    Tech Tips

    Use the same procedure described for the LH side.

  22. INSTALL FRONT AXLE SHAFT NUT (for 4WD)

    Click here

  23. INSTALL FRONT AXLE HUB GREASE CAP (for 4WD)

    Click here

  24. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

    Click here

  25. INSTALL PROPELLER SHAFT GUARD (for 4WD)

    Click here

  26. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY


    1. Connect the No. 2 fuel pipe sub-assembly, and slide the clamp to secure the hose.

  27. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  28. INSTALL WATER HOSE SUB-ASSEMBLY


    1. B003M8Q

      Install the water hose sub-assembly, and slide the 4 clamps to secure the hose.

  29. CONNECT COOLER COMPRESSOR ASSEMBLY

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  30. INSTALL GENERATOR ASSEMBLY


  31. CONNECT ENGINE WIRE (for LHD)


    1. B003MS0

      Connect the 2 connectors to the engine room relay block.

    2. Connect the engine wire to the engine room relay block with the nut.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
    3. B003KBY

      Attach the 2 claws and install the No. 1 relay block cover side to the engine room relay block.

    4. B003MEX

      Attach the 3 claws and install the No. 1 relay block cover upper to the engine room relay block.

    5. B003Q3H

      Attach the 2 clamps and connect the No. 2 engine wire with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    6. Install the battery tray.

    7. Install the battery.

    8. B003OYA

      Install the battery hold down clamp with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    9. B003NMW

      Tighten the nut and install the positive (+) battery terminal.

      Torque:
      5.35 N*m  { 55 kgf*cm, 47 in.*lbf }

      Tech Tips

      Position the positive (+) battery terminal as shown in the illustration.

      B003JQ2N01
    10. B003RZL

      Connect the engine room main wire to the battery positive cable with the nut.

      Torque:
      7.55 N*m  { 77 kgf*cm, 67 in.*lbf }
    11. B003R6TN01

      Push the engine wire through the dash panel into the cabin.

      Tech Tips

      The wire should be within the range shown in the illustration.

    12. Connect the engine wire and attach the clamp to the bracket.

    13. B003JWU

      Connect the engine wire with the bolt.

      Torque:
      7.55 N*m  { 77 kgf*cm, 67 in.*lbf }
    14. B003K57

      Connect the connector.

    15. B003SFL

      Attach the 2 clamps and connect the 3 connectors to the instrument panel wire.

  32. CONNECT ENGINE WIRE (for RHD)


    1. B003MS0

      Connect the 2 connectors to the engine room relay block.

    2. Connect the engine wire to the engine room relay block with the nut.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
    3. B003KBY

      Attach the 2 claws and install the No. 1 relay block cover side to the engine room relay block.

    4. B003MEX

      Attach the 3 claws and install the No. 1 relay block cover upper to the engine room relay block.

    5. B003Q3H

      Attach the 2 clamps and connect the No. 2 engine wire with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    6. Install the battery tray.

    7. Install the battery.

    8. B003OYA

      Install the battery hold down clamp with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    9. B003NMW

      Tighten the nut and install the positive (+) battery terminal.

      Torque:
      5.35 N*m  { 55 kgf*cm, 47 in.*lbf }

      Tech Tips

      Position the positive (+) battery terminal as shown in the illustration.

      B003JQ2N01
    10. B003RZL

      Connect the engine room main wire to the battery positive cable with the nut.

      Torque:
      7.55 N*m  { 77 kgf*cm, 67 in.*lbf }
    11. B003LK2N01

      Push the engine wire through the dash panel into the cabin.

      Tech Tips

      The wire should be within the range shown in the illustration.

    12. Connect the engine wire and attach the clamp to the bracket.

    13. B003NO8

      Connect the engine wire with the bolt.

      Torque:
      7.55 N*m  { 77 kgf*cm, 67 in.*lbf }
    14. B003KX1

      Connect the connector.

    15. B003KII

      Attach the 2 clamps and connect the 3 connectors to the instrument panel wire.

  33. INSTALL ECM

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  34. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

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  35. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

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  36. INSTALL FLYWHEEL HOUSING SIDE COVER

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  37. INSTALL STARTER ASSEMBLY

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  38. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

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  39. INSTALL NO. 2 MANIFOLD STAY

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  40. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  41. INSTALL MANIFOLD STAY

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  42. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  43. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

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  44. INSTALL INTAKE AIR SURGE TANK

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  45. CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      Do not hit other parts with the pulley when installing the vane pump.

    2. Connect the connector.

  46. INSTALL RADIATOR ASSEMBLY

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  47. CONNECT NO. 1 OIL COOLER INLET HOSE

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  48. CONNECT NO. 1 OIL COOLER OUTLET HOSE

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  49. INSTALL FAN SHROUD

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  50. INSTALL RADIATOR RESERVOIR

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  51. INSTALL RADIATOR HOSE INLET

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  52. INSTALL RADIATOR HOSE OUTLET

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  53. INSTALL NO. 1 RADIATOR AIR GUIDE

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  54. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly with the 3 bolts.

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

    2. Connect the 3 clamps to the air cleaner case sub-assembly.

  55. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  56. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE

    Click here

  57. INSTALL RADIATOR SIDE DEFLECTOR LH

    Click here

  58. INSTALL RADIATOR SIDE DEFLECTOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  59. INSTALL FRONT UPPER FENDER APRON SEAL LH


    1. Install the front upper fender apron seal LH with 6 new clips.

  60. INSTALL FRONT UPPER FENDER APRON SEAL RH


    1. Install the front upper fender apron seal RH with 6 new clips.

  61. INSTALL FRONT FENDER SEAL LH


    1. Install the front fender seal LH with 6 new clips.

  62. INSTALL FRONT FENDER SEAL RH


    1. Install the front fender seal RH with 6 new clips.

  63. ADD DIFFERENTIAL OIL (for 4WD)

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  64. INSTALL NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  65. INSTALL NO. 2 ENGINE UNDER COVER

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  66. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Torque:
    for M6 bolt
    11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }
    for M8 bolt
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  67. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood sub-assembly to the 2 hood hinge assemblies with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. Connect the washer nozzle hose.

    3. Adjust the hood sub-assembly.

      Click here

  68. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  69. ADD ENGINE OIL

    Click here

  70. ADD ENGINE COOLANT

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  71. INSPECT FOR COOLANT LEAK

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  72. INSPECT FOR FUEL LEAK

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  73. INSPECT FOR OIL LEAK

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  74. INSPECT FOR EXHAUST GAS LEAK

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  75. INSPECT IGNITION TIMING

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  76. INSPECT ENGINE IDLE SPEED

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  77. INSPECT CO/HC

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  78. INSTALL V-BANK COVER

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