Engine Unit: Installation

HINT:

• The mounting bolts are tightened in 2 steps (steps and (e)).
• If any one of the mounting bolts is broken or deformed, replace it.

1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

   Fig 1: Applying Adhesive Threads To Mounting Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front spacer, the drive plate and the rear spacer on the crankshaft.
3. Hold the crankshaft pulley bolt with a wrench, and install and evenly tighten the 8 mounting bolts, a little at a time for several times as in the sequence shown.

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

   If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.

   Fig 2: Drive Plate Bolt Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the mounting bolt with paint.
5. Retighten the mounting bolts by 90° in the numerical order shown.
6. Check that the painted mark is now at a 90° angle to (e).

Fig 3: Tightening Mounting Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Check the torque converter clutch installation. (See INSTALLATION )
2. Attach the transmission to the engine.
3. Install the ground strap and 10 bolts.

   Torque: 

   37 N.m (380 kgf.cm, 27 ft.lbf) for 14 mm head 

   72 N.m (730 kgf.cm, 53 ft.lbf) for 17 mm head 

Fig 4: Installing Transmission To Engine

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive to 2 or 3 threads from the bolt end.

   Adhesive: 

   Part No. 08833-00070, THREE BOND 1324 or equivalent 

   Fig 5: Applying Adhesive To Converter Clutch Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.

   Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) 

   HINT:

   Fig 6: Installing Torque Converter Clutch Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   First install the black colored bolt, install the other bolts.

3. Install the flywheel housing under cover with the bolt.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

Fig 7: Installing Flywheel Under Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the 5 connectors.
2. Connect the 2 wire clamps.

1. Attach the engine chain hoist to the engine hangers.
2. Slowly lower the engine and the transmission assembly into the engine compartment.
3. Attach the engine mounting brackets to the frame brackets.
   Fig 8: Lowering Engine And Transmission Assembly Into Engine Compartment

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Keep the engine level with a jack.
   Fig 9: Keeping Engine Level With A Jack

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the frame crossmember with the 8 bolts and the 4 nuts.

   Torque: 

   50 N.m (510 kgf.cm, 37 ft.lbf) for bolts 

   74 N.m (750 kgf.cm, 55 ft.lbf) for nuts 

   Fig 10: Installing Frame Crossmember

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the transfer case protector with the 3 bolts.
7. Install the 2 nuts and the 4 bolts holding the engine mounting brackets to the frame brackets.

   Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) 

   Fig 11: Installing Engine Mounting Brackets To Frame Brackets

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the engine chain hoist.

Install the PS pump with the 3 bolts.

Torque: 62 N.m (632 kgf.cm, 46 ft.lbf) 

1. Install the A/C compressor with the 3 bolts.

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

   Fig 12: Installing A/C Compressor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the A/C compressor connector.

1. Install the transfer shift lever.
   1. Install a new gasket and the shift lever with the 4 bolts.
   2. Connect the transfer shift lever rod to the shift lever with the bushing, the wave washer, the plate washer and the clip.
   Fig 13: Installing Transfer Shift Lever

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the transfer shift lever boot with the 4 bolts.
3. Install the shift lever assembly.
   1. Connect the transmission control rod to the shift lever assembly with the nut.

      Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

   2. Install the shift lever assembly with the 6 bolts.

      Torque: 8.3 N.m (86 kgf.cm, 73 in.lbf) 

      Fig 14: Installing Shift Lever Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Connect the connector.
4. Install the console upper cover.
5. Install the transfer shift lever knob.

1. Connect the 2 PS air hoses to the hose clamp on the No. 3 RH timing belt cover.
2. Connect the generator wire.
3. Connect the generator connector.
4. Connect the hose clamp for the PS air hose.
5. Connect the PS air hose to upper intake manifold.
6. Connect the 2 heater hoses.
7. Connect the engine wire clamp to the bracket on the cowl panel.
8. Connect the engine wire grommet to the cowl panel.
9. Connect the ground strap connector.
10. Connect the fuel main hose and the clamps.
11. Connect the fuel return hose and the clamp.
12. Connect the air inlet hose to the charcoal canister.
13. Connect the EVAP hose to the charcoal canister.
14. Connect the engine wire to the clamp on the right fender apron.
15. Connect the clamp on battery negative (-) cable to the relay box.
16. Connect the battery negative (-) cable to the right fender apron.
17. Connect the battery positive (+) terminal cable.

1. Connect the 3 wire harness connectors.
2. Install the ECM with the 3 screws.
3. Connect the 3 connectors to the ECM.
4. Install the glove compartment door.
5. Install the lower No. 2 panel.

1. Temporarily install the fan pulley, the fan and the fluid coupling assembly with the 4 nuts.
2. Install the generator drive belt. (See INSTALLATION )
3. Tighten the 4 nuts holding the fluid coupling to the fan bracket.

1. Place the fan shroud in the installation position.
2. Install the radiator with the 2 support collars, the 2 nuts and the 2 bolts.
3. Connect the 2 A/T oil cooler hoses to the radiator.
4. Install the lower radiator hose.
5. Attach the lower side of the fan shroud to the brackets of the radiator, and install the fan shroud with the 2 bolts.
6. Install the 2 brackets on the wire to the radiator with the 2 bolts.
7. Install the 2 clamps on the A/C discharge tube to the brackets on the wire with the 2 nuts.
8. Connect the upper radiator hose to the front water bypass joint.

1. Install the grommet to the reservoir.
2. Attach the lower side of the reservoir to the fan shroud.
3. Install the reservoir with the 2 bolts.
4. Connect the reservoir hose to the radiator.
5. Install the clamp on the wire to the reservoir.

Check for abnormal noise, shock, slippage, and make sure the shift points is correct and operation is smooth.