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Partial Engine ASSY: Replacement

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.
  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  PRECAUTION  ) 
  2. REMOVE FRONT WHEELS 
  3. REMOVE ENGINE UNDER COVER RH 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE FRONT FENDER APRON SEAL RH 
  6. DRAIN ENGINE OIL 
  7. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  8. DRAIN AUTOMATIC TRANSAXLE FLUID 
  9. REMOVE BATTERY 
  10. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT  ) 
  11. REMOVE VANE PUMP V BELT (See  REPLACEMENT  ) 
  12. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the 4 bolts and control rod.
    Fig 1: Removing Engine Moving Control Rod
    G02853492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 Engine Mounting Stay No. 2 RH Bolt
    G02853493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE UNION TO CHECK VALVE HOSE 
    1. Remove the vacuum hose for the brake booster.
  15. REMOVE V-BANK COVER SUB-ASSY 
    1. Using a 5 mm hexagon wrench, remove the 3 nuts.
    2. Disconnect the 2 clips, and remove the cover.
    Fig 3: Disconnecting V-Bank Cover Sub-Assy
    G02853494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE AIR CLEANER INLET ASSY 
  17. REMOVE AIR CLEANER ASSEMBLY WITH HOSE 
  18. REMOVE AIR CLEANER BRACKET 
  19. REMOVE AIR CLEANER INLET NO.1 
  20. REMOVE INTAKE AIR CONNECTOR SUB-ASSY 
  21. SEPARATE FUEL PIPE SUB-ASSY NO.1 
    1. Remove the fuel pipe clamp.
      Fig 4: Removing Fuel Pipe Clamp
      G02853495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the tube while pinching part A with fingers as shown in Fig 5 .
    Fig 5: Disconnecting Connector From Tube Pinching Part A With Fingers
    G02853496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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. 
  22. REMOVE RADIATOR HOSE INLET 
  23. REMOVE RADIATOR HOSE OUTLET 
  24. DISCONNECT OIL COOLER INLET HOSE 
  25. DISCONNECT OIL COOLER OUTLET HOSE 
  26. DISCONNECT HEATER INLET WATER HOSE 
  27. DISCONNECT HEATER OUTLET WATER HOSE 
  28. REMOVE GLOVE COMPARTMENT DOOR ASSY 
  29. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the ECM and passenger side 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 J/B. Pull the engine room J/B upward.
        Fig 6: Pulling Engine Room J/B Upward
        G02853497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the engine wire connectors.
      Fig 7: Disconnecting Engine Wire Connectors
      G02853498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Pull out the engine wire.
    4. Remove the body ground.
  30. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (See  OVERHAUL  ) 
  31. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 
    Fig 8: Disconnecting Oil Reservoir To Pump Hose
    G02853499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT STEERING GEAR OUTLET RETURN TUBE 
    Fig 9: Disconnecting Steering Gear Outlet Return Tube
    G02853500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET 
  34. REMOVE EXHAUST PIPE ASSY FRONT 
  35. DISCONNECT FRONT STABILIZER LINK ASSY LH 
    1. Using a 6 mm socket hexagon wrench, hold the ball stud.
    2. Remove the nut and disconnect the stabilizer link.
  36. DISCONNECT FRONT STABILIZER LINK ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  37. REMOVE FRONT AXLE HUB LH NUT 
    1. Using SST and a hammer, strike the lock nut covering to remove it.

      SST 09930-00010

      Fig 10: Striking Lock Nut Cover To Remove Axle Hub LH Nut
      G02853501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  38. REMOVE FRONT AXLE HUB RH NUT 

    HINT:

    Use the same procedures described for the LH side.

  39. 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 of foreign matter. 
  40. DISCONNECT SPEED SENSOR FRONT RH 

    HINT:

    Use the same procedures described for the LH side.

  41. DISCONNECT TIE ROD ASSY LH 
    1. Remove the cotter pin and nut.
    2. Using SST, disconnect the tie rod end from the steering knuckle.

      SST 09628-62011

    Fig 11: Disconnecting Tie Rod End From Steering Knuckle
    G02853502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the dust cover of the ball joint. 
  42. DISCONNECT TIE ROD ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  43. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH 
    1. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
      Fig 12: Disconnecting Front Suspension Arm Sub-Assembly Lower
      G02853503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer, disconnect the drive shaft from the axle hub.
  44. DISCONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH 

    HINT:

    Use the same procedures described for the LH side.

  45. REMOVE STARTER ASSY (See  REMOVAL & INSTALLATION (V6)  ) 
  46. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 
  47. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft.

