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):
INSTALLATION
1. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
(a) Using a 19 mm deep socket wrench, install the EFI engine coolant temperature sensor and a new gasket.
Torque: 20 N*m (200 kgf/cm, 14 ft. lbs.)
2. INSTALL KNOCK CONTROL SENSOR
3. 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) Using a 24 mm deep socket wrench install the oil pressure switch.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
4. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
(a) Install the engine mounting bracket front No. 1 LH with the 6 bolts.
Torque: 54 N*m (551 kgf/cm, 40 ft. lbs.)
5. INSTALL WATER PUMP PULLEY
6. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
(a) Install the idler pulley sub-assembly No. 2 and cover plate with the bolt.
Torque: 43 N*m (438 kgf/cm, 32 ft. lbs.)
7. INSTALL TIMING GEAR COVER NO.2
(a) Install the timing gear cover No. 2 with the 2 bolts.
Torque: 6.0 N*m (61 kgf/cm, 53 in. lbs.)
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.
(b) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 N*m (438 kgf/cm, 32 ft. lbs.)
(c) Tighten the other bolts.
Torque: 43 N*m (438 kgf/cm, 32 ft. lbs.)
HINT: Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)
9. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 N*m (650 kgf/cm, 47 ft. lbs.)
10. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 N*m (551 kgf/cm, 40 ft. lbs.)
11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket as shown in the illustration.
(b) Install the exhaust manifold sub-assembly RH with the 6 nuts.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
12. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
(a) Install the insulator No. 2 with the 3 bolts.
Torque: 8.5 N*m (87 kgf/cm, 75 in. lbs.)
13. INSTALL MANIFOLD STAY NO.2
(a) Install the manifold stay No. 2 with the 2 bolts.
Torque: 34 N*m (347 kgf/cm, 25 ft. lbs.)
14. INSTALL OIL LEVEL GAUGE GUIDE SUBASSEMBLY
(a) Install 2 new O-rings to the oil level gauge guide.
(b) Apply a coat of engine oil lightly to the O-rings.
(c) Push in the oil level gauge guide end into the guide hole.
(d) Install the oil level gauge guide No. 1 with the bolt.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
(e) Install the oil level gauge guide No. 2 with the bolt.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
(f) Install the oil level gauge.
15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket as shown in the illustration.
(b) Install the exhaust manifold sub-assembly RH with the 6 nuts.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
16. INSTALL INTAKE MANIFOLD
17. INSTALL ENGINE MOUNTING STAY NO.2 RH
(a) Install the mounting stay No. 2 RH with the bolt.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
18. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 N*m (102 kgf/cm, 7 ft. lbs.)
19. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
CAUTION: DO NOT apply oil to the bolts listed below:
(a) Install a new gasket to the intake air surge tank.
(b) Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.
(c) Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.
(d) Connect the connector.
(e) Install the vacuum hose clamp with the bolt.
Torque: 5.4 N*m (55 kgf/cm, 48 in. lbs.)
(f) Connect the No. 1 ventilation hose.
(g) Install the clamp and connect the throttle with motor body assembly connector.
(h) Connect the vapor feed hose.
(i) Connect the 2 water by-pass hoses to the throttle with motor body assembly.
20. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY
SST 09213-70011, 09330-00021
21. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
22. INSTALL STARTER ASSEMBLY
23. INSTALL ENGINE WIRE
24. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
25. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
26. INSTALL FRONT FRAME ASSEMBLY
(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 N*m (969 kgf/cm, 70 ft. lbs.)
(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 N*m (887 kgf/cm, 64 ft. lbs.)
27. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts and nut.
Torque: 43 N*m (438 kgf/cm, 32 ft. lbs.)
(b) Install the pressure feed tube clamp bolt.
Torque: 9.8 N*m (100 kgf/cm, 87 in. lbs.)
28. 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 plates RH and LH with the 4 bolts and 2 nuts.
Torque:
A 85 N*m (867 kgf/cm, 63 ft. lbs.)
B 32 N*m (329 kgf/cm, 24 ft. lbs.)
(d) Install the front suspension member brace rears RH and LH with the 4 bolts and 2 nuts.
Torque:
C 85 N*m (867 kgf/cm, 63 ft. lbs.)
D 32 N*m (329 kgf/cm, 24 ft. lbs.)
29. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Temporarily install the cooler compressor with the 4 bolts.
(b) Install the compressor with the 4 bolts by tightening the bolt in the order shown in the illustration.
Torque: 25 N*m (250 kgf/cm, 18 ft. lbs.)
(c) Install the 2 connector clamps.
30. INSTALL GENERATOR ASSEMBLY
31. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
(a) Align the matchmarks on the intermediate shaft and control valve shaft, and install the bolt.
Torque: 35 N*m (360 kgf/cm, 26 ft. lbs.)
32. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 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 N*m (413 kgf/cm, 30 ft. lbs.)
NOTICE: First tighten the green colored bolt, then the other 5 bolts.
(e) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 N*m (80 kgf/cm, 69 in. lbs.)
33. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
(a) Install the exhaust pipe support bracket No. 1 with the 2 bolts.
Torque: 21 N*m (214 kgf/cm, 15 ft. lbs.)
34. INSTALL FRONT SUSPENSION ARM SUBASSEMBLY 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 N*m (764 kgf/cm, 55 ft. lbs.)
35. INSTALL FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO.1 RH
HINT: Use the same procedures described for the LH side.
