Partial Engine ASSY: Replacement

WARNING: This page is about a different car, the 2004 Lexus LS 430. However, it is still accessible from the selected car via links, so may be relevant.

WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See PRECAUTION )
DISCONNECT BATTERY NEGATIVE TERMINAL
REMOVE HOOD SUB-ASSY
REMOVE V-BANK COVER
REMOVE AIR CLEANER INLET NO.1
REMOVE INTAKE AIR CONNECTOR PIPE
REMOVE AIR CLEANER ASSY
REMOVE FRONT WHEEL
REMOVE ENGINE UNDER COVER NO.1
REMOVE ENGINE UNDER COVER NO.2
DRAIN ENGINE OIL
DRAIN ENGINE COOLANT
DRAIN AUTOMATIC TRANSMISSION FLUID
REMOVE RADIATOR ASSY (See REPLACEMENT )
DISCONNECT FUEL PIPE SUB-ASSY NO.2 (See PRECAUTION )
REMOVE FAN AND GENERATOR V BELT (SEE DRIVE BELT )
DISCONNECT ENGINE WIRE
1. Disconnect the engine wire from the ECM box.
2. Remove the nut, and disconnect the generator wire from the generator.
3. Disconnect the wire for generator wire from the wire clamp on generator.
4. Remove the bolt, and disconnect the ground cable from the stay on the generator.
5. Remove the 2 bolts, and disconnect the PS oil hose from the No. 1 oil pan. } Remove the bolt, and disconnect the ground strap from the body.
DISCONNECT AIR HOSE NO.5
DISCONNECT FUEL VAPOR FEED HOSE NO.2
DISCONNECT HEATER WATER INLET HOSE A
DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
DISCONNECT VANE PUMP OIL RESERVOIR ASSY
DISCONNECT VANE PUMP ASSY
1. Disconnect the 2 PS air hoses.
2. Remove the 2 screws and RH engine under cover.
3. Disconnect the PS oil pressure switch connector.
4. Remove the 2 bolts and nut, and disconnect the pump from the engine.
5. Support the pump securely.
DISCONNECT COOLER COMPRESSOR ASSY
1. Disconnect the compressor connector.
2. Disconnect the wire clamp from the wire bracket on the compressor.
3. Remove the bolt, nut and stay.
4. Remove the bolt, and disconnect the wire bracket from the compressor.
5. Remove the bolt, and disconnect the compressor from the engine.
6. Support the cooler compressor securely
REMOVE FRONT FLOOR BRACE CENTRE
1. Remove the 4 bolts and brace center.
REMOVE EXHAUST PIPE ASSY (SEE REPLACEMENT )
REMOVE W/CATALYST CONVERTER ASSY
REMOVE FRONT FLOOR HEAT INSULATOR NO. 1
REMOVE PARKING BRAKE CABLE HEAT INSULATOR
REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PROPELLER W/CENTER BEARING SHAFT ASSY )
REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY
REMOVE STEERING SLIDING W/SHAFT YOKE SUB-ASSY
1. Check the steering wheel at the straight-ahead position.
2. Remove the 2 bolts and sliding yoke from the steering intermediate shaft.
  
  Fig 1: Removing Steering Sliding W/Shaft Yoke Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT DISC BRAKE CYLINDER ASSY RH (See FRONT BRAKE DISC )
REMOVE DISC BRAKE CYLINDER ASSY LH (See FRONT BRAKE DISC )
REMOVE FRONT SUSPENSION UPPER ARM ASSY RH (See UPPER CONTROL ARM & BALL JOINT )
REMOVE FRONT SUSPENSION UPPER ARM ASSY LH (See UPPER CONTROL ARM & BALL JOINT )
REMOVE PNEUMATIC FRONT RH W/SHOCK ABSORBER CYLINDER ASSY (See PNEUMATIC CYLINDER )
REMOVE PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY (See PNEUMATIC CYLINDER )
REMOVE HEIGHT CONTROL SENSOR LINK SUB-ASSY FRONT (See REPLACEMENT )
REMOVE STABILIZER BRACKET FRONT (See STABILIZER BAR )
DISCONNECT POWER STEERING GEAR HOUSING ASSY
1. Remove the bolt, and disconnect the 2 PS oil tubes from the front frame.
2. Remove the 4 bolts, and disconnect the PS gear housing from the front frame.
3. Suspend the PS gear housing securely.
  
