Engine Assembly Installation

Install the idler pulley with the bolt.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

HINT:

"DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

w/ Idler Pulley Cover Plate (PU107013ARMXY3):

1. Install the idler pulley cover plate, idler pulley and No. 2 idler pulley cover plate with the bolt.
   

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

   NOTICE:

   1. If it is necessary to replace the pulley or either plate, replace the No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate as a set with new parts.
      
   2. When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3".
      

w/o Idler Pulley Cover Plate (PU107013ARMXY1):

1. Install the idler pulley and No. 2 idler pulley cover plate with the bolt.
   

   Torque:

   54 N*m{551 kgf*cm, 40 ft.*lbf}

   NOTICE:

   1. If it is necessary to replace the pulley or plate, replace both the pulley and plate with a set of new parts that includes a No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate.
      
   2. When replacing parts, make sure to replace the No. 2 idler pulley with a new pulley marked "PU107013ARMXY3".
      

for Integrated Type:
Install the 2 No. 2 idler pulleys with the 2 bolts.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

Install a new O-ring to the oil dipstick guide.

Apply a light coat of engine oil to the O-ring.

Push in the oil dipstick guide end into the guide hole of the oil pan.

Install the oil dipstick guide with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the oil dipstick gauge.

Install the 6 ignition coils with the 6 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install a new gasket and oil filler cap housing with the 2 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install a new O-ring to the water outlet pipe.

Install 2 new gaskets and the water by-pass joint with the 2 bolts and 4 nuts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}for bolts

9.0 N*m{92 kgf*cm, 80 in.*lbf}for nuts

Connect the engine coolant temperature sensor connector.

Install the 2 camshaft timing oil control valves with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Set a new gasket on each cylinder head.

NOTICE:

1. Align the port holes of the gasket and cylinder head.
   
2. Be careful of the installation direction.
   

Set the intake manifold on the cylinder heads.

Install and uniformly tighten the 10 bolts in several passes.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Connect the 6 fuel injector connectors.

Install a new gasket and the oil filter bracket with the 3 bolts and 2 nuts.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install a new gasket to the water inlet housing with thermostat.

Install the water inlet housing with thermostat with the 3 nuts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Temporarily install the V-ribbed belt tensioner with the 5 bolts.

Install the V-ribbed belt tensioner by tightening bolt 1 and then bolt 2.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Tighten the other bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

HINT:

Each bolt length is as follows:

A = 70 mm (2.76 in.)

B = 33 mm (1.30 in.)

Install the idler pulley with the 3 bolts.

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Install the engine mounting bracket with engine mounting insulator with the 3 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install the engine mounting bracket with engine mounting insulator with the 4 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Attach an engine sling device and chain block to the engine hangers.

Remove the engine from the engine stand.

Slowly lower the engine assembly into the engine compartment.

Install the engine mounting brackets to the frame with the 4 bolts and 4 nuts.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Remove the 4 bolts and 2 engine hangers.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the flywheel.

Install and tighten the 8 mounting bolts uniformly in several steps.

Torque:

83 N*m{846 kgf*cm, 61 ft.*lbf}

Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel.

SST

09301-00110

NOTICE:

Make sure not to insert the clutch disc facing the wrong direction.

Align the matchmarks on the clutch cover and flywheel.

Loosely install the 6 bolts.

Tighten the 6 bolts as described below.

1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
   

2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
   

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

Lightly move SST up and down, and right and left.

SST

09301-00110

Check that the disc is in the center, and then tighten the bolts.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the front spacer, drive plate and rear spacer to the crankshaft.

Install and uniformly tighten the 8 bolts in several steps in the order shown in the illustration.

Torque:

83 N*m{846 kgf*cm, 61 ft.*lbf}

Manual transmission for 4WD:
Install the manual transmission to the vehicle (Toyota Fortuner RM0000011B0004X.html).

Manual transmission for Pre runner:
Install the manual transmission to the vehicle (Toyota Fortuner RM0000011AJ003X.html).

Install the automatic transmission to the vehicle (Toyota Fortuner RM0000013F4003X.html).

Install the starter with the 2 bolts.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Install the starter wire to terminal 30 with the nut.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the starter connector.

