Engine Unit: Installation

HINT:

• The mounting bolts are tightened in 2 steps (steps ( c) 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.
   1. Adhesive: Part Ho. 08833-00070, THREE BOND 1324 or equivalent 
   Fig 1: Applying Adhesive To Threads Of Mounting Bolt End

   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 in Fig 2 .
   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 Bolts In 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 in Fig 3 .
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.
   1. 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 Ground Strap & Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply adhesive to 2 or 3 threads from the bolt end.
   1. Adhesive: Part No. 08833-00070, 1324 or equivalent 
   Fig 5: Applying Adhesive To Threads From Bolt End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
   1. Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) 

   HINT:

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

   Fig 6: Holding Crankshaft Pulley Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the flywheel housing under cover with the bolt.
   1. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 
Fig 7: Installing Flywheel Housing Under Cover With Bolt
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

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the frame crossmember with the 8 bolts and the 4 nuts.
   Fig 10: Installing Frame Crossmember With Bolts & Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) for bolts 74 N.m (750 kgf.cm, 55 ft.lbf) for nuts 
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.
   1. Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) 
8. Remove the engine chain hoist.

Fig 11: Installing Nuts & Bolts Holding Engine Mounting Brackets To Frame Brackets

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the PS pump with the 3 bolts.

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

1. Install the A/C compressor with the 3 bolts.
   Fig 12: Installing A/C Compressor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 
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.
2. Install the transfer shift lever boot with the 4 bolts.
   Fig 13: Installing Transfer Shift Lever Boot With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the shift lever assembly.
   1. Connect the transmission control rod to the shift lever assembly with the nut.
      1. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 
   2. Install the shift lever assembly with the 6 bolts.
      1. Torque: 8.3 N.m (86 kgf.cm, 73 in.lbf) 
   3. Connect the connector.
   Fig 14: Installing Shift Lever Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. 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 GENERATOR )
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.