  Fig 2: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE W/ TRANSMISSION ASSEMBLY
1. Remove the nut and No. 1 V-bank cover bracket from the No. 2 engine hanger,
2. Attach the engine chain hoist to the engine hangers.
  
  Fig 3: Attaching Engine Chain Hoist To Engine Hangers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 hole plugs.
4. Remove the 4 nuts holding the engine mounting insulator to the front suspension crossmember.
5. Remove the 4 bolts, 4 nuts and rear engine mounting member.
  
  Fig 4: Identifying Bolts, Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Lift the engine out of the vehicle slowly and carefully.
  HINT:
  
  Make sure the engine is clear of all wiring, hose and cable.
7. Place the engine and transmission assy onto the stand.
  
  Fig 5: Removing Out Engine
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT ENGINE WIRE
1. Disconnect the engine wire from the transmission.
  1. Disconnect the VSV connector.
  2. Disconnect the PNP switch connector.
  3. Disconnect the solenoid connector.
  4. Disconnect the direct clutch speed sensor connector.
  5. Disconnect the engine wire from the 3 wire clamps.
  6. Disconnect the oil level sensor connector.
REMOVE TRANSMISSION OIL FILTER TUBE SUB-ASSY
REMOVE OIL COOLER OUTLET TUBE NO.1
REMOVE OIL COOLER INLET TUBE NO.1
REMOVE AUTOMATIC TRANSMISSION ASSY
1. Remove the torque converter clutch bolts.
  1. Remove the 2 bolts and flywheel housing under cover.
  2. Turn the crankshaft damper bolt to gain access to each bolt.
  3. Hold the crankshaft damper bolt with a wrench, and remove the 6 bolts.
2. Remove the 10 bolts and ground strap.
3. Remove the transmission together with the torque converter clutch from the engine.
  
  Fig 6: Identifying Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
1. Remove the 8 bolts, rear spacer, ring gear and front spacer.
INSTALL ENGINE STAND
REMOVE THROTTLE BODY ASSY (See REPLACEMENT )
REMOVE INTAKE MANIFOLD ASSY
1. Disconnect the VSV connector for EVAR
2. Disconnect the EVAP hose from the VSV for EVAR
3. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
4. Remove the bolt and V-bank cover bracket No. 2.
5. Remove the bolt and V-bank cover bracket No. 3.
  
  Fig 7: Removing VSV, EVAP, And V-Bank Cover Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Disconnect the VSV connector for ACIS.
7. Remove the bolt and V-bank cover bracket No. 1.
8. Remove the bolt and V-bank cover fastener.
  
  Fig 8: Disconnecting VSV Connector For ACIS
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from the upper intake manifold and camshaft bearing cap.
10. Disconnect the 2 wire clamps on the engine wire (PH side) from the brackets on the RH delivery pipe.
11. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water by pass joint and RH cylinder head.
  
  Fig 9: Disconnecting Engine Wire Protector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Disconnect the 8 injector connectors,
13. Remove the 6 bolts, 4 nuts, intake manifold assy and 2 gaskets.
  
  Fig 10: Disconnecting Injector Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT INTAKE MANIFOLD ASSY
1. Upper intake manifold:
  Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for war-page.
  
  Maximum warpage: 0.15 mm (0.0059 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 11: Measuring Surface Contacting Cylinder Head For Warpage (Upper Intake Manifold)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Lower intake manifold
  Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  
  Maximum warpage: 0.15 mm (0.0059 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 12: Measuring Surface Contacting Cylinder Head For Warpage (Lower Intake Manifold)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ASSY (See STARTER )
REMOVE GENERATOR ASSY (See GENERATOR )
REMOVE WATER INLET HOUSING
1. Remove the 2 bolts and inlet housing.
REMOVE WATER BY-PASS JOINT FR
1. Disconnect the ECT sensor connector.
2. Remove the 4 nuts, water by pass joint and 2 gaskets.
  
