Partial Engine Assembly: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry. However, it is still accessible from the selected car via links, so may be relevant.

WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See PRECAUTION )
REMOVE FRONT WHEELS
REMOVE ENGINE UNDER COVER RH
REMOVE ENGINE UNDER COVER LH
REMOVE FRONT FENDER APRON SEAL RH
DRAIN ENGINE OIL
DRAIN ENGINE COOLANT (See COOLANT )
DRAIN AUTOMATIC TRANSAXLE FLUID
REMOVE BATTERY
REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See REPLACEMENT )
REMOVE VANE PUMP V BELT (See REPLACEMENT )
REMOVE ENGINE MOVING CONTROL ROD
1. Remove the 4 bolts and control rod.
  
  Fig 1: Removing Bolts And Control Rod
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE MOUNTING STAY NO. 2 RH
1. Remove the bolt, mounting stay No. 2 RH and mounting bracket No. 2 RH.
  
  Fig 2: Removing Bolt, Mounting Stay (RH) And Mounting Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE UNION TO CHECK VALVE HOSE
1. Remove the vacuum hose for the brake booster.
REMOVE V-BANK COVER SUB-ASSEMBLY
1. Using a 5 mm hexagon wrench, remove the 3 nuts.
2. Disconnect the 2 clips, and remove the cover.
  
  Fig 3: Disconnecting Clips From V-Bank Cover Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CLEANER INLET ASSEMBLY
REMOVE AIR CLEANER ASSEMBLY WITH HOSE
REMOVE AIR CLEANER BRACKET
REMOVE AIR CLEANER INLET NO. 1
REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY
SEPARATE FUEL PIPE SUB-ASSEMBLY NO. 1
1. Remove the fuel pipe clamp.
  
  Fig 4: Removing Fuel Pipe Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the connector from the tube while pinching part A with fingers as shown.
  NOTE:
  - Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
  - Disconnect the connector with your hands.
  - Do not bend, fold or rotate the nylon tube.
  - If the pipe and connector are stuck together, push and pull the connector until it comes free.
  - Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
    
    Fig 5: Disconnecting Connector From Pipe
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RADIATOR HOSE INLET
REMOVE RADIATOR HOSE OUTLET
DISCONNECT OIL COOLER INLET HOSE
DISCONNECT OIL COOLER OUTLET HOSE
DISCONNECT HEATER INLET WATER HOSE
DISCONNECT HEATER OUTLET WATER HOSE
REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
DISCONNECT ENGINE WIRE
1. Disconnect the engine wire from the ECM and J/B.
2. Disconnect the engine wire from the engine room J/B.
  1. Remove the nut and separate the wire harness.
  2. Using a screwdriver, unlock the engine room junction block. Disconnect the engine wire by pulling it upward.
    
    Fig 6: Disconnecting Engine Wire From ECM And J/B
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the connector.
3. Pull out the engine wire.
4. Remove the body ground.
  
  Fig 7: Pulling Out Engine Wire
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (See REPLACEMENT )
DISCONNECT OIL RESERVOIR TO PUMP HOSE NO. 1

Fig 8: Disconnecting Oil Reservoir To Pump Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT STEERING GEAR OUTLET RETURN TUBE

Fig 9: Disconnecting Steering Gear Outlet Return Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET
REMOVE EXHAUST PIPE ASSEMBLY FRONT
DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
1. Using a 6 mm socket hexagon wrench, hold the ball stud.
2. Remove the nut and disconnect the stabilizer link.
DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT:

Use the same procedures described for the LH side.
REMOVE FRONT AXLE HUB LH NUT
1. Using SST and a hammer, strike the lock nut covering to remove it.
  SST 09930-00010
  NOTE:
  - Set the drive shaft's groove so that it faces up. Then use the SST and hammer.
  - Remove the covering from the lock nut completely or the screw of the drive shaft may be damaged.
  - Do not sharpen the tip of the SST.
2. Using a 30 mm socket wrench, remove the lock nut.
  
  Fig 10: Striking Lock Nut Covering Using SST And Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT AXLE HUB RH NUT
HINT:

Use the same procedures described for the LH side.
DISCONNECT SPEED SENSOR FRONT LH
1. Remove the bolt and disconnect the speed sensor from the steering knuckle.
  NOTE: Keep the speed sensor tip and connection free from foreign matter.
DISCONNECT SPEED SENSOR FRONT RH
HINT:

Use the same procedures described for the LH side.
DISCONNECT TIE ROD ASSEMBLY LH
1. Remove the cotter pin and nut.
2. Using SST, disconnect the tie rod end from the steering knuckle.
  SST 09628-62011
  
  NOTE: Do not damage the dust cover of the ball joint.
  
