Installation
HINT:
Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft, No. 2 camshaft, No. 3 camshaft sub-assembly, No. 4 camshaft sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.
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1. INSTALL ENGINE HANGER
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2. REMOVE ENGINE FROM ENGINE STAND
(a) Attach an engine sling device and hang the engine assembly with a chain block.
NOTICE:
Pay attention to the angle of the engine sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
(b) Lift the engine assembly and remove it from the engine stand.
(c) Place the engine assembly onto a work bench.
3. INSTALL ENGINE ASSEMBLY
HINT:
Perform "Inspection After Repairs" after replacing the engine assembly.
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(a) Attach an engine sling device and hang the engine assembly with a chain block.
NOTICE:
Pay attention to the angle of the engine sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
(b) Slowly lower the engine assembly into the engine assembly compartment.
(c) Install the front engine mounting insulator LH with the 3 nuts and 2 bolts. Torque: Nut A : 72 N·m {734 kgf·cm, 53 ft·lbf} Nut B : 50 N·m {510 kgf·cm, 37 ft·lbf} |
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(d) Install the front engine mounting insulator RH with the 3 nuts and 2 bolts.
Torque:
Nut A :
72 N·m {734 kgf·cm, 53 ft·lbf}
Nut B :
50 N·m {510 kgf·cm, 37 ft·lbf}
(e) Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.
4. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)
(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021
(b) Install the crank angle sensor plate, drive plate and ring gear sub-assembly and rear drive plate spacer to the crankshaft.
Text in Illustration *1 |
Crank Angle Sensor Plate |
*2 |
Drive Plate and Ring Gear Sub-assembly |
*3 |
Rear drive plate Spacer |
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Automatic Transmission Side |
HINT:
As the crank angle sensor plate, drive plate and ring gear sub-assembly and rear drive plate spacer are not reversible, be sure to install it in the direction shown in the illustration.
(c) Clean the bolts and bolt holes.
(d) Apply adhesive to 2 or 3 threads at the end of the 8 bolts. Text in Illustration
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
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(e) Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration. Torque: 83 N·m {846 kgf·cm, 61 ft·lbf} NOTICE: Do not start the engine for at least an hour after installing the drive plate. |
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5. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021
(b) Install the crank angle sensor plate and flywheel sub-assembly to the crankshaft.
Text in Illustration *1 |
Crank Angle Sensor Plate |
|
Manual Transmission Side |
(c) Clean the bolts and bolt holes.
(d) Apply adhesive to 2 or 3 threads at the end of the 8 bolts. Text in Illustration
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
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(e) Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration. Torque: 30 N·m {306 kgf·cm, 22 ft·lbf} |
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(f) Mark paint marks on the bolt heads on the engine upper side.
Text in Illustration *a |
Paint Mark |
|
Engine Upper Side |
(g) Tighten the bolts 90° in the sequence shown in the illustration.
NOTICE:
Do not start the engine for at least an hour after installing the flywheel sub-assembly.
6. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
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7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)
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8. CONNECT SUCTION HOSE SUB-ASSEMBLY
(a) Connect the suction hose sub-assembly with the bolt.
Torque:
7,5 N·m {76 kgf·cm, 66 in·lbf}
(b) Attach the clamp to connect the wire harness to the suction hose sub-assembly.
(c) Connect the engine oil pressure switch assembly connector.
9. CONNECT ENGINE WIRE
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10. CONNECT NO. 1 FUEL TUBE SUB-ASSEMBLY
(a) Connect the No. 1 fuel tube sub-assembly to the fuel delivery pipe sub-assembly.
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11. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY
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12. CONNECT WATER HOSE SUB-ASSEMBLY
(a) Connect the water hose sub-assembly. Text in Illustration
HINT: The direction of the hose clip is indicated in the illustration. |
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13. CONNECT UNION TO CHECK VALVE HOSE (for Vacuum Brake Booster)
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14. CONNECT ENGINE WIRE
(a) Attach the grommet to the wire harness support. Text in Illustration
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(b) Pass the wire harness into the vehicle and install the wire harness support.
(c) Connect the 7 ECM connectors.
(d) Attach the clamp to connect the engine wire.
(e) Install the instrument lower panel assembly.
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(f) Attach the claw to connect the engine wire.
(g) Attach the claw to connect the engine wire to the engine room relay block.
(h) Install the nut.
Torque:
8,5 N·m {87 kgf·cm, 75 in·lbf}
(i) Connect the engine wire connector.
(j) Attach the clamp to connect the engine wire.