Set a new gasket to the LH cylinder head with the oval shape facing backward.

NOTICE:

Be careful of the installation direction.

Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the A/F sensor connector.

Set a new gasket to the RH cylinder head with the oval shape facing forward.

NOTICE:

Be careful of the installation direction.

Install the exhaust manifold with the 6 nuts. Uniformly tighten the nuts in several passes.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the A/F sensor connector.

Install the RH and LH fender apron seals with the 10 clips.

Install the RH and LH fender seals with the 10 clips.

Install the front tires.

Install the front pipe to the pipe support.

Install a new gasket and the front pipe to the exhaust manifold.

Install the front pipe with the 2 nuts.

Torque:

62 N*m{632 kgf*cm, 46 ft.*lbf}

Connect the No. 2 engine wire to the cylinder block.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Connect the 2 engine room junction block connectors and attach the wire clamp.

Connect the cable to the engine room junction block with the nut.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Attach the 4 claws to install the side relay block cover.

Install the upper relay block cover.

Connect the ground wire with the nut.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Connect the ground wire to the frame with the bolt.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Push the engine wire through the dash panel into the cabin.

Connect the A.D.D. connector.

Connect the ECM connectors.

1. Connect the 5 ECM connectors.
   

2. Connect the 4WD control ECU connector.
   

3. Install the glove compartment door.
   

Connect the wire clamp to the engine mounting bracket front LH with the bolt.

Install a new gasket to the intake air surge tank.

Using an 8 mm hexagon socket wrench, install the intake air surge tank with the 4 bolts. Install the 2 nuts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Install the 2 surge tank stays with the 4 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install the oil baffle plate with the bolt.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the throttle body bracket with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install the 3 wire harness clamps and hose clamp.

Connect the throttle body with motor connector.

Connect the 2 VSV connectors.

Connect the ventilation hose.

Connect the purge line hose.

Connect the 2 water by-pass hoses.

Connect the heater water inlet hose.

Connect the heater water outlet hose.

Connect the fuel pipe.

1. Check that there is no damage or contamination in the connected part of the pipe.
   

2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
   





3. After completing the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
   

Install the fuel pipe clamp.

Connect the fuel pipe.

1. Check that there is no damage or contamination in the connected part of the pipe.
   

2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
   





3. After completing the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
   

Install the fuel pipe clamp.

Install the compressor and cooler bracket with the 4 bolts and tighten the bolts in the order shown in the illustration.

Torque:

24.5 N*m{ 250 kgf*cm, 18 ft.*lbf}

Connect the connector and attach the clamp.

Install the generator and adjusting bar with the 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install the generator wire with the nut.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the terminal cap.

Connect the generator connector.

Install the vane pump with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

NOTICE:

Do not hit other parts with the pulley when installing the vane pump.

Connect the oil pressure switch connector.

Temporarily install the fan with fluid coupling with the 4 nuts.

While turning the belt tensioner counterclockwise, align its holes, and then insert a pin of φ6 mm (0.24 in.) into the holes to fix the belt tensioner.

Install the V-ribbed belt.

HINT:

If it is hard to install the V-ribbed belt, perform the following procedure.

1. Put the V-ribbed belt on everything except the PS pump as shown in the illustration.
   

2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the PS pump.
   

While turning the belt tensioner counterclockwise, remove the pin.

Set the fan shroud into the engine compartment.

Connect the 2 oil cooler hoses with the hose clamp.

Install the radiator with the 4 bolts.

Torque:

12 N*m{122 kgf*cm, 9 ft.*lbf}

Attach the 4 clamps to the radiator side.

Connect the 2 front airbag sensor connectors.

Install the deflector with the 2 clips and attach the claw.

Install the deflector with the 2 clips and attach the claw.

Attach the 6 claws to install the radiator grille.

Install the 2 clips and 2 screws.

Install the hood with the 4 bolts and adjust the hood to the correct position.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Connect the washer nozzle hose.

Clean and install the oil drain plug with a new gasket.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Add fresh engine oil.

Standard capacity:

Item	Specified Condition
Drain and refill with oil filter change	5.5 liters (5.8 US qts, 4.8 Imp. qts)
Drain and refill without oil filter change	5.2 liters (5.5 US qts, 4.6 Imp. qts)
Dry fill	6.6 liters (7.0 US qts, 5.8 Imp. qts)

Install the oil filler cap.

Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf} for cylinder block drain cock plug

Standard capacity:

Item	Specified Condition
A/T	9.8 liters (10.4 US qts, 8.6 Imp. qts)
M/T	8.5 liters (9.0 US qts, 7.5 Imp. qts)

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Fill the radiator reservoir with TOYOTA Super Long Life Coolant (SLLC) to the F line.

Install the radiator cap.

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens.
   While the thermostat is open, circulate the coolant for several minutes.
   

2. Maintain the engine speed at 2,500 to 3,000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

Stop the engine and wait until the coolant cools down to ambient temperature.

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Check the coolant level in the radiator reservoir.
If the coolant level is below the L line, add SLLC to the reservoir F line.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17.1 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the cylinder block and head.

Connect the intelligent tester to the DLC3.

1. Turn the ignition switch ON.
   

   NOTICE:

   Do not start the engine.

2. Push the intelligent tester main switch ON.
   

3. To perform the Active Test, enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

Check for fuel leaks.

1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.
   

Start the engine, and check that there are no oil leaks after performing maintenance.

Install the V-bank cover with the 2 nuts.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

When using intelligent tester:
Check the ignition timing.

1. Connect the intelligent tester to the DLC3.
   

   HINT:

   Refer to the intelligent tester operator's manual for further details.

   Standard ignition timing:

   7 to 24°BTDC @ idle
   (Transmission in neutral position)
   

2. Disconnect the intelligent tester from the DLC3.
   

When not using intelligent tester:
Check the ignition timing.

1. Remove the air cleaner cap.
   

2. Connect the tester probe of a timing light to the green-red lead wire of the ignition coil connector of the No. 1 cylinder.
   





3. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
   

   SST

   09843-18040
   





4. Using the timing light, check the ignition timing.
   

   Standard ignition timing:

   10 +-2° BTDC @ idle
   (Transmission in neutral position)
   

5. Remove SST from the DLC3.
   

6. Check the ignition timing.
   

   Standard ignition timing:

   7 to 24° BTDC @ idle
   (Transmission in neutral position)
   

7. Disconnect the timing light from the engine.
   

8. Install the air cleaner cap.
   

When using intelligent tester:
Check the idle speed.

1. Connect the intelligent tester to the DLC3.
   

   HINT:

   Refer to the intelligent tester operator's manual for further details.

2. Switch the air conditioning OFF.
   

3. Race the engine at 2,500 rpm for approximately 90 seconds.
   

4. Check the idle speed.
   

   Standard idle speed:

   700 +-50 rpm
   (Transmission in neutral position)
   

   If the idle speed is not as specified, check the air intake system.
   

5. Disconnect the intelligent tester from the DLC3.
   

When not using intelligent tester:
Check the idle speed.

1. Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3.
   

   SST

   09843-18030
   

2. Switch the air conditioning OFF.
   

3. Race the engine speed at 2,500 rpm for approximately 90 seconds.
   

4. Check the idle speed.
   

   Standard idle speed:

   700 +-50 rpm
   (Transmission in neutral position)
   

   If the idle speed is not as specified, check the air intake system.
   

5. Disconnect the tachometer from the DLC3.
   

Start the engine.

Keep the engine speed at 2,500 rpm for approximately 180 seconds.

Insert a CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idling.

Immediately check CO/HC concentration at idle and/or 2,500 rpm.

HINT:

When performing the 2 mode (2,500 rpm and idle) test, check that the CO/HC concentration complies with local regulations.

If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

1. Check the A/F sensor operation and heated oxygen sensor operation.
   

2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.
   
   

   CO	HC	Symptom	Causes
   Normal	High	Rough idle	1. Faulty ignitions: Incorrect timing Plugs are contaminated, shorted, or gaps are defective 2. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. Leaky cylinder
   Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks: PCV hose Intake manifold Throttle body 2. Lean mixture causing misfire
   High	High	Rough idle (Black smoke from exhaust)	1. Restricted air filter 2. Faulty SFI system: Faulty pressure regulator Defective ECT sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty MAF sensor