  Fig 11: Disconnecting Tie Rod End From Steering Knuckle Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT TIE ROD ASSEMBLY RH
HINT:

Use the same procedures described for the LH side.
DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
1. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
2. Using a plastic hammer, disconnect the drive shaft from the axle hub.
  
  Fig 12: Removing Bolt And Nuts For Front Suspension Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT:

Use the same procedures described for the LH side.
REMOVE STARTER ASSEMBLY (See )
REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
1. Using SST, hold the crankshaft.
  SST 09213-54015 (91651-60855), 09330-00021
2. Remove the 2 bolts and flywheel housing under cover.
  
  Fig 13: Using SST, Hold The Crankshaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 6 torque converter setting bolts.
  
  Fig 14: Removing Torque Converter Setting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY
1. Loosen the sliding yoke bolt.
  
  Fig 15: Loosening Sliding Yoke Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Place matchmarks on the steering intermediate shaft and control valve shaft.
3. Remove the bolt and disconnect the steering intermediate shaft.
  
  Fig 16: Removing Bolt For Steering Intermediate Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. To prevent the steering wheel from rotating, fix the wheel with the seat belt.
  NOTE: If the steering wheel is not fixed, the spiral cable will be damaged.
  
  Fig 17: Prevent The Steering Wheel From Rotating Using Seat Belt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR ASSEMBLY (See REMOVAL & INSTALLATION )
REMOVE GENERATOR BRACKET NO. 2
REMOVE GENERATOR BELT ADJUSTING BAR
1. Remove the 2 bolts, 2 nuts and the adjusting bar.
  
  Fig 18: Removing Generator Bracket Bolts, Nuts, And Adjusting Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH
1. Remove the bolt, nut and adjusting bar bracket.
2. Remove the 3 bolts and disconnect the compressor.
  HINT:
  
  Hang up the hoses instead of detaching them.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine lifter.
2. Remove the 4 bolts, 2 nuts, and frame side rail plate sub-assembly RH and LH.
  
  Fig 20: Removing Bolts, Nuts, And Frame Side Rail Plate Sub-Assembly (RH) And (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.
4. Carefully, remove the engine assembly from the vehicle.
  
  Fig 21: Removing Bolts, Nuts, And Front Suspension Member Brace Rear (RH) And (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the engine hanger as shown.
  No. 2 engine hanger: Part No. 12282-20020
  
  Bolt: Part No. 91621-60822
  
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
6. Using a chain block and an engine sling device, hang the engine assembly.
  
  Fig 22: Installing Engine Hanger
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE VANE PUMP ASSEMBLY
1. Remove the power steering oil pressure sensor harness.
2. Remove the pressure feed tube clamp.
3. Remove the 2 bolts and vane pump.
  
  Fig 23: Removing Vane Pump Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT FRAME ASSEMBLY
1. Remove the 2 nuts and disconnect the engine mounting insulator RH and LH.
  
  Fig 24: Disconnecting Engine Mounting Insulator RH & LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt and disconnect the engine mounting insulator FR.
  
  Fig 25: Disconnecting Engine Mounting Insulator FR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See REMOVAL & INSTALLATION )
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See REMOVAL & INSTALLATION )
REMOVE ENGINE WIRE
REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (See REPLACEMENT )
REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (See INSPECTION )
INSTALL ENGINE STAND
REMOVE INTAKE AIR SURGE TANK
1. Disconnect the throttle motor connector.
2. Disconnect the water bypass hose No. 3.
3. Disconnect the water bypass hose No. 2.
4. Disconnect the union to check valve hose.
  
  Fig 26: Disconnecting Throttle Motor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the ventilation hose.
  
  Fig 27: Disconnecting Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Remove the 3 nuts and separate the pressure feed tube.
  
  Fig 28: Removing Nuts And Separate Pressure Feed Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the 2 bolts and engine hunger No. 1.
8. Remove the 2 bolts and surge tank stay No. 1.
9. Remove the 2 bolts and surge tank stay No. 2.
  
  Fig 29: Removing Engine Hunger & Surge Tank Stays
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a socket hexagon wrench 8, remove the 4 bolts.
11. Remove the 2 nuts, emission control valve bracket and surge tank.
12. Remove the gasket from the surge tank.
  