15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (for Manual Transmission)
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16. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Manual Transmission)
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17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (for Manual Transmission)
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18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Manual Transmission)
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19. INSTALL COOLER COMPRESSOR ASSEMBLY
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20. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
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21. CONNECT SUCTION HOSE SUB-ASSEMBLY
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22. INSTALL GENERATOR ASSEMBLY
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23. CONNECT VANE PUMP ASSEMBLY
(a) Install the vane pump assembly with the 2 bolts.
Torque:
21 N·m {214 kgf·cm, 15 ft·lbf}
(b) Install the bolt to connect the earth wire harness.
Torque:
8,5 N·m {87 kgf·cm, 75 in·lbf}
(c) Connect the oil pressure switch connector.
NOTICE:
Make sure that no oil adheres to the connector.
24. INSTALL FAN AND GENERATOR V BELT
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25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
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26. INSTALL THROTTLE BODY BRACKET
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27. INSTALL NO. 1 SURGE TANK STAY
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28. INSTALL NO. 2 SURGE TANK STAY
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29. INSTALL RADIATOR ASSEMBLY
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30. INSTALL FAN SHROUD
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31. CONNECT TRANSMISSION OIL COOLER HOSE (for Automatic Transmission)
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32. CONNECT RADIATOR RESERVE TANK HOSE
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33. INSTALL NO. 2 RADIATOR HOSE
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34. INSTALL NO. 1 RADIATOR HOSE
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35. INSTALL RADIATOR SIDE DEFLECTOR LH
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36. INSTALL RADIATOR SIDE DEFLECTOR RH
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37. INSTALL RADIATOR SUPPORT TO FRAME SEAL
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38. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Install the air cleaner case sub-assembly with the 3 bolts.
Torque:
12 N·m {122 kgf·cm, 9 ft·lbf}
(b) Install the air cleaner filter element sub-assembly.
39. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
40. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE
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41. INSTALL RADIATOR GRILLE
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42. INSTALL V-BANK COVER SUB-ASSEMBLY
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43. INSTALL BATTERY TRAY
44. INSTALL BATTERY
45. INSTALL BATTERY CLAMP SUB-ASSEMBLY
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46. CONNECT CABLE TO POSITIVE BATTERY TERMINAL
Torque:
5,4 N·m {55 kgf·cm, 48 in·lbf}
47. INSTALL FRONT FENDER SEAL LH (for Manual Transmission)
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48. INSTALL FRONT FENDER SEAL RH (for Manual Transmission)
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49. INSTALL FRONT FENDER APRON UPPER SEAL LH
(a) Install the front fender apron upper seal LH with the 5 clips.
50. INSTALL FRONT FENDER APRON UPPER SEAL RH
(a) Install the front fender apron upper seal RH with the 5 clips.
51. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood sub-assembly with the 4 bolts.
Torque:
13 N·m {133 kgf·cm, 10 ft·lbf}
(b) Connect the washer nozzle hose.
52. ADJUST HOOD SUB-ASSEMBLY
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53. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
Transmission | See page |
|---|---|
AC60E |
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AC60F |
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54. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)
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55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque:
5,4 N·m {55 kgf·cm, 48 in·lbf}
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
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56. ADD ENGINE COOLANT
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57. ADD ENGINE OIL
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58. INSPECT FOR FUEL LEAK
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59. INSPECT FOR ENGINE OIL LEAK
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60. INSPECT FOR EXHAUST GAS LEAK
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61. CHECK ENGINE OIL LEVEL
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62. PERFORM RESET MEMORY (for Automatic Transmission)
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63. INSPECT IGNITION TIMING
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64. INSPECT ENGINE IDLE SPEED
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65. INSPECT CO/HC
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66. CHARGE REFRIGERANT (for HFC-134a(R134a))
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67. CHARGE REFRIGERANT (for HFO-1234yf(R1234yf))
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68. WARM UP ENGINE (for HFC-134a(R134a))
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69. WARM UP ENGINE (for HFO-1234yf(R1234yf))
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70. CHECK FOR REFRIGERANT GAS LEAK (for HFC-134a(R134a))
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71. CHECK FOR REFRIGERANT GAS LEAK (for HFO-1234yf(R1234yf))
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72. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
Torque:
30 N·m {306 kgf·cm, 22 ft·lbf}
73. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (w/ Off Road Package)
Torque:
30 N·m {306 kgf·cm, 22 ft·lbf}
Test yourself
A quick Toyota Tacoma quiz: every answer comes with an explanation and a link to the manual page.