  Fig 13: Removing Water By-Pass Joint Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER BY-PASS JOINT RR
1. Disconnect the heater inlet hose from the water by pass joint.
2. Remove the 4 nuts, water by pass joint and 2 gaskets.
  
  Fig 14: Removing Water By-Pass Joint Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER BY-PASS PIPE SUB-ASSY
1. Disconnect the heater outlet hose from the water by pass pipe.
2. Disconnect the wire clamp (for knock sensor bank 1, 2) from the bracket of the water by pass pipe.
3. Remove the bolt.
4. Pull out the water by pass pipe from the water pump.
5. Remove the O-ring from the water by pass pipe.
REMOVE OIL LEVEL GAGE GUIDE
REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
REMOVE CAMSHAFT POSITION SENSOR
REMOVE WT SENSOR
REMOVE KNOCK SENSOR
1. Disconnect the 2 knock sensor connectors.
2. Remove the 2 nuts and 2 knock sensors.
  
  Fig 15: Removing Nuts And Knock Sensors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE HANGER NO. 1
REMOVE ENGINE HANGER NO.2
REMOVE IGNITION COIL ASSY
REMOVE OIL FILTER BRACKET SUB-ASSY
1. Disconnect the oil pressure switch connector.
2. Remove the stud bolt, 2 nuts and oil filter bracket with gasket
REMOVE CRANKSHAFT POSITION SENSOR
REMOVE ENGINE OIL LEVEL SENSOR
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
REMOVE EXHAUST MANIFOLD SUB-ASSY RH
1. Remove the 8 nuts, exhaust manifold and gasket.
  
  Fig 16: Removing Nuts, Exhaust Manifold And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST MANIFOLD SUB-ASSY RH
1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for war-page.
  Maximum warpage: 0.50 mm (0.0197 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 17: Inspecting Exhaust Manifold Sub-Assy RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
REMOVE EXHAUST MANIFOLD SUB-ASSY LH
1. Remove the 8 nuts, exhaust manifold and gasket.
  
  Fig 18: Removing Nuts, Exhaust Manifold And Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT EXHAUST MANIFOLD SUB-ASSY LH
1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  Maximum warpage: 0.50 mm (0.0197 in.)
  
  If the warpage is greater than the maximum, replace the manifold.
  
  Fig 19: Inspecting Exhaust Manifold Sub-Assy LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WIRING HARNESS HEAT INSULATOR NO. 2
REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 RH
REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 LH
INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
1. Install the mounting bracket with the 4 bolts.
  Torque: 36 N.m (367 kgf.cm, 27 ft.lbf)
  
  HINT:
  
  The LH mounting bracket is marked with "L".
  
  Fig 20: Installing Mounting Bracket LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE MOUNTING BRACKET FRONT NO. 1 RH
1. Install the mounting bracket with the 4 bolts.
  Torque: 36 N.m (367 kgf.cm, 27 ft.lbf)
  
  HINT:
  
  The RH mounting bracket is marked with "R".
  
  Fig 21: Installing Mounting Bracket RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WIRING HARNESS HEAT INSULATOR NO. 2
INSTALL EXHAUST MANIFOLD SUB-ASSY LH
1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
  NOTE: Be careful of the installation direction.
  
  Fig 22: Identifying New Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
  Torque: 44 N.m (449 kgf.cm, 32 ft lfb)
  
  Fig 23: Installing Exhaust Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
INSTALL EXHAUST MANIFOLD SUB=ASSY RH
1. Place a new gasket on the cylinder head with the white mark facing the manifold side.
  NOTE: Be careful of the installation direction.
  
