Toyota Tacoma manuals

Toyota Tacoma 2015-2018 Service Manual: Installation

INSTALLATION

CAUTION / NOTICE / HINT

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.

Click here PROCEDURE

PROCEDURE

1. INSTALL ENGINE HANGER

Click here 2. REMOVE ENGINE FROM ENGINE STAND

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.

Click here (a) Attach an engine sling device and hang the engine assembly with a chain block.

(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}

(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

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

*a

Adhesive

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(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.

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

*a

Adhesive

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(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}

(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)

Click here 7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

Click here 8. CONNECT SUCTION HOSE SUB-ASSEMBLY

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

Click here 10. CONNECT NO. 1 FUEL TUBE SUB-ASSEMBLY

10. CONNECT NO. 1 FUEL TUBE SUB-ASSEMBLY

(a) Connect the No. 1 fuel tube sub-assembly to the fuel delivery pipe sub-assembly.

Click here 11. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

11. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

Click here 12. CONNECT WATER HOSE SUB-ASSEMBLY

12. CONNECT WATER HOSE SUB-ASSEMBLY

(a) Connect the water hose sub-assembly.

Text in Illustration

*a

Top

*b

LH

HINT:

The direction of the hose clip is indicated in the illustration.

13. CONNECT UNION TO CHECK VALVE HOSE (for Vacuum Brake Booster)

Click here 14. CONNECT ENGINE WIRE

14. CONNECT ENGINE WIRE

(a) Attach the grommet to the wire harness support.

Text in Illustration

*a

Grommet

*b

Wire Harness Support

(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.

Click here (f) Attach the claw to connect the engine wire.

(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)

Click here 16. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Manual Transmission)

16. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Manual Transmission)

Click here 17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (for Manual Transmission)

17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (for Manual Transmission)

Click here 18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Manual Transmission)

18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Manual Transmission)

Click here 19. INSTALL COOLER COMPRESSOR ASSEMBLY

19. INSTALL COOLER COMPRESSOR ASSEMBLY

Click here 20. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

20. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

Click here 21. CONNECT SUCTION HOSE SUB-ASSEMBLY

21. CONNECT SUCTION HOSE SUB-ASSEMBLY

Click here 22. INSTALL GENERATOR ASSEMBLY

22. INSTALL GENERATOR ASSEMBLY

Click here 23. CONNECT VANE PUMP ASSEMBLY

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

Click here 25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

Click here 26. INSTALL THROTTLE BODY BRACKET

26. INSTALL THROTTLE BODY BRACKET

Click here 27. INSTALL NO. 1 SURGE TANK STAY

27. INSTALL NO. 1 SURGE TANK STAY

Click here 28. INSTALL NO. 2 SURGE TANK STAY

28. INSTALL NO. 2 SURGE TANK STAY

Click here 29. INSTALL RADIATOR ASSEMBLY

29. INSTALL RADIATOR ASSEMBLY

Click here 30. INSTALL FAN SHROUD

30. INSTALL FAN SHROUD

Click here 31. CONNECT TRANSMISSION OIL COOLER HOSE (for Automatic Transmission)

31. CONNECT TRANSMISSION OIL COOLER HOSE (for Automatic Transmission)

Click here 32. CONNECT RADIATOR RESERVE TANK HOSE

32. CONNECT RADIATOR RESERVE TANK HOSE

Click here 33. INSTALL NO. 2 RADIATOR HOSE

33. INSTALL NO. 2 RADIATOR HOSE

Click here 34. INSTALL NO. 1 RADIATOR HOSE

34. INSTALL NO. 1 RADIATOR HOSE

Click here 35. INSTALL RADIATOR SIDE DEFLECTOR LH

35. INSTALL RADIATOR SIDE DEFLECTOR LH

Click here 36. INSTALL RADIATOR SIDE DEFLECTOR RH

36. INSTALL RADIATOR SIDE DEFLECTOR RH

Click here 37. INSTALL RADIATOR SUPPORT TO FRAME SEAL

37. INSTALL RADIATOR SUPPORT TO FRAME SEAL

Click here 38. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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

Click here 41. INSTALL RADIATOR GRILLE

41. INSTALL RADIATOR GRILLE

Click here 42. INSTALL V-BANK COVER SUB-ASSEMBLY

42. INSTALL V-BANK COVER SUB-ASSEMBLY

Click here 43. INSTALL BATTERY TRAY

43. INSTALL BATTERY TRAY

44. INSTALL BATTERY

45. INSTALL BATTERY CLAMP SUB-ASSEMBLY

Click here 46. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

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)

Click here 48. INSTALL FRONT FENDER SEAL RH (for Manual Transmission)

48. INSTALL FRONT FENDER SEAL RH (for Manual Transmission)

Click here 49. INSTALL FRONT FENDER APRON UPPER SEAL LH

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

Click here 53. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

53. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

Transmission

See page

AC60E

AC60F

54. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

Click here 55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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.

Click here 56. ADD ENGINE COOLANT

56. ADD ENGINE COOLANT

Click here 57. ADD ENGINE OIL

57. ADD ENGINE OIL

Click here 58. INSPECT FOR FUEL LEAK

58. INSPECT FOR FUEL LEAK

Click here 59. INSPECT FOR ENGINE OIL LEAK

59. INSPECT FOR ENGINE OIL LEAK

Click here 60. INSPECT FOR EXHAUST GAS LEAK

60. INSPECT FOR EXHAUST GAS LEAK

Click here 61. CHECK ENGINE OIL LEVEL

61. CHECK ENGINE OIL LEVEL

Click here 62. PERFORM RESET MEMORY (for Automatic Transmission)

62. PERFORM RESET MEMORY (for Automatic Transmission)

Click here 63. INSPECT IGNITION TIMING

63. INSPECT IGNITION TIMING

Click here 64. INSPECT ENGINE IDLE SPEED

64. INSPECT ENGINE IDLE SPEED

Click here 65. INSPECT CO/HC

65. INSPECT CO/HC

Click here 66. CHARGE REFRIGERANT (for HFC-134a(R134a))

66. CHARGE REFRIGERANT (for HFC-134a(R134a))

Click here 67. CHARGE REFRIGERANT (for HFO-1234yf(R1234yf))

67. CHARGE REFRIGERANT (for HFO-1234yf(R1234yf))

Click here 68. WARM UP ENGINE (for HFC-134a(R134a))

68. WARM UP ENGINE (for HFC-134a(R134a))

Click here 69. WARM UP ENGINE (for HFO-1234yf(R1234yf))

69. WARM UP ENGINE (for HFO-1234yf(R1234yf))

Click here 70. CHECK FOR REFRIGERANT GAS LEAK (for HFC-134a(R134a))

70. CHECK FOR REFRIGERANT GAS LEAK (for HFC-134a(R134a))

Click here 71. CHECK FOR REFRIGERANT GAS LEAK (for HFO-1234yf(R1234yf))

71. CHECK FOR REFRIGERANT GAS LEAK (for HFO-1234yf(R1234yf))

Click here 72. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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}

Components
COMPONENTS ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ILLUSTRATION ...

Engine
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