Installation

2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE MOUNTING INSULATOR LH

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

(a) Temporarily install the engine mounting insulator with the 4 bolts.

(b) Tighten the 4 bolts in the sequence shown in the illustration.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(c) Install the air cleaner bracket with the bolt.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

2. INSTALL ENGINE MOUNTING SPACER

HINT
Perform this procedure only when replacement of the engine mounting spacer is necessary.

(a) Temporarily install the engine mounting spacer with the 2 bolts.

(b) Tighten the 2 bolts in the sequence shown in the illustration.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

(a) Temporarily install the engine mounting insulator with the 3 bolts.

(b) Tighten the 3 bolts in the sequence shown in the illustration.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(c) Install the radiator reservoir bracket with the bolt.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

4. INSTALL REAR ENGINE MOUNTING INSULATOR

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

(a) Temporarily install the engine mounting insulator with the 2 bolts and 2 nuts.

(b) Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

5. REMOVE ENGINE STAND

(a) Install the No. 1 and No. 2 engine hangers with the 2 bolts as shown in the illustration.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

HINT
* Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

(b) Attach an engine sling device and hang the engine with a chain block.

(c) Lift the engine and remove it from the engine stand.

6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

7. INSTALL AUTOMATIC TRANSAXLE

(a) for 2WD:

Install the automatic transaxle Installation.

(b) for 4WD:

Install the automatic transaxle .

8. INSTALL STARTER ASSEMBLY Installation

9. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the suspension crossmember to the engine with the bolt.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

HINT
When installing the suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

10. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

11. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine.

12. INSTALL ENGINE AND TRANSAXLE

(a) Place the engine on an engine lifter.

HINT
Place the engine on wooden blocks or equivalent so that the engine is level.

(b) Remove the 2 bolts and No. 1 and No. 2 engine hangers.

(c) Operate the engine lifter and install the engine to the vehicle.

NOTICE:
Make sure that the engine is clear of all wiring and hoses.

(d) Temporarily install the front suspension crossmember with the 2 bolts.

(e) Temporarily install the member brace rear RH and LH with the 6 bolts.

(f) Install the engine mounting insulator LH with the bolt and nut.

Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

NOTICE:
While holding the bolt in place, tighten the nut.

(g) Install the engine mounting insulator RH with the bolt and 2 nuts.

for bolt and nut A - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

for nut B - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

(h) Tighten the front suspension member bolts.

for bolt A - Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

(i) Tighten the member brace rear bolts.

for bolt B - Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

for bolt C - Torque : 93 Nm (948 kgf-cm, 69 ft-lbf)

13. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the engine mounting insulator with the bolt and nut.

14. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Install the crossmember with the 6 bolts.

for bolt A - Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

for bolt B - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(b) Tighten the bolt and nut holding the engine mounting insulator.

Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

15. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

(a) Install the reinforcement with the 4 bolts.

Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

16. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

(a) Install the reinforcement with the 4 bolts.

Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

17. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

18. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

19. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

20. INSTALL TORQUE CONVERTER SETTING BOLT

(a) Apply a few drops of adhesive to 2 or 3 threads at the tip of the 6 torque converter clutch mounting bolts.

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Install the 6 torque converter clutch setting bolts while holding the crankshaft pulley bolt with a wrench.

Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

HINT
First install the black colored bolt, and then the 5 remaining silver colored bolts.

(c) Install the flywheel housing under cover.

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

(a) Install the propeller shaft assembly Installation.

22. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

23. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

24. INSTALL DRIVE SHAFT

(a) for 2WD:

Install the front drive shafts Installation.

(b) for 4WD:

Install the front drive shafts Installation.

25. INSTALL FRONT AXLE SHAFT NUT Installation

26. CONNECT WIRE HARNESS AND HOSE

(a) Connect the heater hoses.

(b) Connect the vacuum hose.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(d) Connect the engine wire and install the nut.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(e) Connect the 3 junction connectors.

(f) Connect the engine wire with the 3 clamps and install the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(g) Connect the starter wire harness with the clamp, and then install the terminal nut and cover the nut with the cap.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

27. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push the tube connector onto the pipe until the tube connector makes a "click" sound.

NOTICE:
* Before connecting the connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.
* After connecting the fuel tube connector and pipe, check that they are securely connected by trying to pull them apart.
(b) Install the No. 1 fuel pipe clamp.

28. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

29. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

30. CONNECT NO. 2 RADIATOR HOSE Installation

31. CONNECT NO. 1 RADIATOR HOSE Installation

32. INSTALL GENERATOR ASSEMBLY Installation

33. INSTALL WIRE HARNESS CLAMP BRACKET Installation

34. INSTALL FAN & GENERATOR V BELT Installation

35. INSTALL RADIATOR RESERVOIR Installation

36. INSTALL ECM Installation

37. INSTALL AIR CLEANER CASE Installation

38. INSTALL AIR CLEANER ASSEMBLY Installation

39. INSTALL BATTERY BRACKET REINFORCEMENT Installation

40. INSTALL FRONT BATTERY BRACKET Installation

41. INSTALL BATTERY TRAY

42. INSTALL BATTERY

43. INSTALL BATTERY INSULATOR

44. INSTALL BATTERY CLAMP SUB-ASSEMBLY Installation

45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

46. CHARGE REFRIGERANT Service and Repair

47. ADD TRANSFER OIL (for 4WD)

48. ADD AUTOMATIC TRANSAXLE FLUID

(a) for 2WD:

Add automatic transmission fluid Installation.

(b) for 4WD:

Add automatic transmission fluid .

49. ADD ENGINE OIL Replacement

50. ADD ENGINE COOLANT Service and Repair

51. INSPECT SHIFT LEVER POSITION

52. INSPECT FOR FUEL LEAK Installation

53. INSPECT FOR OIL LEAK Replacement

54. INSPECT FOR COOLANT LEAK Testing and Inspection

55. INSPECT FOR REFRIGERANT LEAK Service and Repair

56. INSPECT IGNITION TIMING Engine

57. INSPECT ENGINE IDLE SPEED Engine

58. INSPECT CO/HC Engine

59. INSTALL FRONT WHEEL

60. ADJUST WHEEL ALIGNMENT

(a) Adjust the front wheel alignment Service and Repair.

61. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the under cover with the 3 clips.

62. INSTALL REAR ENGINE UNDER COVER RH

(a) Install the under cover with the 3 clips.

63. INSTALL REAR ENGINE UNDER COVER LH

(a) Install the under cover with the 2 clips.

64. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the under cover with the 8 screws and 8 clips.

65. INSTALL RADIATOR SUPPORT OPENING COVER Installation

66. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

67. RESET MEMORY

(a) When replacing the engine assembly, perform the Reset Memory procedure (A/T initialization) for U241E (2WD) Programming and Relearning or for U140F (4WD) .