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Section 444 (Hood): Overhaul

WARNING: This page is about a different car, the 2003 Toyota 4Runner. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

The installation is in the reverse order of the removal. However, when there is a special point concerning the installation, it is indicated.

  1. REMOVE RADIATOR GRILLE 
    1. Remove the 2 bolts and auxiliary catch release lever.
    2. Remove the bolt and hood auxiliary catch hook.
    3. Remove the 10 nuts and radiator grille.
  2. REMOVE HOOD INSULATOR 
    1. Using a clip remover, remove the 11 clips and hood insulator.
  3. REMOVE HOOD BULGE ASSY 
    1. Remove the screw and 5 nuts, as shown in Fig 1.
      Fig 1: Removing Screw And Nuts
      G02814185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the hood bulge.
    3. Remove the hood air intake guide No. 1 retainer.
    4. Using a drill of less than phis 4 mm (0.16 in.), drill out the rivet heads and remove the hood bulge.
      Fig 2: Removing Hood Bulge Assembly
      G02814186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Dimension (A): 5 mm (0.20 in.) 

    5. Gently and vertically put the drill onto the rivet, and cut the rivet flanges.
    6. Remove the hood bulge plate and air intake guide.
      NOTE:
      • Prizing the hole with a drill can lead to damage to the rivet hole or breaking the drill.
      • Be careful with the cut rivet, because it is hot.
    7. Even if the flange is taken off, continue drilling and push out the remaining fragments using the drill.
    8. Using a vacuum cleaner, remove the drilled rivet and dust from the inside of the hood bulge.
  4. REMOVE HOOD SUPPORT ASSY (See  HOOD SUPPORT ASSEMBLY  ) 
  5. REMOVE HOOD SUB-ASSY 
    1. Remove the windshield washer hose.
    2. Remove the 4 bolts and hood.
  6. REMOVE HOOD HINGE ASSY LH 
    1. Remove the 2 bolts and hood hinge.
  7. REMOVE HOOD HINGE ASSY RH 
    1. Remove the 2 bolts and hood hinge.
  8. REMOVE RADIATOR SUPPORT SEAL UPPER 
    1. Using a clip remover, remove the 8 clips and support seal.
  9. REMOVE HOOD LOCK ASSY 
      NOTE:

      Tape the screwdriver tip before use.

      Fig 3: Disengaging Clips
      G02814187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, disengage the 4 clips.
    2. Remove the hood lock release lever protector.
      NOTE: Removing the protector damages the clips inside the protector, therefore the use of a new protector is necessary on installation.
    3. Remove the 3 bolts and hood lock.
      Fig 4: Removing Hood Lock Assembly
      G02814188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. w/ Security system: Disconnect the connector.
  10. INSTALL HOOD LOCK ASSY 
    1. w/ Security system:

      Connect the connector.

    2. Install the hood lock assy with the 3 bolts.
      Fig 5: Installing Hood Lock Assembly LH
      G02814189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Adjust the hood lock position so that the striker will come in, by moving the striker (See ADJUSTMENT ).
    4. Tighten the hood lock bolts after the adjustment.

      Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 

  11. INSTALL HOOD HINGE ASSY LH 
    1. Install the hood hinge with the 2 bolts.

      Torque: 13.0 N.m (130 kgf.cm, 10 ft.lbf) 

  12. INSTALL HOOD HINGE ASSY RH 
    1. Install the hood hinge with the 2 bolts.

      Torque: 13.0 N.m (130 kgf.cm, 10 ft.lbf) 

  13. INSTALL HOOD SUB-ASSY 
    1. Install the hood with the 4 bolts.

      Torque: 13.0 N.m (130 kgf.cm, 10 ft.lbf) 

  14. INSTALL HOOD SUPPORT ASSY (See  REPLACEMENT  ) 

    Torque: 17.5 N.m (180 kgf.cm, 13 ft.lbf) 

  15. INSTALL HOOD BULGE ASSY 
    1. Install the hood bulge plate and hood air intake guide to the hood bulge.
    2. Using a hand riveter or air riveter with nose piece, strike rivets into the hood bulge assy.
      Fig 6: Installing Hood Bulge Assembly
      G02814190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • If the rivet is not positioned perpendicularly, it will bend the mandrel.
      • Do not prize a riveter, because the riveter will be damaged and the mandrel will be bent.
        Fig 7: Identifying Wrong Handling Of Mandrel
        G02814191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not tilt the riveter when removing the rivet, because the materials are not tightened firmly.
        Fig 8: Identifying Wrong Installing Of Riveter
        G02814192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Install the rivet while attaching the materials, because they are not tightened firmly.
        Fig 9: Identifying Wrong Installing Of Rivet
        G02814193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the hood air intake guide No. 1 retainer with the screw and hood bulge assy.
    4. Install the hood bulge assy to the hood with the 5 nuts.
      Fig 10: Installing Hood Bulge Assembly
      G02814194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

  16. INSTALL RADIATOR GRILLE 
    1. Install the radiator grille with the 12 nuts.

      Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

    2. Install the hood auxiliary catch hook with the bolt.

      Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 

    3. Install the auxiliary catch release lever with the 2 bolts.

      Torque: 8.0 N.m (82 kgf.cm, 71 in..lbf) 

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