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):
COMPONENTS (Part 13):
COMPONENTS (Part 14):
COMPONENTS (Part 15):
INSTALLATION
1. REMOVE ENGINE STAND
(a) Install the 2 engine hangers with the 2 bolts as shown in the illustration.
Engine hanger part No.
Engine hanger part No.:
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(b) Attach an engine sling device and hang the engine with a chain block.
(c) Remove the bolts and engine assembly from the engine stand.
2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
4. INSTALL ENGINE ASSEMBLY
(a) Slowly lower the engine assembly into the engine compartment.
NOTICE: Make sure that the engine is clear of all wiring and hoses.
(b) Attach the engine mounting insulators to the vehicle.
(c) Install the 4 engine mounting insulator's bolts.
Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf)
(d) Remove the 2 bolts and 2 engine hangers.
5. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Connect the hose and install the water by-pass pipe with the 2 bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (90119-08216), 09330-00021
(b) Install the crankshaft angle sensor plate, drive gear and rear drive plate spacer to the crankshaft.
(c) Install and uniformly tighten 10 new bolts in the sequence shown in the illustration.
Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf)
NOTICE:
^ Do not reuse the flywheel installation bolts.
^ Do not strike or damage the flywheel installation bolts. Be sure to handle them carefully.
(d) Mark the upside of each flywheel installation bolt with paint.
(e) Tighten the flywheel installation bolts another 90° as shown.
(f) Check that the painted marks are now at a 90° angle to the upside.
7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD: Refer to the following procedures.
(b) for 4WD: Refer to the following procedures.
8. INSTALL STARTER ASSEMBLY
9. INSTALL STARTER COVER
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
11. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
12. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
13. INSTALL FRONT FENDER APRON SEAL REAR RH
14. INSTALL FRONT FENDER APRON SEAL RH
15. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
(a) Install the front propeller shaft.
16. INSTALL PROPELLER SHAFT ASSEMBLY
(a) for 2WD: Refer to the following procedures.
(b) for 4WD: Refer to the following procedures.
17. INSTALL EXHAUST PIPE ASSEMBLY
(a) for Regular Cab Standard Deck: Refer to the following procedures.
(b) except Regular Cab Standard Deck: Refer to the following procedures.
18. INSTALL GENERATOR ASSEMBLY
19. CONNECT VANE PUMP ASSEMBLY
20. CONNECT COOLER COMPRESSOR ASSEMBLY
21. CONNECT WIRE HARNESS AND HOSE
(a) Connect the 2 connectors and 2 clips to the engine room junction block.
(b) Install the engine wire with the nut. Then connect the 2 clips.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(c) Connect the 4 air injection control driver connectors.
(d) Install the ground wire with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(e) Connect the cable to the positive (+) battery terminal.
(f) Install the wire to the positive (+) battery cable with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(g) Connect the 2 air injection system hoses.
(h) Install the ground wire with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(i) Connect the 2 air pump connectors and install the connector bracket with the nut.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
(j) Connect the 4 connectors to the connector holder block.
(k) Connect the heater hoses.
(l) Connect the ECM connector and clamp.
HINT: Refer to the following procedures to connect the ECM connector.
(m) Connect the union to check valve hose.
(n) Connect the purge line hose.
22. CONNECT FUEL MAIN AND RETURN HOSE
(a) Connect the fuel main and return hoses.
(b) Install the fuel pipe clamp.
23. INSTALL RADIATOR ASSEMBLY
24. INSTALL FAN SHROUD
25. INSTALL FAN AND GENERATOR V BELT
26. INSTALL OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Install the oil cooler.
27. INSTALL RADIATOR SIDE DEFLECTOR LH
28. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Trailer Towing System)
29. INSTALL OUTLET RADIATOR HOSE
30. INSTALL INLET RADIATOR HOSE
31. INSTALL AIR CLEANER ASSEMBLY
32. INSTALL AIR CLEANER HOSE ASSEMBLY
33. ADD ENGINE OIL
34. ADD ENGINE COOLANT
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTICE: Some systems need to be initialized after the cable is reconnected.
36. INSPECT FOR OIL LEAK
(a) Inspect for engine oil leak.
37. INSPECT FOR COOLANT LEAK
38. INSPECT FOR EXHAUST GAS LEAK
39. INSPECT FOR FUEL LEAK
40. INSPECT SHIFT LEVER POSITION
(a) for Column shift: Refer to the following procedures.
(b) for Floor shift: Refer to the following procedures.
41. INSTALL V-BANK COVER SUB-ASSEMBLY
42. INSTALL COWL TOP OUTER PANEL SUB-ASSEMBLY
43. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Install the windshield wiper motor.
44. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(b) Attach the lower part of the 2 hood supports to the hood support bolt ball joints.
NOTICE: Install the hood support while supporting the hood by hand.
(c) Attach the hood support clips.
NOTICE: Check that the hood support is engaged in the ball joint and that it cannot be pulled out.
45. ADJUST HOOD SUB-ASSEMBLY
46. INSTALL NO. 1 ENGINE UNDER COVER
47. INSPECT IGNITION TIMING
48. INSPECT ENGINE IDLE SPEED
49. INSPECT CO/HC
50. CHECK ENGINE OIL LEVEL
51. CHECK ENGINE COOLANT LEVEL