36. INSTALL TIE ROD ASSEMBLY LH
(a) Connect the tie rod end to the steering knuckle with the castle nut.
Torque: 49 N*m (500 kgf/cm, 36 ft. lbs.)
NOTICE:
^ Prevent lubricants from contacting the thread and taper portions.
^ After tightening the castle nut, tighten additional 60° so that a cotter pin can be inserted.
(b) Insert a new cotter pin.
37. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
38. INSTALL SPEED SENSOR FRONT LH
39. INSTALL SPEED SENSOR FRONT RH
HINT: Use the same procedures described for the LH side.
40. INSTALL FRONT AXLE HUB LH NUT
(a) Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 N*m (2,998 kgf/cm, 217 ft. lbs.)
(b) Using a chisel and hammer, tap the hub nut.
41. INSTALL FRONT AXLE HUB RH NUT
HINT: Use the same procedures described for the LH side.
42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(a) Using a 6 mm socket hexagon wrench, hold the ball stud and install the nut.
Torque: 74 N*m (755 kgf/cm, 55 ft. lbs.)
43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.
44. INSTALL EXHAUST PIPE ASSEMBLY FRONT
45. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
46. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
(a) Connect the oil reservoir to pump hose No. 1.
47. CONNECT STEERING GEAR OUTLET RETURN TUBE
(a) Connect the steering gear outlet return tube.
48. CONNECT FUEL TUBE 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.
^ Check if the pipe and the connector are securely connected by trying to pull them apart.
(b) Install the fuel pipe clamp No. 1.
49. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
50. CONNECT ENGINE WIRE
(a) Install the nut and connect the wire harness to the engine room J/B.
Torque: 8.4 N*m (85 kgf/cm, 74 in. lbs.)
(b) Install the engine wire to the body with the 2 nuts.
Torque: 6.0 N*m (61 kgf/cm, 53 in. lbs.)
51. CONNECT HEATER WATER OUTLET HOSE A
52. CONNECT HEATER WATER INLET HOSE A
53. CONNECT OIL COOLER OUTLET HOSE
54. CONNECT OIL COOLER INLET HOSE
55. INSTALL RADIATOR HOSE OUTLET
56. INSTALL RADIATOR HOSE INLET
57. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
58. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
(a) Install the intake air resonator with the bolt and clip.
Torque: 5.0 N*m (51 kgf/cm, 44 in. lbs.)
59. INSTALL AIR CLEANER INLET NO.1
(a) Install the air cleaner inlet No. 1 with the bolt.
Torque: 5.0 N*m (51 kgf/cm, 44 in. lbs.)
60. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf/cm, 44 in. lbs.)
(b) Install the air cleaner cap with the hose clamp and 3 clips.
(c) Connect the MAF meter connector and clamp.
(d) Connect the 3 vacuum hoses and ventilation hose No. 2.
61. INSTALL AIR CLEANER INLET NO.2
(a) Install air cleaner inlet No. 2 with the 2 bolts.
Torque: 5.0 N*m (51 kgf/cm, 44 in. lbs.)
62. CONNECT VACUUM HOSES
Vacuum House Routing Diagram:
63. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL RH
64. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH
65. INSTALL FRONT DOOR SCUFF PLATE RH
66. INSTALL RELAY BLOCK COVER UPPER
67. INSTALL ENGINE MOUNTING CONTROL BRACKET
(a) Temporarily install the mounting stay No. 2 RH and mounting bracket with the 3 bolts and 2 nuts.
68. INSTALL ENGINE MOVING CONTROL ROD
(a) Temporarily install the moving control rod and mounting stay No. 3 RH with the 3 bolts.
(b) Tighten the bolt A.
Torque: 44 N*m (450 kgf/cm, 32 ft. lbs.)
(c) Tightening the bolt B in the order shown in the illustration.
Torque: 38 N*m (387 kgf/cm, 28 ft. lbs.)
(d) Tighten the 2 nuts.
Torque: 23 N*m (235 kgf/cm, 17 ft. lbs.)
69. INSTALL RADIATOR RESERVE TANK ASSEMBLY
70. INSTALL FAN AND GENERATOR V BELT
HINT: Install the V-ribbed belt.
SST 09249-63010
71. INSTALL COWL TOP PANEL OUTER
72. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
73. INSTALL FRONT WHEELS
Torque: 103 N*m (1,050 kgf/cm, 76 ft. lbs.)
74. ADD AUTOMATIC TRANSAXLE FLUID
75. ADD ENGINE OIL
76. ADD ENGINE COOLANT
77. ADD POWER STEERING FLUID
78. BLEED POWER STEERING SYSTEM
79. INSPECT FOR OIL LEAK
80. INSPECT FOR ENGINE COOLANT LEAK
81. INSPECT FOR FUEL LEAK
82. INSPECT FOR EXHAUST GAS LEAK
83. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT: Adjust the front wheel alignment.
84. INSPECT IGNITION TIMING
85. INSPECT ENGINE IDLE SPEED
86. CHECK FUNCTION OF THROTTLE BODY
87. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Fit the 3 retainers and install the V-bank cover.
88. INSPECT CO/HC
89. CHECK ABS SPEED SENSOR SIGNAL
(a) ABS WITH EBD SYSTEM
(b) ABS WITH EBD & BA & TRAC & VSC SYSTEM
90. PERFORM INITIALIZATION
(a) Some systems need initialization when disconnecting the cable from the negative battery terminal.
Testing and Inspection Programming and Relearning