      SST 09213-54015 (91651-60855), 09330-00021

      Fig 13: Holding Crankshaft Using SST
      G02853504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and flywheel housing under cover.
    3. Remove the 6 torque converter setting bolts.
    Fig 14: Removing Torque Converter Setting Bolts
    G02853505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. DISCONNECT STEERING INTERMEDIATE SHAFT ASSY 
    1. Loosen the sliding yoke bolt.
      Fig 15: Loosening Sliding Yoke Bolt
      G02853506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place matchmarks on the steering intermediate shaft and control valve shaft.
      Fig 16: Placing Matchmarks On Steering Intermediate & Control Valve Shaft
      G02853507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and disconnect the steering intermediate shaft.
    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: Fixing Wheel With Seat Belt
    G02853508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE GENERATOR ASSY (See  REMOVAL & INSTALLATION  ) 
  50. REMOVE GENERATOR BRACKET NO.2 
  51. REMOVE GENERATOR BELT ADJUSTING BAR 
    1. Remove the 2 bolts, 2 nuts and the adjusting bar.
    Fig 18: Removing Generator Belt Adjusting Bar
    G02853509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH 
    1. Remove the bolt, nut and adjusting bar bracket.
      Fig 19: Adjusting Bar Bracket
      G02853510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and disconnect the compressor.

    HINT:

    Hang up the hoses instead of detaching them.

  53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.
      Fig 20: Removing Frame Side Rail Plate RH & LH
      G02853511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.
      Fig 21: Removing Front Suspension Member Brace Rear RH & LH
      G02853512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Carefully, remove the engine assembly from the vehicle.
    5. Install the engine hanger as shown in Fig 22
      • No. 2 engine hanger:  Part No. 12282-20020
      • Bolt:  Part No. 91621-60822
      Fig 22: Installing Engine Hanger
      G02853513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a chain block and an engine sling device, hang the engine assembly.
  54. REMOVE VANE PUMP ASSY 
    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 Assy
    G02853514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE FRONT FRAME ASSY 
    1. Remove the 2 nuts and disconnect the engine mounting insulator RH and LH.
      Fig 24: Disconnecting Engine Mounting Insulator RH & LH
      G02853515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the engine mounting insulator FR.
    Fig 25: Disconnecting Engine Mounting Insulator FR
    G02853516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE FRONT DRIVE SHAFT ASSY LH (See  OVERHAUL  ) 
  57. REMOVE FRONT DRIVE SHAFT ASSY RH (See  OVERHAUL  ) 
  58. REMOVE ENGINE WIRE 
  59. REMOVE AUTOMATIC TRANSAXLE ASSY (See  REPLACEMENT  ) 
  60. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See  REPLACEMENT  ) 
  61. INSTALL ENGINE STAND 
  62. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the throttle body connector.
    2. Disconnect the water by-pass hose No. 3.
    3. Disconnect the water by-pass hose No. 2.
    4. Disconnect the union to check valve hose.
      Fig 26: Removing Intake Air Surge Tank
      G02853517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the ventilation hose.
      Fig 27: Disconnecting Ventilation Hose
      G02853518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 nuts and separate the pressure feed tube.
      Fig 28: Separating Pressure Feed Tube Nuts
      G02853519Courtesy 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 Surge Tank Stay Bolts
      G02853520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using an 8 mm socket hexagon wrench, 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 Surge Tank
    G02853521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. 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: Inspecting Intake Air Surge Tank
    G02853522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE IGNITION COIL ASSY 
  65. 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
      G02853523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly, loosen and remove the 9 bolts and 2 nuts in the sequence shown in Fig 33 . Remove the intake manifold.
    Fig 33: Removing Intake Manifold In Sequence
    G02853524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSPECT INTAKE MANIFOLD 
    1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and air intake surge tank for warpage.
      Fig 34: Inspecting Intake Manifold
      G02853525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum warpage: 

    SPECIFICATION CONDITION

    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.

  67. REMOVE WATER OUTLET (See  REPLACEMENT  ) 
  68. REMOVE EXHAUST MANIFOLD SUB-ASSY RH 
    1. Disconnect the A/F sensor connector.
    2. Remove the 3 bolts and insulator.
      Fig 35: Removing Insulator Bolts
      G02853526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 6 nuts in the sequence shown in Fig 36 .
      Fig 36: Removing Exhaust Manifold In Sequence
      G02853527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the manifold and gasket.
  69. INSPECT EXHAUST MANIFOLD SUB-ASSY 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 Surface Contacting Cylinder Head For Warpage
    G02853528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE MANIFOLD STAY NO.2 
    1. Remove the 2 bolts and manifold stay.
    Fig 38: Removing Manifold Stay Bolts
    G02853529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 
    1. Remove the 2 bolts and insulator.
      Fig 39: Removing Insulator Bolts
      G02853530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and insulator.
    Fig 40: Removing Exhaust Manifold Heat Insulator No. 2
    G02853531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 
    1. Uniformly loosen and remove the 7 nuts in the sequence shown in Fig 41 .
      Fig 41: Removing Exhaust Manifold Converter Sub-Assy In Sequence
      G02853532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the converter and gasket.
  73. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY 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 Surface Contacting Cylinder Head For Warpage
    G02853533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE DRIVE SHAFT BEARING BRACKET 
  75. REMOVE PUMP BRACKET 
    1. Remove the 3 bolts and pump bracket.
    Fig 43: Removing Pump Bracket Bolts
    G02853534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE GENERATOR BRACKET NO.1 
  77. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 
  78. REMOVE WATER INLET PIPE 
  79. REMOVE WATER INLET 
  80. REMOVE THERMOSTAT 
  81. REMOVE ENGINE OIL PRESSURE SWITCH ASSY 
    Fig 44: Removing Engine Oil Pressure Switch Assy
    G02853535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE KNOCK SENSOR 
    1. Remove 2 nuts and 2 sensor.
  83. REPLACE PARTIAL ENGINE ASSY 
  84. INSTALL KNOCK SENSOR 
    1. Install the 2 knock sensors with the 2 nuts, as shown in Fig 45 .

