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2001 f150 radiator core support installation instructions

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This bracket kit fits the 2001-10 Toyota Highlander. For the ’01-’07 Toyota Highlander, follow the instructions below. For ’08-’10 Toyota Highlander instructions, see the separate section included in these instructions. Important: please use all supplied bolts and parts and read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. Fig.C Fig.D Fig.E 1. Start by removing four plastic fasteners that attach the grille to the core support (Fig.C). 2. Once all the fasteners are removed, squeeze and push out a square plastic clip fastener for the grille, located between the headlight housing and the radiator support frame on each side. 3. Pull back the grille and remove the Phillips screw that attaches the fascia to the hood latch support (Fig.D). 4. On each side, remove three plastic fasteners: two of the plastic fasteners are attaching the fender liner to the fascia (Fig.E); the other plastic fastener is attaching the fender liner to the frame rail (Fig.F) 5. Remove ten 10mm (head) bolts (Fig.G) and two plastic fasteners (Fig.H) attaching the lower splash shield to the fascia and the sub frame. 6. On both sides, pull back the fender liner and remove one 10mm screw attaching the corner of the fascia to the fender (Fig.I). Fig.K Plastic fastener MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 KIT# 1180-1 05/14/10 KS 9. Remove the foam shock absorption core by pulling forward (Fig. L). Note: this will not be reinstalled. Retain the foam shock absorption core and attachment hardware so that it can be replaced if the bracket is ever removed. 10. Remove six 14mm (head) bolts to remove the bumper core (Fig.M). Note: this will not be reinstalled. Retain the bumper core and attachment hardware so that it can be replaced if the bracket is ever removed. 11. Remove the alignment studs at the end of each frame rail (Fig.N). 12. Now, place the main receiver brace into the ends of the frame rails (Fig.O). 13. Bolt the main receiver brace into place using the three supplied 10mm x 1.25 x 35mm bolts, flat washers and lock washers (Fig.P). Repeat for the other side. Tighten to the torque specifications listed at the end of these instructions.