  Fig 30: Removing 2 Nuts, Emission Control Valve Bracket And Surge Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE AIR SURGE TANK
1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  Maximum warpage: 0.10 mm (0.0039 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 31: Measuring Manifold Flange Surface For Warpage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE IGNITION COIL ASSEMBLY
REMOVE INTAKE MANIFOLD
1. Remove the nut and disconnect the ground cable.
2. Disconnect the 6 fuel injector connectors.
  
  Fig 32: Disconnecting Fuel Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly, loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.
  
  Fig 33: Removing Bolts And Nuts For Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT INTAKE MANIFOLD

Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake surge tank for warpage.

Maximum warpage:

INTAKE MANIFOLD MAXIMUM WARPAGE

Item	Specified Condition
Intake air surge tank side	0.15 mm (0.0059 in.)
Cylinder head side	0.08 mm (0.0031 in.)

If warpage is greater than the maximum, replace the manifold.

Fig 34: Inspecting Warpage Using A Precision Straight Edge And Feeler Gauge

REMOVE WATER OUTLET (See REPLACEMENT )
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Disconnect the A/F sensor connector.
2. Remove the 3 bolts and insulator.
  
  Fig 35: Removing Bolts And Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Uniformly loosen and remove the 6 nuts in the sequence shown.
4. Remove the manifold and gasket.
  
  Fig 36: Removing Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  Maximum warpage: 0.50 mm (0.0196 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 37: Measuring Warpage Using Precision Straight Edge And Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANIFOLD STAY NO. 2
1. Remove the 2 bolts and manifold stay.
  
  Fig 38: Removing Bolts And Manifold Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
1. Remove the 2 bolts and insulator.
  
  Fig 39: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, nut and insulator.
  
  Fig 40: Removing Bolts, Nut And Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
1. Uniformly loosen and remove the 7 nuts in the sequence shown.
2. Remove the converter and gasket.
  
  Fig 41: Removing Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  Maximum warpage: 0.50 mm (0.0196 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 42: Measuring Warpage Using Precision Straight Edge And Feeler Gauge
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRIVE SHAFT BEARING BRACKET
REMOVE PUMP BRACKET
1. Remove the 3 bolts and pump bracket.
  
  Fig 43: Removing Bolts And Pump Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRACKET NO. 1
REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
REMOVE WATER INLET PIPE
REMOVE WATER INLET
REMOVE THERMOSTAT
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Remove the oil pressure switch.
  
  Fig 44: Removing Oil Pressure Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE KNOCK SENSOR
1. 1MZ-FE:
  Using SST, remove the 2 sensors.
  
  SST 09816-30010
  
  Fig 45: Removing Knock Sensors Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 3MZ-FE:
  Remove the 2 nuts and 2 sensors.
REPLACE PARTIAL ENGINE ASSEMBLY
INSTALL KNOCK SENSOR
1. 1MZ-FE:
  Using SST, install the 2 knock control sensors.
  
  SST 09816-30010
  
  Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
  
  Fig 46: Installing Knock Control Sensors Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 3MZ-FE:
  Install the 2 knock sensors with the 2 nuts, as shown.
  
  Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
  
  Fig 47: Installing Knock Sensors Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.
  Adhesive:
  
  Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent
2. Install the oil pressure switch.
  Torque: 15 N.m (152 kgf.cm, 11 ft.lbf)
  
  Fig 48: Installing Oil Pressure Switch
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THERMOSTAT (See REPLACEMENT )
INSTALL WATER INLET (See REPLACEMENT )
INSTALL WATER INLET PIPE (See REPLACEMENT )
INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
Torque: 25 N.m (255 kgf.cm, 18 ft.lbf)
INSTALL GENERATOR BRACKET NO. 1
Torque: 58 N.m (591 kgf.cm, 43 ft.lbf)
INSTALL PUMP BRACKET
Torque: 32 N.m (326 kgf.cm, 24 ft.lbf)

Fig 49: Installing Pump Bracket
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
1. Install a new gasket and the converter sub-assy No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
2. Retighten nuts 1 and 2 as shown.
  
  Fig 50: Installing Exhaust Manifold Converter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
Torque: 8.5 N.m (87 kgf.cm, 55 in.lbf)
INSTALL MANIFOLD STAY NO. 2
Torque: 34 N.m (347 kgf.cm, 25 ft.lbf)
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Install a new gasket and the exhaust manifold RH. Uniformly tighten the 5 nuts in the sequence shown. See Fig 51.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
2. Retighten nuts 1 and 2 as shown.
  