      Torque:  20 N.m (204 kgf.cm, 15 ft.lbf)

    Fig 45: Installing Knock Sensor
    G02853536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL ENGINE OIL PRESSURE SWITCH ASSY 
    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 46: Installing Engine Oil Pressure Switch Assembly
    G02853537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL THERMOSTAT (See  REPLACEMENT  ) 
  87. INSTALL WATER INLET (See  REPLACEMENT  ) 
  88. INSTALL WATER INLET PIPE (See  REPLACEMENT  ) 
  89. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 

    Torque:  25 N.m (255 kgf.cm, 18 ft.lbf)

  90. INSTALL GENERATOR BRACKET NO.1 

    Torque:  58 N.m (591 kgf.cm, 43 ft.lbf)

  91. INSTALL PUMP BRACKET 

    Torque:  32 N.m (326 kgf.cm, 24 ft.lbf)

    Fig 47: Installing Pump Bracket
    G02853538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. INSTALL DRIVE SHAFT BEARING BRACKET 

    Torque:  64 N.m (653 kgf.cm, 47 ft.lbf)

  93. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 
    1. Install a new gasket and the converter with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in Fig 48 .

      Torque:  49 N.m (500 kgf.cm, 36 ft.lbf)

    2. Retighten nuts 1 and 2 as shown in Fig 48 .
    Fig 48: Installing Exhaust Manifold Converter Sub-Assembly
    G02853539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 

    Torque:  8.5 N.m (87 kgf.cm, 75 in.lbf)

  95. INSTALL MANIFOLD STAY NO.2 

    Torque:  34 N.m (347 kgf.cm, 25 ft.lbf)

  96. INSTALL EXHAUST MANIFOLD SUB-ASSY RH 
    1. Install a new gasket and the exhaust manifold with the 5 nuts. Uniformly tighten the 5 nuts in the sequence shown in Fig 49 .

      Torque:  49 N.m (500 kgf.cm, 36 ft.lbf)

    2. Retighten nuts 1 and 2 shown in Fig 49 .
    Fig 49: Installing Exhaust Manifold Sub-Assembly RH
    G02853540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. INSTALL WATER OUTLET (See  REPLACEMENT  ) 
  98. 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 in Fig 50 .

      Torque:  15 N.m (153 kgf.cm, 11 ft.lbf)

      Fig 50: Installing Intake Manifold Bolts In Sequence
      G02853541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  99. INSTALL IGNITION COIL ASSY 

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

  100. 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 an 8 mm socket hexagon wrench, 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 hanger 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 by-pass hose No. 2.
    11. Connect the water by-pass hose No. 3.
    12. Connect the throttle motor connector.
  101. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See  REPLACEMENT  ) 
  102. INSTALL AUTOMATIC TRANSAXLE ASSY (See REPLACEMENT  REPLACEMENT  ) 
  103. INSTALL FRONT DRIVE SHAFT ASSY RH (See  OVERHAUL  ) 
  104. INSTALL FRONT DRIVE SHAFT ASSY LH (See  OVERHAUL  ) 
  105. INSTALL FRONT FRAME ASSY 
    1. Install the engine mounting insulator RH and LH with the 2 nuts.