Front Bumper Installation – TOYOTA FJ CRUISER Step 1 Very Important Before beginning installation, assure that vehicle has been pulled forward into work-area with the wheels straight and that the ground is level. The clearances around the FJ bumper are critical to proper installation and fitment. Moving vehicle with wheels turned causes slight frame twist preventing ease of removal of OE bumper and installation of new bumper without issue. Make sure you have plenty of room to work around front of vehicle. Open the hood at this time, you will need to see down through the inner-body core-support while removing your OE bumper and installing your Body Armor FJ Bumper. Step 2 a. Unpack bumper using staple puller to remove staples. Save all packing materials and take care not to tear cartons. b. Remove hardware and Check parts/hardware list to confirm all parts and necessary hardware are included. c. It’s a good idea to spray all OE attaching hardware at this time with penetrating oil before beginning removal of OE bumper. This will ease removal as well as to help assure that none of the bolts’ / nuts’ threads are damaged during removal. Use extra caution when working with the bumper mounting studs & nuts. Step 3Prep bumper for install: You may install your auxilary lights in the light pockets. The light tab is slotted to allow for adjustment for adjustment for light grilles. You may also attach a second set of lights on the top deck . Also attach the grill guard at this time. Step 4 a. Begin removing OE bumper following instructions and photos on the following page for detailed descriptions and references. When done, proceed to Step 4 here. Step 5 a. If equipped, remove OE chassis skid plate and set aside for install after new bumper is installed. Save OE hardware to re-install the skid plate once new bumper is installed (3 upper bolts and 2 lower bolts, lowers have spacers between frame & skid plate). b. Remove the (3) outer hold-down hex nuts holding bumper to frame-caps on both passenger and driver sides. Un-clip the outer ends of the bumper from the outer bumper support clips (see Photo 5 on following page) by pulling bumper fascia down and out of clip on driver and passenger sides. Next, while a helper holds the bumper in place, loosen and remove the inner hold-down hex nuts on both passenger and driver sides. Reference Photo 1 on the last page for stud locations. The bumper should now slide off the front of the locating / mounting studs in the frame-caps. Remove slowly prevent paint damage. Save hold-down nuts. c. Remove the outer bumper support clips from both driver and passenger sides (see Photo 5 on following page) Step 6 a. If you bought a winch, skip to Step 6b. If you did not purchase a winch, you can mount the winch cover plate / lower bumper fascia, and fairlead slot cover plate to the bumper now, using (6) 3/8″ x 1″ bolts with (2) flat washers, (1) lock washer, and (1) hex nut on each bolt. See photos 4 & 5 on the last page for reference. b. If you purchased a winch for your FJ, now is the time to mount it in the bumper. The winch will bolt down using the fairlead mounting bracket and 10mm bolts to secure winch & fairlead bracket to bumper. The roller fairlead bolts to the fairlead bracket using the 1/2″ hex nuts supplied. See photo 3 on the last page for reference. Be sure to mount with the correct side of winch to passenger side for solenoid pack installation / clearance. Once the winch is bolted in, you can mount the winch cover plate / lower bumper fascia to the bottom of the bumper using (4) of the 3/8″ x 1″ bolts with (2) flat washers, (1) lock washer and (1) hex nut on each bolt. If you purchased lights, mount them to the light tabs. It the lights have a protective grille you should be able. to use the cover. Important: Follow winch mfr’s directions for cable to winch / solenoid / battery connections. Use caution to assure clearance of any and all bumper / winch / mounting surfaces at all cable end connections. Coil cables and lay in winch mount plate to protect against damage while installing bumper onto vehicle. Place coiled cables in winch mount plate to assure no interference with the radiator, a/c line and / or inner body core support during bumper installation. Cables to be run in Step 7. Step 7 Along with your helper, one person on each side, guide your Body Armor FJ Bumper onto the the frame-cap mounting studs. Use caution guiding the bumper on slowly and evenly to prevent paint damage. Locating / mounting studs and bumper mounting plates can be seen down through inner-body core support while guiding bumper into place. Make sure the bumper does not contact grill or fascia while installing bumper as this can cause paint damage. While you or your helper hold the bumper in place, thread the OE hold-down nuts onto mounting studs to hold the bumper in place, hand tighten at this time. Step 8 Confirm bumper is even side-to-side, torque hold-down nuts to 80 ft.lbs. Again confirm bumper is even and there are no clearance issues between the bumper and any part of the body and / or inner-body core-support. You can now run the winch cables through the inner-body core support to the battery. If you purchased a set of lights to be used with your bumper, you can now wire them up, please follow the detailed light manufacturer instructions. **Body Armor is not responsible for any issues with respect to the wiring, operation or warranties to the lights Step 9 a. Fit the wheel well inner-liner end-caps to the bottom of the bumper at each corner and bolt up with supplied 1/4″ x .75″ phillips- head machine screws, (2) each side, into drilled / threaded holes in bottom corners of bumper. See photos 6 & 7 on the last page. b. Next, using the OE hardware and spacers, re-install your chassis skidplate, making sure it’s straight before tightening. c. Using the (2) remaining 1/4″ x .75″ phillips-head machine screws, mount your license plate to threaded holes in the bumper face. d. Re-install the grill by snapping onto clips and using the OE push-pins and screws to hold down in OE locations. ** trimming off the front inner fender is a customer option, it is not required. We recommend you check the torque of all bolts after about two weeks, and after every off-road / trail run thereafter to assure tightness


1. Installation Review and Vehicle Preparation. (a) Review the entire instruction instructions provided before beginning the installation (b) Review the parts list/kit contents to ensure that all parts are present before beginning the installation. If any items are missing contact Technical Support at (800) 688-5912 before proceeding. (c) Remove any low-octane fuel from the vehicle. Ensure that ONLY 91 octane or higher unleaded gasoline is used. (d) Place the vehicle onto vehicle hoist. (e) Protect the vehicle with protection blankets over the fenders and front of the vehicle. (f) Disconnect and remove the battery. (g) When draining the cooling system into a clean container in Step 3, save this coolant as it will be reused. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause the hot engine coolant and steam to blow out from the radiator. (h) All parts that are removed and not reused should be saved for the customer, i.e., “discard” means to save for the customer 2. Cover Removal. (a) Remove the engine V-bank cover by Lifting the front of the cover and pulling away from the firewall (Fig 2-1). Discard these parts. (b) If installed, remove the No. 1 engine under cover (Fig 2-2) by removing the 3 screws and 5 bolts. Save these parts for reuse. 3. Drain Engine Coolant. CAUTION: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. (a) Loosen the radiator drain cock plug (Fig. 3-1). (b) Remove the radiator cap. Then drain the coolant from the radiator into a clean container so it can be reused (Fig. 3-1). (c) Loosen the 2 cylinder block drain cock plugs (Fig.3-1). Then drain the coolant from the engine and save for reuse. (d) Tighten the 2 cylinder block drain cock plugs. Torque: 13 Nm (10 ft lbf) 4. Fan and Shroud Removal. (a) Remove the upper radiator hose. Mark the radiator end of this hose with a marker or tape. This hose will be re-installed inverted and the mark will help identify the ends. (b) Loosen the 4 nuts holding the fluid coupling fan (Figs. 4-1). (c) Remove the fan/generator V-rib belt. Discard this belt as it will be replaced by a new belt. (d) Disconnect the reservoir hose from the upper radiator tank. (e) For vehicles with Trailer Towing System: Detach the claw to open the No. 1 hose clamp on the side of the fan shroud (Fig 4-2). (f) Remove the 2 bolts holding the fan shroud (Figs 4-3). Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan. Retain these parts for reuse. Temporarily re-install the 4 nuts to keep the pulley in place (reference Fig 4-1). Do not tighten. CAUTION: Be careful not to damage the radiator core. It is helpful to protect the radiator core with a piece of cardboard to prevent damage during subsequent steps. 5. Air Cleaner Lower Box Replacement. (a) Remove the air cleaner hose by disconnecting the vacuum and ventilation hoses and loosening the 2 clamps. (Fig 5-1). Discard this hose and clamps


