Installation
ENGINE ASSEMBLYCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
COMPONENTS (Part 12):
COMPONENTS (Part 13):
COMPONENTS (Part 14):
COMPONENTS (Part 15):
COMPONENTS (Part 16):
COMPONENTS (Part 17):
INSTALLATION
1. INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the oil pressure switch.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)
3. INSTALL THERMOSTAT
4. INSTALL WATER INLET
5. INSTALL WATER INLET PIPE
6. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
7. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
8. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
9. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install drive shaft bearing bracket.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
10. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
(a) Install a new gasket and the converter with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
(b) Retighten nuts 1 and 2 as shown in the illustration.
11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
12. INSTALL MANIFOLD STAY NO.2
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket and the exhaust manifold with the 5 nuts. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
(b) Retighten nuts 1 and 2 shown in the illustration.
14. INSTALL WATER OUTLET
15. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
(b) Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
(c) Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
(d) Connect the heater inlet water hose.
16. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
17. INSTALL INTAKE AIR SURGE TANK
(a) Install a new gasket to the intake air surge tank.
(b) Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
(c) Using an 8 mm socket hexagon wrench, tighten the 4 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
(d) Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
(e) Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
(f) Install the engine hanger No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
(g) Install the pressure feed tube with the 3 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
(h) Connect the ventilation hose.
(i) Connect the union to check valve hose.
(j) Connect the water by-pass hose No. 2.
(k) Connect the water by-pass hose No. 3.
(l) Connect the throttle motor connector.
18. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
19. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
20. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
21. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
22. INSTALL FRONT FRAME ASSEMBLY
(a) Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
23. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
HINT: After adjusting the V-ribbed belt, tighten bolt A.
24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the engine lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts.
Torque: Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Torque: Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)
(d) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque: Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Torque: Bolt D and Nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
25. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Install the compressor with the 3 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
(b) Install the adjusting bar bracket with the bolt and nut.
Torque:
Bolt 25 Nm (250 kgf-cm, 18 ft. lbs.)
Nut 26 Nm (260 kgf-cm, 19 ft. lbs.)
26. INSTALL GENERATOR BELT ADJUSTING BAR
(a) Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
Nut A 43 Nm (438 kgf-cm, 32 ft. lbs.)
Bolt B 18 Nm (184 kgf-cm, 13 ft. lbs.)
Bolt C 8.0 Nm (82 kgf-cm, 71 inch lbs.)
27. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
28. INSTALL GENERATOR ASSEMBLY
29. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) Align the matchmarks on the intermediate shaft and control valve shaft, and install the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
(b) Tighten the sliding yoke bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
30. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
(a) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(b) Using kerosene or gasoline, clean the bolts thoroughly.
(c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Install the 6 torque converter set bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)
NOTICE: First tighten the green colored bolt and then tighten the 5 bolts.
(e) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
31. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
32. INSTALL STARTER ASSEMBLY
33. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
(a) Install the drive shaft to the steering knuckle.
(b) Install the suspension lower arm with the bolt and 2 nuts.
Torque: 75 Nm (764 kgf-cm, 55 ft. lbs.)
34. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT: Use the same procedures described for the LH side.
35. INSTALL TIE ROD ASSEMBLY LH
(a) Connect the tie rod end to the steering knuckle with the castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
NOTICE:
^ 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.
(b) Insert a new cotter pin.
36. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
37. INSTALL SPEED SENSOR FRONT LH
38. INSTALL SPEED SENSOR FRONT RH
HINT: Use the same procedures described for the LH side.
39. INSTALL FRONT AXLE HUB LH NUT
(a) Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (2,998 kgf-cm, 217 ft. lbs.)
(b) Using a chisel and hammer, tapped the hub nut.
40. INSTALL FRONT AXLE HUB RH NUT
HINT: Use the same procedures described for the LH side.
41. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(a) Using a 6 mm socket hexagon wrench, hold the ball stud and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
42. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
43. INSTALL FRONT EXHAUST PIPE ASSEMBLY
44. INSTALL FRONT EXHAUST PIPE NO.1 SUPPORT BRACKET
45. CONNECT NO.1 FUEL PIPE SUB-ASSEMBLY
(a) Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.
NOTICE:
^ 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.
(b) Install the fuel pipe clamp.
46. INSTALL AIR CLEANER ASSEMBLY
47. CONNECT VACUUM HOSES
(a) Connect the vacuum hoses.
48. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Fit the 2 retainers and install the V-bank cover.
(b) Using a 5 mm socket hexagon wrench, tighten the 3 nuts.
Torque: 7.9 Nm (81 kgf-cm, 70 inch lbs.)
49. INSTALL ENGINE MOUNTING STAY NO.2 RH
(a) Install the mounting stay and mounting bracket with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
50. INSTALL ENGINE MOVING CONTROL ROD
(a) Install the control rod and bracket with the 4 bolts.
Torque:
Bolt A 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B 23 Nm (235 kgf-cm, 17 ft. lbs.)
51. INSTALL VANE PUMP V BELT
52. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
53. INSPECT DRIVE BELT TENSION
54. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
56. ADD AUTOMATIC TRANSAXLE FLUID
57. ADD ENGINE OIL
58. ADD ENGINE COOLANT
59. ADD POWER STEERING FLUID
60. BLEED POWER STEERING FLUID
61. INSPECT OIL LEAK
62. CHECK FOR ENGINE COOLANT LEAKS
63. INSPECT FOR FUEL LEAKS
64. CHECK FOR EXHAUST GAS LEAKS
65. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
66. INSPECT IGNITION TIMING
67. INSPECT ENGINE IDLE SPEED
68. INSPECT CO/HC
69. CHECK ABS SPEED SENSOR SIGNAL
HINT: Check the ABS speed sensor signal.
70. PERFORM INITIALIZATION Testing and Inspection and Programming and Relearning
(a) Perform initialization procedure.
CAUTION: Some systems need initialization after reconnecting the cable to the negative battery terminal.