Installation
ENGINE ASSEMBLYCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
COMPONENTS (Part 12):
INSTALLATION
1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket front No. 1 RH with the 4 bolts.
Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.)
3. INSTALL EXHAUST MANIFOLD
4. INSTALL AIR SWITCHING VALVE ASSEMBLY
5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
7. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
8. INSTALL GENERATOR ASSEMBLY
9. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
10. INSTALL IGNITION COIL ASSEMBLY
11. INSTALL VENTILATION PIPE
(a) Install the ventilation pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
12. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install a new gasket, then install the water by-pass pipe No. 1.
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
13. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket onto the engine coolant temperature sensor.
(b) Using a 19 mm deep socket wrench, install the engine coolant temperature sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
14. INSTALL KNOCK SENSOR
15. INSTALL FUEL INJECTOR ASSEMBLY
16. INSTALL THERMOSTAT
17. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Install engine mounting bracket front No. 1 LH with the 4 bolts.
Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.)
18. INSTALL OIL LEVEL GAGE GUIDE
(a) Install the oil level gage guide with the bolt.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
19. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
20. INSTALL ENGINE WIRE
21. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)
22. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
23. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY
24. INSTALL NO. 2 FUEL HOSE
25. INSTALL FUEL HOSE
26. INSTALL INTAKE AIR CONNECTOR
27. INSTALL REAR END PLATE
28. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)
29. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
30. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
31. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)
32. INSTALL ENGINE ASSEMBLY
(a) Attach the engine sling device and chain block to the engine hangers.
(b) Keep the engine level, and align the engine mounting bracket front No. 1 RH w/ engine mounting insulator front and LH with the body mountings.
(c) Attach the engine mounting bracket front No. 1 RH w/ engine mounting insulator front and LH, and install the 4 bolts and nuts.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
(d) Remove the bolts, then remove the engine hangers.
33. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
34. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
35. INSTALL FRONT EXHAUST PIPE ASSEMBLY
36. INSTALL EXHAUST PIPE ASSEMBLY TAIL
37. INSTALL ENGINE WIRE
38. CONNECT NO. 1 AIR INJECTION HOSE
(a) Connect the fuel vapor feed hose.
39. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
(a) Connect the fuel feed hose.
40. CONNECT NO. 2 FUEL HOSE
41. CONNECT FUEL HOSE
42. INSTALL WATER HOSE SUB-ASSEMBLY
(a) Install the water hose.
43. INSTALL RADIATOR HOSE INLET
44. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
45. INSTALL NO. 2 RADIATOR HOSE
46. INSTALL VANE PUMP ASSEMBLY
47. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
48. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
49. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
50. INSTALL FAN SHROUD
51. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
52. INSTALL BATTERY TRAY
53. INSTALL BATTERY
54. ADD ENGINE COOLANT
55. ADD ENGINE OIL
56. CHECK FOR ENGINE OIL LEVEL
57. CHECK FOR FUEL LEAKAGE
58. CHECK FOR ENGINE COOLANT LEAKAGE
59. CHECK FOR OIL LEAKAGE
60. CHECK FOR EXHAUST GAS LEAKAGE
61. INSPECT IGNITION TIMING
62. INSPECT ENGINE IDLE SPEED
63. INSPECT CO/HC
64. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type)
(a) Install the engine under cover No. 1 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
65. INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type, Regular Cab)
(a) Install the engine under cover No. 2 with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
66. INSTALL HOOD SUB-ASSEMBLY