Installation

2TR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:

INSTALLATION

1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (Testing and Inspection)





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-lbf)
3. INSTALL EXHAUST MANIFOLD (Installation)

4. INSTALL AIR SWITCHING VALVE ASSEMBLY (Installation)

5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (Installation)

6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (Installation)

7. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (Installation)

8. INSTALL GENERATOR ASSEMBLY (Service and Repair)

9. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
10. INSTALL IGNITION COIL ASSEMBLY (Installation)





11. INSTALL VENTILATION PIPE
(a) Install the ventilation pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)





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-lbf)





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-lbf)
14. INSTALL KNOCK SENSOR (Installation)

15. INSTALL FUEL INJECTOR ASSEMBLY (Installation)

16. INSTALL THERMOSTAT (Installation)





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-lbf)





18. INSTALL OIL LEVEL GAGE GUIDE
(a) Install the oil level gage guide with the bolt.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
19. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
20. INSTALL ENGINE WIRE
21. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System) (Installation)

22. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET (Installation)

23. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY (Installation)

24. INSTALL NO. 2 FUEL HOSE (Installation)

25. INSTALL FUEL HOSE (Installation)

26. INSTALL INTAKE AIR CONNECTOR (Installation)

27. INSTALL REAR END PLATE (Installation)

28. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) (Installation)

29. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) (Installation)

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-lbf)
(d) Remove the bolts, then remove the engine hangers.
33. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (Service and Repair)
34. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY





35. INSTALL FRONT EXHAUST PIPE ASSEMBLY (Installation)

36. INSTALL EXHAUST PIPE ASSEMBLY TAIL (Installation)

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 (Installation)

41. CONNECT FUEL HOSE (Installation)





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) (Installation)

45. INSTALL NO. 2 RADIATOR HOSE
46. INSTALL VANE PUMP ASSEMBLY (Installation)

47. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
48. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
49. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (Installation)

50. INSTALL FAN SHROUD (Installation)

51. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH (Installation)

52. INSTALL BATTERY TRAY
53. INSTALL BATTERY
54. ADD ENGINE COOLANT (Service and Repair)

55. ADD ENGINE OIL (Installation)

56. CHECK FOR ENGINE OIL LEVEL
57. CHECK FOR FUEL LEAKAGE
58. CHECK FOR ENGINE COOLANT LEAKAGE (Testing and Inspection)

59. CHECK FOR OIL LEAKAGE
60. CHECK FOR EXHAUST GAS LEAKAGE
61. INSPECT IGNITION TIMING (Engine)

62. INSPECT ENGINE IDLE SPEED (Engine)

63. INSPECT CO/HC (Engine)

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-lbf)
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-lbf)
66. INSTALL HOOD SUB-ASSEMBLY (Service and Repair)