  Fig 51: Installing A New Gasket And Exhaust Manifold (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER OUTLET (See REPLACEMENT )
INSTALL INTAKE MANIFOLD
1. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown.
  
  Fig 52: Installing Intake Manifold With Nuts, Bolts And Washers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
2. Retighten the water outlet mounting bolts and nuts.
  Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
3. Install the ground cable with the nut.
  Torque: 8.4 N.m (86 kgf.cm, 74 in.lbf)
4. Connect the heater inlet water hose.
INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf)
INSTALL INTAKE AIR SURGE TANK
1. Install a new gasket to the intake air surge tank.
2. Install the intake air surge tank and emission control valve bracket with the 2 nuts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
3. Using a socket hexagon wrench 8, tighten the 4 bolts.
  Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
4. Install the surge tank stay No. 2 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 15 ft.lbf)
5. Install the surge tank stay No. 1 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 15 ft.lbf)
6. Install the engine hunger No. 1 with the 2 bolts.
  Torque: 20 N.m (199 kgf.cm, 15 ft.lbf)
7. Install the pressure feed tube with the 3 nuts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
8. Connect the ventilation hose.
9. Connect the union to check valve hose.
10. Connect the water bypass hose No. 2.
11. Connect the water bypass hose No. 3.
12. Connect the throttle motor connector.
INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (See INSPECTION )
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (See REPLACEMENT )
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See REMOVAL & INSTALLATION )
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See REMOVAL & INSTALLATION )
INSTALL FRONT FRAME ASSEMBLY
1. Install the engine mounting insulator RH and LH with the 2 nuts.
  Torque: 95 N.m (969 kgf.cm, 70 ft.lbf)
  
  Fig 53: Installing Engine Mounting Insulator (RH) And (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the engine mounting insulator FR with the bolt.
  Torque: 87 N.m (887 kgf.cm, 64 ft.lbf)
  
  Fig 54: Installing Engine Mounting Insulator FR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP ASSEMBLY
1. Install the vane pump with the 2 bolts.
  Torque: 43 N.m (439 kgf.cm, 32 ft.lbf)
  
  HINT:
  
  After adjusting the V-ribbed belt, tighten bolt A.
  
  Fig 55: Installing Vane Pump With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine assembly with transaxle on the engine lifter.
2. Install the engine assembly to the vehicle.
3. Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts.
  Torque:
  
  85 N.m (867 kgf.cm, 63 ft.lbf) for bolt A
  
  32 N.m (326 kgf.cm, 24 ft.lbf) for bolt B and nut
  
  Fig 56: Installing Frame Side Rail Plate (RH) And (LH) With Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
  Torque:
  
  85 N.m (867 kgf.cm, 63 ft.lbf) for bolt C
  
  32N.m (326 kgf.cm, 24 ft.lbf) for bolt D and nut
  
  Fig 57: Installing Front Suspension Member Brace Rear (RH) And (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL COMPRESSOR AND MAGNETIC CLUTCH
1. Install the compressor with the 3 bolts.
  Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
2. Install the adjusting bar bracket with the bolt and nut.
  Torque:
  
  25 N.m (250 kgf.cm, 18 ft.lbf) for bolt
  
  26 N.m (260 kgf.cm, 19 ft.lbf) for nut
  
  Fig 58: Installing Adjusting Bar Bracket With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BELT ADJUSTING BAR
1. Install the adjusting bar with the 2 bolts and 2 nuts.
  Torque:
  
  43 N.m (438 kgf.cm, 32 ft.lbf) for nut A
  
  18 N.m (184 kgf.cm, 13 ft.lbf) for bolt B
  
  8.0 N.m (82 kgf.cm, 71 in.lbf) for bolt C
  
  Fig 59: Installing Adjusting Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR BRACKET NO. 2
Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
INSTALL GENERATOR ASSEMBLY (See REMOVAL & INSTALLATION )
INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
1. Align the matchmarks on the intermediate shaft and control valve shaft, and install the bolt.
  Torque: 35 N.m (357 kgf.cm, 26 ft.lbf)
  
  Fig 60: Aligning Matchmarks On Intermediate Shaft And Control Valve Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the sliding yoke bolt.
  Torque: 35 N.m (357 kgf.cm, 26 ft.lbf)
  
  Fig 61: Tightening Sliding Yoke Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
1. Using SST, hold the crankshaft.
  SST 09213-54015 (91651-60855), 09330-00021
2. Using kerosene or gasoline, clean the bolts thoroughly.
3. Apply adhesive to 2 or 3 threads of the bolt end.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
  