  Fig 24: Identifying New Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
  Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
  
  Fig 25: Installing Exhaust Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
INSTALL ENGINE OIL LEVEL SENSOR
INSTALL CRANKSHAFT POSITION SENSOR (See REPLACEMENT )
INSTALL OIL FILTER BRACKET SUB-ASSY
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
INSTALL IGNITION COIL ASSY
Torque: 7.5 N.m (76.5 kgf.cm, 66 n. lbf)
INSTALL ENGINE HANGER NO. 2
Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
INSTALL ENGINE HANGER NO. 1
Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
INSTALL KNOCK SENSOR
1. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
2. Connect the 2 knock sensor connectors.
  
  Fig 26: Angling Knock Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VVT SENSOR
INSTALL CAMSHAFT POSITION SENSOR
Torque 7.5 N.m (77 kgf.cm, 66 in. lbf)
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (See REPLACEMENT and REPLACEMENT (LH) )
INSTALL OIL LEVEL GAGE GUIDE
Torque: 7.5 N.m (76.5 kgf.cm, 66 in. lbf)
INSTALL WATER BY-PASS PIPE SUB-ASSY
1. Install a new O-ring to the water by pass pipe.
2. Apply soapy water to the O-ring.
3. Push in the water by pass end into the pipe hole of the water pump.
4. Install the water by pass with the bolt.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
5. Install the wire clamp to the bracket of the water by pass pipe.
INSTALL WATER BY-PASS JOINT RR
1. Install 2 new gaskets and the water by pass joint with the 4 nuts. Alternately tighten the nuts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
  
  Fig 27: Installing Water By-Pass Joint Rear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER BY-PASS JOINT FR
1. Install 2 new gaskets and the water by pass joint with the 4 nuts. Alternately tighten the nuts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
2. Connect the ECT sensor connector.
  
  Fig 28: Installing Water By-Pass Joint Front
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER INLET HOUSING
1. Install a new O-ring to the inlet housing.
2. Apply soapy water on the O-ring.
3. Apply seal packing to the sealing groove of inlet housing as shown in the illustration.
  Seal packing: Part No. 08826-00100 or equivalent
  - Install a nozzle that has its opening cut to a 2 to 3 mm (0.08 to 0.12 in.).
  - Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
4. Install the water inlet and housing assy with the 2 bolts. Alternately tighten the bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
  
  Fig 29: Installing Water Inlet And Housing Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ASSY (See GENERATOR )
INSTALL STARTER ASSY (See STARTER )
INSTALL INTAKE MANIFOLD ASSY
1. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
  NOTE: Be careful of the installation direction.
  
  Fig 30: Installing Intake Manifold Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the intake manifold assy with the 6 bolts and 4 nuts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
3. Connect the 8 injector connectors.
  
  Fig 31: Identifying Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the engine wire protector (rear side) with the 2 bolts.
5. Install the engine wire protector (LH side) with the 4 bolts.
6. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
  
  Fig 32: Installing Engine Wire Protector (LH Side)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the V-bank cover fastener with the bolt.
  Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf)
8. Install the V-bank cover bracket No. 1 with the bolt.
  Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf)
9. Connect the VSV connector for ACIS.
  
  Fig 33: Connecting VSV Connector For ACIS
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Install the V-bank cover bracket No. 3 with the bolt.
  Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf)
11. Install the V-bank cover bracket No. 2 With the bolt.
  Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf)
12. Connect the VSV for EVAP to the intake manifold with the bolt.
  Torque: 7.5 N.m (77 kgf.cm, 66 in. lbf)
13. Connect the EVAP hose to the VSV for EVAP.
14. Connect the VSV connector for EVAP.
  
  Fig 34: Installing V-Bank Cover Bracket VSV For EVAP To Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL THROTTLE BODY ASSY (See REPLACEMENT )
REMOVE ENGINE STAND
INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
HINT:

The mounting bolts are tightened in 2 progressive steps (step (c) and (e)).

