Removal and Installation

PARTIAL ENGINE ASSEMBLY (2TR-FE)











COMPONENTS

REPLACEMENT
1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE
3. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (PRE RUNNER AND 4WD TYPE)
a. Remove the 4 bolts, then remove the engine under cover No.1.
4. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.2 (PRE RUNNER AND 4WD TYPE, REGULAR CAB)
a. Remove the 4 bolts, then remove the engine under cover No.2.
5. DRAIN ENGINE COOLANT
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH
9. REMOVE FAN SHROUD
10. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
11. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
12. REMOVE AIR CLEANER CASE
a. Remove the 3 bolts, then remove the air cleaner case.
13. SEPARATE VANE PUMP ASSEMBLY
14. REMOVE RADIATOR HOSE NO.2
15. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
16. REMOVE RADIATOR HOSE INLET





17. SEPARATE WATER HOSE SUB-ASSEMBLY
a. Separate the water hoses.
18. DISCONNECT FUEL HOSE
19. DISCONNECT FUEL HOSE NO.2





20. SEPARATE FUEL VAPOR FEED HOSE ASSEMBLY
a. Disconnect the fuel vapor feed hose.





21. DISCONNECT AIR INJECTION SYSTEM NO.1 HOSE
a. Disconnect the air injection system No.1 hose.
22. DISCONNECT ENGINE WIRE
a. Disconnect the connector from the ECM, then pull the engine wire harness to the compartment side.

NOTICE: Do not forcibly pull the wire harness to the engine compartment side.

b. Disconnect all wire harnesses and connectors in the engine room.
23. REMOVE EXHAUST PIPE ASSEMBLY TAIL
24. REMOVE EXHAUST PIPE ASSEMBLY FRONT
25. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
26. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY





27. REMOVE ENGINE ASSEMBLY
a. Install the engine hanger with the bolt.
Torque: 42 Nm (420 kgf-cm, 30 ft. lbs.)




Part No

NOTICE: Be sure to use the bolts when installing the engine hanger.





b. Attach the engine sling device and chain block to the engine hangers.
c. Remove the 4 bolts and 4 nuts.
d. Lift the engine out of the vehicle slowly and carefully by operating the engine sling device and chain block.

NOTICE: Make sure that no wires, hoses or cables are connected to the engine.

28. REMOVE CLUTCH COVER ASSEMBLY (MANUAL TRANSMISSION)
29. REMOVE CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
30. REMOVE FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
31. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
32. REMOVE REAR END PLATE
33. REMOVE INTAKE AIR CONNECTOR
34. REMOVE FUEL HOSE
35. REMOVE FUEL HOSE NO.2
36. REMOVE THROTTLE W/MOTOR BODY ASSEMBLY
37. REMOVE INTAKE MANIFOLD TO HEAD GASKET NO.1
38. REMOVE IDLE PULLEY ASSEMBLY W/BRACKET
39. REMOVE ENGINE WIRE
40. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY





41. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt, then remove the oil level gage guide.





42. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Remove the 4 bolts, then remove the engine mounting bracket front No.1 LH with engine mounting insulator front.
43. REMOVE THERMOSTAT
44. REMOVE FUEL INJECTOR ASSEMBLY
45. REMOVE KNOCK SENSOR





46. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.





47. REMOVE WATER BY-PASS PIPE NO.1
a. Remove the 2 nuts, then remove the water by-pass pipe No.1.





48. REMOVE VENTILATION PIPE
a. Remove the bolt, then remove the ventilation pipe.
49. REMOVE IGNITION COIL ASSEMBLY
50. REMOVE SPARK PLUG
51. REMOVE GENERATOR ASSEMBLY
52. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
53. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
54. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
55. REMOVE AIR SWITCHING VALVE ASSEMBLY
56. REMOVE EXHAUST MANIFOLD





57. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Remove the 4 bolts, then remove the engine mounting bracket front No.1 together with the engine mounting insulator front.
58. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
59. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY





60. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the engine mounting bracket front No.1 RH with the 4 bolts.
Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.)
61. INSTALL EXHAUST MANIFOLD
62. INSTALL AIR SWITCHING VALVE ASSEMBLY
63. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
64. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
65. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
66. INSTALL GENERATOR ASSEMBLY
67. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
68. INSTALL IGNITION COIL ASSEMBLY





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





70. INSTALL WATER BY-PASS PIPE NO.1
a. Install a new gasket, then install the water by-pass pipe No.1.
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)





71. 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.)
72. INSTALL KNOCK SENSOR
73. INSTALL FUEL INJECTOR ASSEMBLY
74. INSTALL THERMOSTAT





75. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install engine mounting bracket front No.1 LH with the 4 bolts.
Torque: 51 Nm (520 kgf-cm, 38 ft. lbs.)





76. INSTALL OIL LEVEL GAGE GUIDE
a. Install the oil level gage guide with the bolt.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
77. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
78. INSTALL ENGINE WIRE
79. INSTALL IDLE PULLEY ASSEMBLY W/BRACKET
80. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO.1
81. INSTALL THROTTLE W/MOTOR BODY ASSEMBLY
82. INSTALL FUEL HOSE NO.2
83. INSTALL FUEL HOSE
84. INSTALL INTAKE AIR CONNECTOR
85. INSTALL REAR END PLATE
86. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (AUTOMATIC TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
87. INSTALL FLYWHEEL SUB-ASSEMBLY (MANUAL TRANSMISSION)
SST 09213-54015 (91651-60855), 09330-00021
88. INSTALL CLUTCH DISC ASSEMBLY (MANUAL TRANSMISSION)
89. INSTALL CLUTCH COVER ASSEMBLY (MANUAL TRANSMISSION)





90. 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.
91. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
92. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
93. INSTALL EXHAUST PIPE ASSEMBLY FRONT
94. INSTALL EXHAUST PIPE ASSEMBLY TAIL
95. CONNECT ENGINE WIRE





96. CONNECT AIR INJECTION SYSTEM NO.1 HOSE
a. Connect the fuel vapor feed hose.





97. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
a. Connect the fuel feed hose.
98. CONNECT FUEL HOSE NO.2
99. CONNECT FUEL HOSE





100. INSTALL WATER HOSE SUB-ASSEMBLY
a. Install the water hose.
101. INSTALL RADIATOR HOSE INLET
102. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
103. INSTALL RADIATOR HOSE NO.2
104. INSTALL VANE PUMP ASSEMBLY
105. INSTALL AIR CLEANER CASE
a. Install the air cleaner case with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
106. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
107. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
108. INSTALL FAN SHROUD
109. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
110. INSTALL BATTERY TRAY
111. INSTALL BATTERY
112. ADD ENGINE COOLANT
113. ADD ENGINE OIL
114. CHECK ENGINE OIL LEVEL
115. CHECK FOR FUEL LEAKAGE
116. CHECK FOR ENGINE COOLANT LEAKAGE
117. CHECK FOR OIL LEAKAGE
118. CHECK FOR EXHAUST GAS LEAKAGE
119. INSPECT IGNITION TIMING
SST 09843-18040
120. INSPECT ENGINE IDLE SPEED
SST 09843-18030
121. INSPECT CO/HC
122. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1 (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.)
123. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.2 (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.)
124. INSTALL HOOD SUB-ASSEMBLY