      Torque:  95 N.m (969 kgf.cm, 70 ft.lbf)

      Fig 51: Installing Engine Mounting Insulator RH & LH Nuts
      G02853542Courtesy 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 52: Installing Engine Mounting Insulator FR With Bolt
    G02853543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. INSTALL VANE PUMP ASSY 
    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 53: Installing Vane Pump
    G02853544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  107. 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 54: Installing Frame Side rail Plate RH & LH
      G02853545Courtesy 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 
      • 32 N.m (326 kgf.cm, 24 ft.lbf) for bolt D and nut 
    Fig 55: Installing Front Suspension Member Brace Rear RH & LH
    G02853546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. 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 56: Installing Adjusting Bar Bracket
    G02853547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  109. 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 57: Installing Generator Belt Adjusting Bar
    G02853548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. INSTALL GENERATOR BRACKET NO.2 

    Torque:  28 N.m (286 kgf.cm, 21 ft.lbf)

  111. INSTALL GENERATOR ASSY (See  REMOVAL & INSTALLATION  ) 
  112. INSTALL STEERING INTERMEDIATE SHAFT ASSY 
    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 58: Aligning Matchmarks On Intermediate & Control Valve Shaft
      G02853549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the sliding yoke bolt.

      Torque:  35 N.m (357 kgf.cm, 26 ft.lbf)

    Fig 59: Tightening Sliding Yoke Bolt
    G02853550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  113. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft.

      SST 09213-54015 (91651-60855), 09330-00021

      Fig 60: Holding Crankshaft Using SST
      G02853551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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

    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 61: Installing Flywheel Housing Under Cover
    G02853552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 

    Torque:  21 N.m (214 kgf.cm, 15 ft.lbf)

  115. INSTALL STARTER ASSY (See  REMOVAL & INSTALLATION (V6)  ) 
  116. INSTALL FRONT SUSPENSION ARM SUB-ASSY 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 62: Installing Suspension Lower Arm
    G02853553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  117. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH 

    HINT:

    Use the same procedures described for the LH side.

  118. INSTALL TIE ROD ASSY LH 
    1. Connect the tie rod end to the steering knuckle with the castle nut.

      Torque:  49 N.m (500 kgf.cm, 36 ft.lbf)

      NOTE:
      • Prevent lubricants from contacting the thread and taper portions. 
      • After tightening the castle nut, tighten it an additional 60° so that a cotter pin can be inserted. 
    2. Insert a new cotter pin.
  119. INSTALL TIE ROD ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  120. INSTALL SPEED SENSOR FRONT LH (See  SPEED SENSOR FRONT  ) 
  121. INSTALL SPEED SENSOR FRONT RH 

    HINT:

    Use the same procedures described for the LH side.

  122. 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)

      Fig 63: Installing Front Axle Hub LH Nut
      G02853554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a chisel and hammer, tapped the hub nut.
  123. INSTALL FRONT AXLE HUB RH NUT 

    HINT:

    Use the same procedures described for the LH side.

  124. INSTALL FRONT STABILIZER LINK ASSY 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)

  125. INSTALL FRONT STABILIZER LINK ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  126. INSTALL EXHAUST PIPE ASSY FRONT (See  REPLACEMENT  ) 
  127. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET (See  REPLACEMENT  ) 
  128. CONNECT FUEL PIPE SUB-ASSY NO.1 
    1. Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.
      Fig 64: Pushing In Fuel Tube Connector To Fuel Pipe
      G02853555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  129. INSTALL AIR CLEANER ASSEMBLY WITH HOSE 
  130. CONNECT VACUUM HOSES 
    Fig 65: Vacuum Hose Routing Diagram
    G02853556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  131. INSTALL V-BANK COVER SUB-ASSY 
    1. Fit the 2 retainers and install the V-bank cover.
    2. Using a 5 mm socket hexagon wrench, tighten the 3 nuts.

      Torque:  7.9 N.m (81 kaf cm, 70 in.lbf)

  132. 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 66: Installing Engine Mounting Stay RH
    G02853557Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  133. 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 67: Installing Control Rod & Bracket
    G02853558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  134. INSTALL VANE PUMP V BELT (See  REPLACEMENT   ) 
  135. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT   ) 
  136. INSPECT DRIVE BELT TENSION (See  INSPECTION   ) 
  137. INSTALL FRONT WHEELS 

    Torque:  103 N.m (1,050 kgf.cm, 76 ft.lbf)

  138. ADD AUTOMATIC TRANSAXLE FLUID (See  REPLACEMENT  ) 
  139. ADD ENGINE OIL (See  LUBRICATION (2MZ-FE)  ) 
  140. ADD ENGINE COOLANT (See  REPLACEMENT  ) 
  141. ADD POWER STEERING FLUID 
  142. BLEED POWER STEERING FLUID (See  ON-VEHICLE INSPECTION  ) 
  143. INSPECT OIL LEAK 
  144. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  145. INSPECT FOR FUEL LEAKS 
  146. CHECK FOR EXHAUST GAS LEAKS 
  147. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See  ADJUSTMENT  ) 
  148. INSPECT IGNITION TIMING (See  INSPECTION  ) 
  149. INSPECT ENGINE IDLE SPEED (See  INSPECTION  ) 
  150. INSPECT CO/HC (See  INSPECTION  ) 
  151. CHECK ABS SPEED SENSOR SIGNAL (See  FREEZE FRAME DATA OF ABS  ) 
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