INSTALLATION INSTRUCTIONS 1) Use only recommended intake gaskets set when installing this intake manifold. 2) Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3) Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 4) Do not use cork or rubber end seals. Use RTV silicone sealer instead. Apply a ¼” high bead across each block end seal surface, overlapping the intake gasket at the four corners. This method will eliminate end seal slippage. 5) WARNING: There is no gasket support for the manifold on the four bolt holes which are numbered 5, 10, 11, and 16 in Figure 1. Damage to the manifold will occur if these four bolts are over-tightened. Hand tighten them with a 6″ box- end wrench. Do not use a torque wrench. Torque all of the remaining manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs. For ease of installation, we recommend using Edelbrock Manifold Bolt & Washer Kit #8564. Figure 2 – 454 c.i.d. Chevrolet Firing Order Firing Order: 1-8-4-3-6-5-7-2 Turn Distributor Counter-Clockwise to Advance Timing 9 15 13 12 11 3 2 10 8 7 6 5 1 4 16 14 A Figure 1 – Intake Manifold Tightening Sequence and Plumbing DONOTUSE A TORQUE WRENCH ON BOLTS 5, 10, 11, &16 Hand Tighten Bolts using a 6″ box end wrench. Tighten remaining bolts to 25 ft./lbs. in sequence shown. A – Water from water core (Use original 1/2″-14 NPTF to 5/8″ hose fitting) B – Water out (3/8″-18 NPTF to 5/8″ hose fitting) C – Power Brakes (1/4″-18 90° elbow & 3/8″-18 to 1/4″-18 adapter) D – To Transmission vacuum modulator E – To MAP Sensor (1/4″ vacuum tee) F – Water in (3/8″-18 NPT to 3/4″ hose) G – 5/16″-18 x 1/2″ bolt

Toyota Matrix XRS Air Intake Removal And Installation Instructions

1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable. 2. Disconnect the mass air sensor electrical connection. 3. Remove the screw that secure the vacuum switching valve to the air cleaner. 4. Remove the stock bracket from the vacuum switching valve. 5. For 2005 and 2006 models, you need to unclip the vacuum switching valve hose from the intake tube, and remove the screw from PWM switching valve. 6. Loosen the clamps at the throttle body and at the air cleaner, then remove the stock intake tube. 7. For 2002 to 2004 models, you need to remove the EVAP OBD canister closed valve vent from the air cleaner. Then unclip the upper air cleaner, then tilt upwards to unclip the PWM vacuum switching valve and the vacuum hose. 8. For 2005 and 2006 models, unclip vacuum switching valve hoses from air box, then unclip the PWM switching valve wire harness from upper airbox. 9. Remove the upper Air cleaner. 10. For 2002 to 2004 models, loosen and remove the bolt that secure the EVAP OBD canister closed valve to the lower air cleaner. 11. Loosen and remove the three bolts that secure the lower air cleaner, then disconnect the vacuum hose from the butterfly valve. 12. Tilt the lower air cleaner upwards to unclip the wire harness. 13. Remove the lower air cleaner. 14. Loosen the battery hold down bracket. 15. Remove the bolt that secures the battery hold down bracket to the radiator core support, then remove the battery hold down bracket. 16. Remove the push clip that secures the air inlet duct to the radiator core support. 17. Loosen and remove the bolt that secures the air inlet duct to the inner fender. 18. Tilt that battery backwards, then remove the air inlet duct. 19. Reinstall the battery hold down bracket. 20. Disconnect two vacuum hoses from the vacuum switching valve. Install of Intake