Installation
2UZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
INSTALLATION
1. REMOVE ENGINE STAND
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Remove the bolts and engine assembly from the engine stand.
2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation
3. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation
5. INSTALL NO. 2 AIR TUBE Installation
6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation
7. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
8. INSTALL NO. 3 AIR TUBE Installation
9. INSTALL ENGINE ASSEMBLY
(a) Slowly lower the engine assembly into the engine compartment.
NOTE: Make sure that the engine is clear of all wiring and hoses.
(b) Attach the engine mounting insulators to the vehicle.
(c) Install the 4 engine mounting insulator's bolts.
Torque: 79 Nm (806 kgf-cm, 58 ft-lbf)
10. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST: 09213-70011
SST: 09330-00021
(b) Install the front drive plate spacer, drive plate and rear drive plate spacer on the crankshaft.
(c) Install and uniformly tighten 8 new bolts in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE:
- Do not reuse the flywheel installation bolts.
- Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
(d) Mark the upside of each flywheel installation bolt with paint.
(e) Retighten the flywheel installation bolts by 90° as shown.
(f) Check that the painted marks are now at a 90° angle to the upside.
11. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD, refer to the following procedures Installation.
(b) for 4WD, refer to the following procedures .
12. INSTALL PROPELLER SHAFT ASSEMBLY
(a) for 2 joint type, refer to the following procedures Installation.
(b) for 3 joint type, refer to the following procedures Installation.
13. INSTALL EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures Installation.
(b) except Regular cab standard deck, refer to the following procedures Installation.
14. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install the water by-pass pipe with the 2 bolts.
15. INSTALL GENERATOR ASSEMBLY Installation
16. CONNECT VANE PUMP ASSEMBLY Installation
17. CONNECT COOLER COMPRESSOR ASSEMBLY Installation
18. CONNECT WIRE HARNESS AND HOSE
(a) Connect the 3 connectors to the engine room junction block.
(b) Install the engine wire with the nut.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Connect the 4 air injection control driver connectors.
(d) Install the ground wire with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Connect the positive (+) battery terminal and install the engine wire with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(f) Connect the air injection system hose.
(g) Install the ground wire with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(h) Connect the air pump connector and install the connector bracket with the bolt.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(i) Connect the 4 connectors to the connector holder block.
(j) Connect the heater hoses.
(k) Connect the ECM connector and clamp.
HINT: Refer to the following procedures to connect the ECM connector Installation.
(l) Connect the vacuum hose assembly.
19. CONNECT FUEL MAIN AND RETURN HOSE
(a) Connect the fuel main and return hoses Service Precautions.
(b) Install the fuel pipe clamp.
20. INSTALL RADIATOR ASSEMBLY Installation
21. INSTALL OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Install the oil cooler Installation.
22. INSTALL FLUID COUPLING ASSEMBLY Installation
23. INSTALL FAN AND GENERATOR V BELT Installation
24. INSTALL RADIATOR HOSE OUTLET
25. INSTALL RADIATOR HOSE INLET
26. INSTALL RADIATOR SIDE DEFLECTOR LH Installation
27. INSTALL RADIATOR SIDE DEFLECTOR RH Installation
28. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Install the air cleaner element onto the air cleaner case.
(c) Install the air cleaner cap.
(1) Fasten the 4 hook clamps.
(2) Connect the MAF meter connector.
(3) Attach the wire harness clamp.
29. INSTALL NO. 2 VENTILATION HOSE
(a) Install the No. 2 ventilation hose and vacuum hose.
30. INSTALL AIR CLEANER HOSE ASSEMBLY
(a) Install the air cleaner hose.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
HINT: Make sure that the clamp band end is aligned with the limit mark when the hose clamp is tightened, as indicated by A and B in the illustration.
(b) Connect the vacuum hose.
(c) Connect the No. 2 ventilation hose.
31. ADD ENGINE OIL Replacement
32. ADD ENGINE COOLANT Service and Repair
33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: Some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
34. INSPECT FOR OIL LEAK
(a) Inspect the engine oil leak Replacement.
35. INSPECT FOR COOLANT LEAK Testing and Inspection
36. INSPECT FOR EXHAUST GAS LEAK Installation
37. INSPECT FOR FUEL LEAK Testing and Inspection
38. INSPECT SHIFT LEVER POSITION Shift Lever Assembly (for Column Shift Type)
39. INSTALL THROTTLE BODY COVER SUB-ASSEMBLY Installation
40. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY Installation
41. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor Installation.
42. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Attach the lower part of the 2 food supports to the hood support bolt ball joints.
NOTE: Install the hood support while supporting the hood by hand.
(c) Attach the hood support clips.
NOTE: Check that the hood support is engaged in the ball joint and it cannot be pulled out.
43. ADJUST HOOD SUB-ASSEMBLY Adjustments
44. INSTALL NO. 1 ENGINE UNDER COVER Replacement
45. CHECK IGNITION TIMING Engine
46. CHECK ENGINE IDLE SPEED Engine
47. CHECK CO/HC Engine
48. CHECK ENGINE OIL LEVEL Testing and Inspection
49. CHECK ENGINE COOLANT LEVEL Testing and Inspection