  Fig 62: Holding Crankshaft Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 6 torque converter set bolts.
  Torque: 41 N.m (418 kgf.cm, 30 ft.lbf)
  
  NOTE: First tighten the green colored bolt and then tighten the 5 bolts.
5. Install the flywheel housing under cover with the 2 bolts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
  
  Fig 63: Installing Flywheel Housing Under Cover With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
INSTALL STARTER ASSEMBLY (See )
INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
1. Install the drive shaft to the steering knuckle.
2. Install the suspension lower arm with the bolt and 2 nuts.
  Torque: 75 N.m (764 kgf.cm, 55 ft.lbf)
  
  Fig 64: Installing Suspension Lower Arm With Bolt And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT:

Use the same procedures described for the LH side.
INSTALL TIE ROD ASSEMBLY LH
1. Connect the tie rod end to the steering knuckle and install a new castle nut.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  NOTE:
  - Prevent any lubricant from contacting the thread and the taper portions.
  - After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin.
2. Insert a new cotter pin.
INSTALL TIE ROD ASSEMBLY RH
HINT:

Use the same procedures described for the LH side.
INSTALL SPEED SENSOR FRONT LH (See SPEED SENSOR FRONT )
INSTALL SPEED SENSOR FRONT RH
HINT:

Use the same procedures described for the LH side.
INSTALL FRONT AXLE HUB LH NUT
1. Using a 30 mm socket wrench, install a new hub nut.
  Torque: 294 N.m (2,998 kgf.cm, 217 ft.lbf)
2. Using a chisel and hammer, tapped the front axle hub LH nut.
  
  Fig 65: Tapping Front Axle Hub (LH) Nut Using Hammer And Chisel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT AXLE HUB RH NUT
HINT:

Use the same procedures described for the LH side.
INSTALL FRONT STABILIZER LINK ASSEMBLY LH
1. Using a 6 mm socket hexagon wrench, hold the ball stud, and install the nut.
  Torque: 74 N.m (755 kgf.cm, 55 ft.lbf)
INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:

Use the same procedures described for the LH side.
INSTALL EXHAUST PIPE ASSEMBLY FRONT (See EXHAUST PIPE ASSY (1MZ-FE/3MZ-FE) )
INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See EXHAUST PIPE ASSY (1MZ-FE/3MZ-FE) )
CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
1. Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.
  NOTE:
  - Check for damage or contamination on the connected part of the pipe.
  - After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.
2. Install the fuel pipe clamp.
  
  Fig 66: Installing Fuel Pipe Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY WITH HOSE
CONNECT VACUUM HOSES

Fig 67: Vacuum Hose Routing Diagram (1 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 68: Vacuum Hose Routing Diagram (2 Of 2)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Using a 5 mm socket hexagon wrench, install the V-bank cover with the 2 nuts.
  Torque: 7.9 N.m (81 kgf.cm, 70 in.lbf)
INSTALL ENGINE MOUNTING STAY NO. 2 RH
1. Install the mounting stay and mounting bracket with the bolt.
  Torque: 64 N.m (653 kgf.cm, 47 ft.lbf)
  
  Fig 69: Installing Mounting Stay And Mounting Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE MOVING CONTROL ROD
1. Install the control rod and bracket with the 4 bolts.
  Torque:
  
  64 N.m (653 kgf.cm, 47 ft.lbf) for bolt A
  
  23 N.m (235 kgf.cm, 17 ft.lbf) for bolt B
  
  Fig 70: Installing Control Rod And Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP V BELT (See OVERHAUL )
INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See REPLACEMENT )
INSPECT DRIVE BELT TENSION (See INSPECTION )
INSTALL FRONT WHEELS
ADD AUTOMATIC TRANSAXLE FLUID (See AUTOMATIC TRANSAXLE FLUID )
ADD ENGINE OIL
ADD ENGINE COOLANT (See COOLANT )
ADD POWER STEERING FLUID
BLEED POWER STEERING FLUID (See ON-VEHICLE INSPECTION )
CHECK FOR OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
INSPECT FOR FUEL LEAKS
CHECK FOR EXHAUST GAS LEAKS
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See FRONT WHEEL ALIGNMENT )
INSPECT IGNITION TIMING (See INSPECTION )
INSPECT ENGINE IDLE SPEED (See INSPECTION )
INSPECT CO/HC (See INSPECTION )
CHECK ABS SPEED SENSOR SIGNAL (See PRE-CHECK )