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Engine Assembly: Installation

  1. INSTALL KNOCK SENSOR 
    1. Install the knock sensor (See INSTALLATION ).
  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive: 

      Part No.08833-00080 THREE BOND 1344, 

      LOCTITE 242 or equivalent. 

    2. Using a deep socket wrench 24 mm, install the oil pressure switch.

    Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

  3. INSTALL THERMOSTAT 
    1. Install the thermostat (See INSTALLATION ).
  4. INSTALL WATER INLET 
    1. Install the water inlet (TMC made) (See INSTALLATION ).
  5. INSTALL WATER INLET PIPE 
    1. Install the water inlet pipe (TMC made) (See INSTALLATION ).
  6. INSTALL WATER INLET 
    1. Install the water inlet (TMMWV made) (See INSTALLATION ).
  7. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1 
    1. Install the compressor mounting bracket No. 1 (See INSTALLATION ).
  8. INSTALL GENERATOR BRACKET NO. 1 Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 
  9. INSTALL PUMP BRACKET Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 
  10. INSTALL ENGINE MOUNTING BRACKET RH Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 
  11. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY NO. 2 
    1. Install the exhaust manifold converter sub-assembly No. 2 (See INSTALLATION  ).
  12. INSTALL MANIFOLD STAY NO. 2 Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 
  13. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2 
    1. Install the exhaust manifold heat insulator No. 2 (See INSTALLATION  ).
  14. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3 
    1. Install the manifold converter insulator No. 3 (See INSTALLATION  ).
  15. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the ignition coil assembly (See ADJUSTMENT  ).
  16. INSTALL WATER OUTLET 
    1. Install the water outlet (See INSTALLATION  ).
  17. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold (See ADJUSTMENT  ).
  18. INSTALL INTAKE AIR SURGE TANK 
    1. Install the intake air surge tank (See ADJUSTMENT  ).
  19. INSTALL EMISSION CONTROL VALVE SET 
    1. Install the emission control valve set (See ADJUSTMENT  ).
  20. INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY SST 09213-54015 (91651-60855), 09330-00021 
    1. Install the drive plate and ring gear sub-assembly (See REMOVAL  ).
  21. INSTALL ENGINE MOUNTING BRACKET RR Torque: 64 N*m (653 kgf*cm, 47 in.*lbf) 
  22. INSTALL AUTOMATIC TRANSMISSION W/ TRANSFER (for 4WD) 
    1. Install the automatic transmission w/ transfer (See INSTALLATION ).
  23. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD) 
    1. Install the transfer stiffener plate RH (See INSTALLATION ).
  24. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) 
    1. Install the automatic transaxle assembly (See INSTALLATION ).
  25. INSTALL ENGINE MOUNTING BRACKET FR 
    1. Install the engine mounting bracket FR (See INSTALLATION ).
  26. INSTALL STARTER ASSEMBLY 
    1. Install the starter assembly (See INSTALLATION ).
  27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 
    1. Install the front drive shaft assembly LH (See INSTALLATION ).
  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) 
    1. Install the front drive shaft assembly RH (See INSTALLATION ).
  29. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) 
    1. Install the front drive shaft assembly RH (See INSTALLATION ).
  30. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulator RH and LH with the 2 nuts.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 1: Installing Engine Mounting Insulator RH And LH
      G04087773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine mounting insulator FR with the nut.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

      Fig 2: Installing Engine Mounting Insulator FR
      G04087774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator RR with the 2 bolts.

    Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 

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

    Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

  32. INSTALL STABILIZER BAR FRONT (for 4WD) Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 
    Fig 3: Installing Engine Mounting Insulator RR
    G04087775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL VANE PUMP ASSEMBLY 
    1. Temporarily tighten the bolt.
    2. Install the adjusting strut to the engine mounting bracket RH with the bolt.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Fig 4: Installing Vane Pump Assembly
      G04087776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the PS pressure tube with the 3 nuts.

    Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

  34. INSTALL VANE PUMP V-BELT 
    1. Install the vane pump V-belt (See INSTALLATION  ).
  35. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY 
    1. Install the exhaust manifold converter sub-assembly (See INSTALLATION  ).
    Fig 5: Connecting PS Pressure Tube
    G04087777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL MANIFOLD STAY 
    1. Install the manifold stay (See INSTALLATION  ).
  37. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Install the exhaust manifold heat insulator No. 1 (See INSTALLATION  ).
  38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Install the engine assembly to the vehicle.
    3. Install the frame side rail plate RH and LH with the 6 bolts and 2 nuts.
      Fig 6: Installing Frame Side Rail Plate RH And LH
      G04087778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A 

      85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt B 

      32 N*m (326 kgf*cm, 24 ft.*lbf) Nut C 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

    4. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
    Fig 7: Installing Front Suspension Member Brace Rear RH And LH
    G04087779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Torque: Bolt A 

    85 N*m (867 kgf*cm, 63 ft.*lbf) Bolt B 

    32 N*m (326 kgf*cm, 24 ft.*lbf) Nut C 

    32 N*m (326 kgf*cm, 24 ft.*lbf) 

  39. INSTALL HEIGHT CONTROL SENSOR LINK SUBASSEMBLY FRONT 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    1. w/ air suspension
  40. CONNECT STEERING INTERMEDIATE SHAFT SUBASSEMBLY 
    1. Connect the steering intermediate shaft subassembly (See INSTALLATION ).
  41. INSTALL FRONT AXLE ASSEMBLY LH 
    1. Install the front axle assembly LH (See INSTALLATION ).
  42. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  43. INSTALL FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH 
    1. Install the front suspension arm sub-assembly lower No. 1 LH (See INSTALLATION ).
  44. INSTALL FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  45. CONNECT TIE ROD END SUB-ASSEMBLY LH 
    1. Connect the tie rod end sub-assembly LH (See INSTALLATION ).
  46. CONNECT TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  47. INSTALL SPEED SENSOR FRONT LH 
    1. Install the speed sensor front LH (See INSTALLATION ).
  48. INSTALL SPEED SENSOR FRONT RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  49. INSTALL FRONT AXLE HUB LH NUT 
    1. Install the front axle hub LH nut (See INSTALLATION ).
  50. INSTALL FRONT AXLE HUB RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  51. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 
    1. Install the front stabilizer link assembly LH (See INSTALLATION ).
  52. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  53. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1 

    Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  54. INSTALL EXHAUST PIPE ASSEMBLY FRONT 
    1. Install the exhaust pipe assembly front (See INSTALLATION ).
  55. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3 
    1. Install the exhaust pipe sub-assembly front No. 3 (See INSTALLATION ).
  56. INSTALL PROPELLER SHAFT (for 4WD) 
    1. Install the propeller shaft (See INSTALLATION ).
  57. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1 
    1. Connect the fuel pipe sub-assembly No. 1 (See FUEL SYSTEM ).
  58. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install the transmission control cable assembly (See INSTALLATION ).
  59. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. Install the compressor and magnetic clutch (See INSTALLATION ).
  60. INSTALL GENERATOR BELT ADJUSTING BAR 
    1. Install the generator belt adjusting bar (See INSTALLATION ).
  61. INSTALL GENERATOR BRACKET NO. 2 
    1. Install the generator bracket No. 2 (See INSTALLATION  ).
  62. INSTALL ENGINE MOUNTING STAY NO. 2 RH 
    1. Install the engine mounting stay No. 2 RH (See INSTALLATION  ).
  63. INSTALL ENGINE MOVING CONTROL ROD 
    1. Install the engine moving control rod (See INSTALLATION  ).
  64. INSTALL GENERATOR ASSEMBLY 
    1. Install the generator assembly (See INSTALLATION ).
  65. INSTALL V-(COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 
    1. Install the V-(cooler compressor to crankshaft pulley) belt No. 1 (See INSTALLATION  ).
  66. INSPECT DRIVE BELT DEFLECTION AND TENSION 
    1. Inspect the drive belt deflection and tension (reference) (See DRIVE BELT  ).
  67. INSTALL AIR CLEANER INLET NO. 1 
    1. Install the air cleaner inlet No. 1 (See INSTALLATION ).
  68. INSTALL AIR CLEANER BRACKET 
    1. Install the air cleaner bracket (See INSTALLATION ).
  69. INSTALL AIR CLEANER CASE 
    1. U(a) Install the air cleaner case (See INSTALLATION ).
  70. INSTALL AIR CLEANER INLET NO. 2 
    1. Install the air cleaner inlet No. 2 (See INSTALLATION ).
  71. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 
    1. Install the air cleaner cap sub-assembly (See INSTALLATION ).
  72. CONNECT VACUUM HOSE 
    Fig 8: Vacuum Hose Routing Diagram
    G04087780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Install the V-bank cover sub-assembly (See ADJUSTMENT  ).
  74. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER 
    1. Install the cowl top panel sub-assembly outer (See INSTALLATION ).
  75. INSTALL WINDSHIELD WIPER LINK ASSEMBLY 
    1. Install the windshield wiper link assembly (See INSTALLATION ).
  76. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY 
    1. Install the cowl top ventilator louver sub-assembly (See INSTALLATION ).
  77. INSTALL FR WIPER ARM LH 
    1. Install the FR wiper arm LH (See INSTALLATION ).
  78. INSTALL FR WIPER ARM RH 
    1. Install the FR wiper arm RH (See INSTALLATION ).
  79. INSTALL FRONT WHEELS 
    1. Install the front wheels (See INSTALLATION  ).
  80. ADD TRANSFER OIL (for 4WD) 
    1. Add transfer oil (See TRANSFER OIL ).
  81. INSPECT TRANSFER OIL (for 4WD) 
    1. Inspect the transfer oil (See TRANSFER OIL ).
  82. ADD AUTOMATIC TRANSAXLE FLUID 
  83. ADD ENGINE OIL 
    1. Add engine oil (See REPLACEMENT ).
  84. ADD ENGINE COOLANT 
    1. Add engine coolant (See COOLANT ).
  85. ADD POWER STEERING FLUID 
  86. BLEED POWER STEERING FLUID 
  87. INSPECT AUTOMATIC TRANSAXLE FLUID 
    1. Inspect the automatic transaxle fluid (See AUTOMATIC TRANSAXLE FLUID ).
  88. CHECK FOR ENGINE OIL LEAKS 
  89. CHECK FOR ENGINE COOLANT LEAKAGE 
    1. Check the engine coolant leakage (See COOLING SYSTEM ).
  90. CHECK POWER STEERING FLUID LEAKAGE 
  91. INSPECT FUEL LEAKAGE 
  92. CHECK FOR EXHAUST GAS LEAKAGE 
  93. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust front wheel alignment (See FRONT WHEEL ALIGNMENT ).
  94. INSPECT STEERING WHEEL CENTER POINT 
  95. INSPECT IGNITION TIMING 

    SST 09843-18040 

    1. Inspect the ignition timing (See ON-VEHICLE INSPECTION  ).
  96. INSPECT ENGINE IDLE SPEED SST 09843-18040 
    1. Inspect the engine idle speed (See ON-VEHICLE INSPECTION  ).
  97. INSPECT CO/HC 
    1. Inspect the CO/HC (See ON-VEHICLE INSPECTION  ).
  98. CHECK ABS SPEED SENSOR SIGNAL 
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