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Section 1 (Engine Unit (4WD)): Installation

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL DRIVE PLATE 
    NOTE:
    • The mounting bolts are tightened in 2 progressive steps (steps  c and  e).
    • If any one of the mounting bolts is broken or deformed, replace it.
    NOTE:
    1. Apply adhesive to 2 or 3 threads of the mounting bolt end.
      1. Adhesive: 
      2. Part No. 08833-00070, THREE BOND 1324 or equivalent 
      Fig 1: Applying Adhesive To Threads Of Mounting Bolt End
      G02927237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front spacer, drive plate and rear spacer on the crankshaft.
    3. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
      1. 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: Installing Front Spacer, Drive Plate & Rear Spacer On Crankshaft
      G02927238Courtesy 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: Retightening Mounting Bolt & Checking Painted Mark Angle
      G02927239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ENGINE ASSEMBLY IN VEHICLE 
    1. Attach the engine chain hoist to the engine hangers.
    2. Slowly lower the engine assembly into the engine compartment.
    3. Attach the engine mounting brackets to the frame brackets.
      Fig 4: Lowering Engine Assembly Into Engine Compartment
      G02927240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts.
      1. Torque: 38 N.m (388 kgf.cm, 28 ft.lbf) 
    5. Remove the engine chain hoist.
      Fig 5: Installing Engine Mounting Bracket To Frame Brackets
      G02927241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL PS PUMP 

    Install the PS pump with the 3 bolts.

    1. Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 
    Fig 6: Installing PS Pump
    G02927242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. w/ A/C: 
    1. INSTALL A/C COMPRESSOR 
    1. Install the A/C compressor with the 3 bolts.
      1. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 
    2. Connect the A/C compressor connector.
  5. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES 
    1. Connect the 2 PS air hoses to 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 the upper intake manifold.
    6. Connect the 2 heater hoses.
    7. Connect the ground strap to the cowl panel.
    8. Connect the fuel inlet hose and clamps.
    9. Connect the fuel return hose and clamp.
    10. Connect the air inlet hose to the charcoal canister.
    11. Connect the EVAP hose to the charcoal canister.
    12. Connect the brake booster tube.
  6. CONNECT ENGINE WIRE TO CABIN 
    1. Push into the engine wire through the cowl panel.
      Fig 7: Installing A/C Compressor
      G02927243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket.
      3. Fig 8: Installing Hoses & Clamp
      G02927244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 3 connectors to the ECM.
    4. Connect the 2 wire harness connectors (cassette connector).
    5. Install the ECM with the 3 screws.
    6. Install the lower No.2 panel.
    7. Install the glove compartment door.
  7. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT 
    1. Temporarily install the fan pulley, the fan and fluid coupling assembly with the 4 nuts.
    2. Install the drive belt. ( GENERATOR )
    3. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
  8. INSTALL BATTERY CABLES 
    1. Connect the battery positive (+) terminal cable.
    2. Connect the battery negative (-) cable to the battery and left fender apron.
    3. Connect the clamp on battery negative (-) cable to No.2 relay box.
  9. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY 
    1. Install the air cleaner case with the 3 bolts.
      1. Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 
    2. Connect the intake air connector to the throttle body.
    3. Connect the MAF meter connector.
    4. w/ A/C:

      Install the suction hose to the intake air connector.

    5. Connect the PS air hose, air inlet hose for EVAP, PCV hose and MAF meter connector to the intake air connector.
  10. INSTALL THROTTLE BODY COVER 
  11. INSTALL TRANSMISSION (See  INSTALLATION  ) 
  12. INSTALL RADIATOR ASSEMBLY (See  INSTALLATION  ) 
  13. INSTALL FRONT STABILIZER BAR (  STABILIZER BAR  ) 
  14. INSTALL FRONT AND REAR PROPELLER SHAFTS (See  INSTALLATION  ) 
  15. INSTALL FRONT EXHAUST PIPES (See  COMPONENTS  ) 
  16. FILL WITH ENGINE COOLANT (See  REPLACEMENT  ) 
  17. FILL WITH ENGINE OIL (See  REPLACEMENT  ) 
  18. START ENGINE AND CHECK FOR LEAKS 
  19. INSTALL ENGINE UNDER COVERS 
  20. INSTALL HOOD 
  21. PERFORM ROAD TEST 

    Check for abnormal noise, shock, slippage, correct shift points and smooth operation.

  22. RECHECK ENGINE COOLANT AND OIL LEVELS 
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