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):
INSTALLATION
1. INSTALL ENGINE HANGER
(a) Install the 2 engine hangers with the 4 bolts shown in the illustration.
Part No.:
Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)
2. REMOVE ENGINE STAND
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Lift the engine, and remove it from the engine stand.
(c) Place the engine onto a working bench.
3. INSTALL DRIVE PLATE AND RING GEAR
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Temporarily install the front spacer, drive plate and rear spacer with the 8 bolts.
(c) Tighten the 8 bolts uniformly in several steps in the order shown in the illustration.
Torque: 83 N*m (46 kgf*cm, 61 ft.*lbf)
NOTICE: Do not start the engine for at least 1 hour after installing.
4. INSTALL ENGINE ASSEMBLY
(a) Attach the engine sling device and hang the engine with the chain block.
(b) Slowly lower the engine into the engine compartment.
(c) Install the front engine mounting insulator LH.
Torque:
for bolt 79 N*m (806 kgf*cm, 58 ft.*lbf)
for nut 72 N*m (734 kgf*cm, 53 ft.*lbf)
(d) Install the front engine mounting insulator RH.
Torque:
for bolt 79 N*m (806 kgf*cm, 58 ft.*lbf)
for nut 72 N*m (734 kgf*cm, 53 ft.*lbf)
(e) Remove the 2 engine hangers and 4 bolts.
5. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
6. CONNECT NO. 1 WATER BY-PASS PIPE
7. CONNECT WIRE HARNESS AND CONNECTOR
8. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
9. INSTALL NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY
10. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover.
11. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
12. INSTALL STARTER ASSEMBLY
(a) Install the starter (for 1.6 kW Type).
(b) Install the starter (for 2.0 kW Type).
13. INSTALL FRONT FENDER APRON SEAL RH
14. INSTALL FRONT FENDER APRON SEAL LH
15. INSTALL BATTERY
16. CONNECT NO. 1 AND NO. 2 FUEL PIPE
(a) Check that there is no damage or contamination in the connected part of pipe.
(b) 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.
(c) After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
(d) Install the fuel pipe clamp to the connector.
17. INSTALL COOLER COMPRESSOR
(a) Install the cooler compressor with the 2 nuts and 2 bolts in several steps in the sequence shown in the illustration.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
(b) Connect the cooler compressor connector.
18. INSTALL GENERATOR ASSEMBLY
19. CONNECT VANE PUMP ASSEMBLY
20. CONNECT HEATER WATER INLET HOSE
(a) Install the heater water pipe bracket with the nut.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(b) Connect the heater water inlet and outlet hose.
HINT: The direction of the hose clamp is indicated in the illustration.
(c) Connect the wire harness clamp.
21. INSTALL RADIATOR ASSEMBLY
22. INSTALL RADIATOR SIDE DEFLECTOR RH
23. INSTALL RADIATOR SIDE DEFLECTOR LH
24. INSTALL FAN SHROUD
25. CONNECT RADIATOR HOSE OUTLET
26. CONNECT RADIATOR HOSE INLET
27. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
28. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
29. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
30. INSTALL FRONT EXHAUST PIPE ASSEMBLY
31. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)
32. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck)
33. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for Regular Cab Standard Deck)
34. INSTALL AIR SWITCHING VALVE ASSEMBLY
35. INSTALL NO. 2 AIR TUBE
36. INSTALL NO. 1 AIR TUBE
37. CONNECT NO. 4 AIR INJECTION SYSTEM HOSE
38. CONNECT NO. 5 AIR INJECTION SYSTEM HOSE
39. CONNECT ENGINE WIRE
(a) Engine Room LH Side:
(1) Install the battery positive cable with the nut labeled H shown in the illustration.
Torque: 12 N*m (125 kgf*cm, 9 ft.*lbf)
(2) Connect the battery positive cable cover.
(3) Install the ground cable with the bolt labeled G shown in the illustration.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(4) Attach the wire harness clamp to the front engine mounting bracket LH, and connect the connector to the crankshaft position sensor labeled F shown in the illustration.
(5) Attach the front ABS junction connector's clamp to the engine room relay block side, and connect the connector labeled E shown in the illustration.
(6) Connect the wire harness bracket with the nut labeled D shown in the illustration.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(7) Connect the No. 2 engine wire's cover to the engine room relay block, and install the No. 2 engine wire with the nut labeled C shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(8) Connect the 2 connectors to the engine room relay block labeled B shown in the illustration.
(9) Connect the 4 connectors to the air injection control driver labeled A shown in the illustration.
(b) Engine Room RH Side:
(1) Install the bracket with the bolt labeled F shown in the illustration.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(2) Attach the 2 wire harness clamps labeled E shown in the illustration.
(3) Connect the 2 air pump connectors labeled D shown in the illustration.
(4) Install the ground cable with the 2 bolts labeled C shown in the illustration.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
(5) Attach the 2 wire harness clamps labeled B shown in the illustration.
(6) Connect the 7 connectors to the junction block labeled B shown in the illustration.
(7) Install the junction block cover.
(8) Connect the ECM connector labeled A shown in the illustration.
40. INSTALL INTAKE AIR SURGE TANK
41. INSTALL AIR CLEANER ASSEMBLY
42. INSTALL NO. 2 AIR CLEANER HOSE
43. INSTALL FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY
44. INSTALL FRONT WIPER MOTOR AND LINK
(a) Install the front wiper motor and link.
45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected.
46. ADD ENGINE OIL
47. INSPECT FOR FUEL LEAK
48. ADD AUTOMATIC TRANSMISSION FLUID
49. ADD ENGINE COOLANT
50. INSPECT FOR COOLANT LEAK
51. ADJUST SHIFT LEVER POSITION
52. INSPECT SHIFT LEVER POSITION
53. INSPECT FOR OIL LEAK
54. INSPECT FOR EXHAUST GAS LEAK
55. CHECK ENGINE OIL LEVEL
56. PERFORM RESET MEMORY
(a) Perform the RESET MEMORY procedures (A/T initialization). Programming and Relearning
57. INSPECT IGNITION TIMING
58. INSPECT ENGINE IDLE SPEED
59. INSPECT CO/HC
60. INSTALL V-BANK COVER
61. INSTALL NO. 1 ENGINE UNDER COVER
62. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
63. CONNECT HOOD SUPPORT ASSEMBLY
64. ADJUST HOOD SUB-ASSEMBLY
65. INSPECT COOLANT LEVEL AT RESERVOIR
66. INSPECT FOR LEAKAGE OF REFRIGERANT