If any one of the mounting bolts is broken or deformed, replace it.
1. Apply adhesive to 2 or 3 threads of the mounting bolt end.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
  
  Fig 35: Applying Adhesive To Threads Of Mounting Bolt End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front spacer, drive plate and rear spacer on the crankshaft.
3. Install and uniformly tighten the 8 mounting bolts in several passes in the sequence shown in the illustration.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  
  If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.
  
  Fig 36: Installing Mounting Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the mounting bolt with paint.
5. Retighten the mounting bolt by 90° in the numerical order shown.
6. Check that the painted mark is now at a 90° angle to step (e).
  
  Fig 37: Tightening Mounting Bolt By 90 Degree
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AUTOMATIC TRANSMISSION ASSY
1. Check the torque converter clutch installation (See INSPECTION ).
2. Attach the transmission to the engine.
3. Install the ground strap and 10 bolts.
  Torque:
  
  72 N.m (734 kgf.cm, 53 ft.lbf) for 17 mm head bolt A
  
  37 N.m (377 kgf.cm, 27 ft.lbf) for 14 mm head bolt B
  
  Fig 38: Identifying Bolts Installation Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the torque converter clutch bolts.
  1. Apply adhesive to 2 or 3 threads of the bolt and.
    Adhesive:
    
    Part No. 08833-00070, THREE BOND 1324 or equivalent
  2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
    Torque: 48 N.m (490 kgf.cm, 35 ft.lbf)
    
    HINT:
    
    First install the black colored bolt, and then install the other bolts.
  3. Install the flywheel housing undercover with the 2 bolts.
    Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
    
    Fig 39: Identifying Torque Converter Clutch Bolt
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL COOLER INLET TUBE NO.1
INSTALL OIL COOLER OUTLET TUBE NO.1
INSTALL TRANSMISSION OIL FILTER TUBE SUB-ASSY
CONNECT ENGINE WIRE
1. Connect the engine wire to the transmission.
  1. Connect the VSV connector.
  2. Connect the PNP switch connector.
  3. Connect the solenoid connector.
  4. Connect the direct clutch speed sensor connector.
  5. Connect the engine wire from the 3 wire clamps.
  6. Connect the oil level sensor connector.
INSTALL ENGINE W/ TRANSMISSION ASSEMBLY
1. Attach the engine chain hoist to the engine hangers.
2. Slowly lower the engine and transmission assembly into the engine compartment.
3. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
  
  Fig 40: Installing Engine W/ Transmission Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Keep the engine level.
  
  Fig 41: Keeping Engine Level
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the rear engine mounting member with the 4 bolts and 4 nuts.
  Torque:
  
  25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolt
  
  13.5 N.m (138 kgf.cm, 10 ft.lbf) for nut
  
  NOTE: Be careful of installation direction.
  
  Fig 42: Installing Rear Engine Mounting Member
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.
  Torque: 68 N.m (693 kgf.cm, 50 ft.lbf)
7. Install the 2 hole plugs.
8. Remove the engine chain hoist,
9. Install the V-bank cover bracket No. 1 to the engine hanger No. 2 with the nut.
  
  Fig 43: Installing Engine Mounting Brackets Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL POWER STEERING GEAR HOUSING ASSY
1. Connect the sliding yoke to the PS gear housing and intermediate shaft.
2. Install the PS gear housing with the 4 bolts.
  Torque: 65 N.m (663 kgf.cm, 48 ft.lbf)
3. Install the 2 PS oil tubes with the bolts.
  
  Fig 44: Installing Power Steering Gear Housing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSY FRONT (See REPLACEMENT )
INSTALL PNEUMATIC FRONT RH W/SHOCK ABSORBER CYLINDER ASSY (See PNEUMATIC CYLINDER )
INSTALL PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSY (See PNEUMATIC CYLINDER )
INSTALL FRONT SUSPENSION UPPER ARM ASSY RH (See UPPER CONTROL ARM & BALL JOINT )
INSTALL FRONT SUSPENSION UPPER ARM ASSY LH (See UPPER CONTROL ARM & BALL JOINT )
INSTALL FRONT DISC BRAKE CYLINDER ASSY RH (See FRONT BRAKE DISC )
INSTALL DISC BRAKE CYLINDER ASSY LH (See FRONT BRAKE DISC )
INSTALL STEERING SLIDING W/SHAFT YOKE SUB-ASSY
1. Tighten the 2 bolts for sliding yoke.
  Torque: 35 N.m (357 kgf.cm, 26 ft.lbf)
  
