ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL ENGINE HANGER

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  2. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


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

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }

  3. INSTALL FRONT ENGINE MOUNTING HEAT INSULATOR RH


    1. Install the front engine mounting heat insulator RH to the front engine mounting insulator with the bolt.

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

  4. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  5. REMOVE ENGINE 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.

  6. 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.

      B0068Q2C01
      *A for LHD
      *B for RHD
      *a

      Front Engine Mounting Insulator

      (LH side)
      *b

      Front Engine Mounting Insulator

      (RH side)
      *c Claw (Stopper)
      B0068HS Front

    3. Remove the 2 bolts and 2 engine hangers.

  7. INSTALL REAR END PLATE


    1. Install the rear end plate to the cylinder block with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Connect the No. 1 water by-pass pipe to the rear end plate with the bolt.

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

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

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

    Click here

  10. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  11. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

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

    Click here

  13. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


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


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

    Click here

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

    Click here

  17. CONNECT STEERING SLIDING YOKE (for 4WD)

    Click here

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

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

  22. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM ASSEMBLY LH (for 4WD)

    Click here

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

    Click here

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

    Click here

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

    Click here

  26. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 2WD and Pre-Runner)

    Click here

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

    Click here

  28. INSTALL PROPELLER SHAFT GUARD

    Click here

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

    Click here

  30. INSTALL PROPELLER SHAFT GUARD (for 4WD)

    Click here

  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  32. CONNECT ENGINE WIRE


    1. Connect the sensor bracket to the right side of the frame with the bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. Connect the air fuel ratio sensor connector.

    3. Connect the wire clamp to the front engine mounting bracket LH with the bolt.

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

    4. Attach the clamp.

    5. Connect the 2 connectors to the engine room relay block.

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

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

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

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

    9. B00696FN01

      Attach the clamp and install the No. 2 engine wire with the bolt.

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

      Tech Tips

      Position the No. 2 engine wire as shown in the illustration.

    10. 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 }

    11. Install the battery tray.

    12. Install the battery.

    13. Install the battery hold down clamp with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    14. B0068Q8N01

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

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

      Tech Tips

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

    15. Connect the engine room main wire to the positive (+) battery terminal with the nut.

      Torque:
      7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

    16. Connect the connector to the engine room main wire.

    17. B0068HVN01

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

      Tech Tips

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

    18. w/ Secondary Air Injection System:


      1. Connect the engine wire to the air injection control bracket with the bolt.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      2. Attach the clamp.

      3. Connect the air injection control driver connector.

    19. w/o Secondary Air Injection System:


      1. Connect the engine wire to the air injection control bracket with the bolt.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

    20. 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

    Click here

  35. CONNECT NO. 1 FUEL HOSE

    Click here

  36. CONNECT NO. 2 FUEL HOSE

    Click here

  37. CONNECT NO. 4 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

    Click here

  38. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the intake manifold, and slide the clamp to secure the hose.

  39. CONNECT PURGE LINE HOSE


    1. Connect the purge line hose to the purge VSV, and slide the clamp to secure the hose.

  40. INSTALL STARTER ASSEMBLY

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  41. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

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  42. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring and the engine oil level dipstick guide with the bolt.

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

  43. INSTALL ENGINE OIL LEVEL DIPSTICK

  44. CONNECT VANE PUMP ASSEMBLY


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

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

    2. Connect the power steering oil pressure switch connector.

  45. CONNECT HEATER HOSE


    1. Connect the heater water outlet hose to the heater radiator unit sub-assembly, and slide the clamp to secure the hose.

    2. Connect the heater water inlet hose to the heater radiator unit sub-assembly, and slide the clamp to secure the hose.

  46. INSTALL RADIATOR ASSEMBLY

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  47. CONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission)

    Click here

  48. CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

    Click here

  49. INSTALL FAN SHROUD

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  50. INSTALL RADIATOR RESERVOIR

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  51. CONNECT AIR PUMP INLET (w/ Secondary Air Injection System)

    Click here

  52. INSTALL RADIATOR HOSE OUTLET

    Click here

  53. INSTALL RADIATOR HOSE INLET

    Click here

  54. INSTALL NO. 1 RADIATOR AIR GUIDE

    Click here

  55. INSTALL RADIATOR SIDE DEFLECTOR LH


  56. INSTALL RADIATOR SIDE DEFLECTOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  57. INSTALL INTAKE AIR CONNECTOR

    Click here

  58. 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. Attach the 3 wire harness clamps.

  59. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner cap sub-assembly.

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


    1. Install the air cleaner cap sub-assembly with air cleaner hose and tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Attach the 4 clamps.

    3. Connect the intake mass air flow meter connector and attach the 2 wire harness clamps.

  61. 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 to the hood sub-assembly.

    3. Adjust the hood sub-assembly.

      Click here

  62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  63. ADD ENGINE OIL

    Click here

  64. ADD ENGINE COOLANT

    Click here

  65. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transmission)


  66. INSPECT SHIFT LEVER POSITION (for Automatic Transmission)


  67. ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


  68. ADJUST AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


  69. ADD MANUAL TRANSMISSION OIL (for Manual Transmission)


  70. ADD DIFFERENTIAL OIL (for 4WD)

    Click here

  71. INSPECT FOR FUEL LEAK

    Click here

  72. INSPECT FOR OIL LEAK

    Click here

  73. INSPECT FOR COOLANT LEAK

    Click here

  74. INSPECT FOR EXHAUST GAS LEAK

    Click here

  75. INSPECT IGNITION TIMING

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  76. INSPECT ENGINE IDLE SPEED

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  77. CHECK CO/HC

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  78. CHECK THROTTLE BODY WITH MOTOR ASSEMBLY

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  79. INSTALL FRONT FENDER SEAL LH


    1. for 2WD:


      1. Install the front fender seal LH with 5 new clips.

    2. for 4WD and Pre-Runner:


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

  80. INSTALL FRONT FENDER SEAL RH


    1. for 2WD:


      1. Install the front fender seal RH with 5 new clips.

    2. for 4WD and Pre-Runner:


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

  81. INSTALL FRONT UPPER FENDER APRON SEAL LH


    1. for 2WD:


      1. Install the front upper fender apron seal LH with 5 new clips.

    2. for 4WD and Pre-Runner:


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

  82. INSTALL FRONT UPPER FENDER APRON SEAL RH


    1. for 2WD:


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

    2. w/ Secondary Air Injection System:


      1. Install the front upper fender apron seal RH with 5 new clips.

    3. w/o Secondary Air Injection System:


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

  83. INSTALL NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY (w/ Cover)

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

  84. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

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

  85. INSTALL NO. 1 ENGINE UNDER COVER (for 2WD)

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

  86. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. for 2WD:

      Torque:
      for M8 bolt
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for M10 bolt
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    2. for 4WD and Pre-Runner:

      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 }

  87. CHECK ABS SPEED SENSOR SIGNAL (for 4WD)