Operation CHARM: Car repair manuals for everyone.

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 Installation

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 (for Automatic Transmission)





34. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)





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

Reassembly