  Fig 45: Installing Steering Sliding W/Shaft Yoke Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY
INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (SEE PROPELLER W/CENTER BEARING SHAFT ASSY )
INSTALL PARKING BRAKE CABLE HEAT INSULATOR
INSTALL FRONT FLOOR HEAT INSULATOR NO.1
INSTALL W/CATALYST CONVERTER ASSY
INSTALL EXHAUST PIPE ASSY (SEE REPLACEMENT )
INSTALL FRONT FLOOR BRACE CENTER
INSTALL COOLER COMPRESSOR ASSY
1. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.
  Torque:
  
  49 N.m (500 kgf.cm, 36 ft.lbf) for bolt
  
  29 N.m (296 kgf.cm, 21 ft.lbf) for nut
2. Connect the compressor connector.
3. Install the wire clamp.
  
  Fig 46: Installing Cooler Compressor Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP ASSY
1. Install the vane pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
  Torque:
  
  39.2 N.m (400 kgf.cm, 29 ft.lbf) for bolt
  
  43.1 N.m (440 kgf.cm, 32 ft.lbf) for nut
2. Connect the PS oil pressure switch connector.
3. Install the RH engine under cover with the 2 screws.
4. Connect the 2 PS air hoses to the vane pump.
  
  Fig 47: Installing Vane Pump Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL VANE PUMP OIL RESERVOIR ASSY
CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
CONNECT HEATER WATER INLET HOSE A
CONNECT FUEL VAPOR FEED HOSE NO. 2
CONNECT AIR HOSE NO. 5
CONNECT ENGINE WIRE
1. Connect the engine wire from the ECM box.
2. Install the nut, and connect the generator wire to the generator.
3. Connect the wire for generator wire to the wire clamp on generator.
4. Connect the ground cable to the stay on generator with the bolt.
5. Connect the PS oil hose to the No. 1 oil pan with the 2 bolts.
6. Connect the ground strap to the body with the 2 bolts.
INSTALL FAN AND GENERATOR V BELT (See GENERATOR )
CONNECT FUEL PIPE SUB-ASSY NO.2 (See REPLACEMENT )
INSTALL RADIATOR ASSY (See REPLACEMENT )
INSTALL ENGINE UNDER COVER NO.2
INSTALL ENGINE UNDER COVER NO.1
INSTALL FRONT WHEEL
INSTALL AIR CLEANER ASSY
INSTALL INTAKE AIR CONNECTOR PIPE
INSTALL AIR CLEANER INLET NO.1
INSTALL V-BANK COVER
INSTALL HOOD SUB-ASSY (See OVERHAUL )
CONNECT BATTERY NEGATIVE TERMINAL
POWER WINDOW CONTROL SYSTEM INITIALIZE (See INITIALIZATION )
FRONT POWER SEAT CONTROL SYSTEM INITIALIZE (See INITIALIZATION )
ADD AUTOMATIC TRANSMISSION FLUID
ADD ENGINE COOLANT (See REPLACEMENT )
ADD ENGINE OIL (See REPLACEMENT )
ADD POWER STEERING FLUID
BLEED POWER STEERING FLUID
INSPECT AUTOMATIC TRANSMISSION FLUID (SEE ADJUSTMENT )
INSPECT ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS
INSPECT FOR FUEL LEAKS
CHECK FOR EXHAUST GAS LEAKS
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
INSPECT IGNITION TIMING
INSPECT ENGINE IDLE SPEED
INSPECT CO/HC
ADJUST ENGINE (See INSPECTION )
CHECK ABS SPEED SENSOR SIGNAL (SEE TEST MODE PROCEDURE )