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Partial Engine Assembly (3MZ-FE): Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  2013 PRECAUTIONS  ) 
  2. REMOVE FRONT WHEELS 
  3. REMOVE ENGINE UNDER COVER NO.1 
  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH 
  5. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY RH 
  6. REMOVE FRONT FENDER APRON SEAL LH 
  7. REMOVE FRONT FENDER APRON SEAL RH 
  8. DRAIN ENGINE OIL 
  9. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  10. DRAIN AUTOMATIC TRANSAXLE FLUID 
  11. DRAIN TRANSFER OIL (4WD TYPE) 
  12. REMOVE FR WIPER ARM LH (See  REPLACEMENT  ) 
  13. REMOVE FR WIPER ARM RH (See  REPLACEMENT  ) 
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See  REPLACEMENT  ) 
  15. REMOVE WINDSHIELD WIPER LINK ASSY (See  REPLACEMENT  ) 
  16. REMOVE COWL PANEL SUB-ASSY 
  17. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER 
  18. 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 1: Removing V-Bank Cover Sub-Assy
    G03033185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE BATTERY 
  20. REMOVE AIR CLEANER CAP SUB-ASSY 
  21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY 
  22. REMOVE AIR CLEANER CASE 
  23. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT  ) 
  24. REMOVE VANE PUMP V BELT (See  REPLACEMENT  ) 
  25. REMOVE GENERATOR ASSY (See  GENERATOR  ) 
  26. REMOVE GENERATOR BRACKET NO.2 
  27. REMOVE GENERATOR BELT ADJUSTING BAR 
    1. Remove the 2 bolts, 2 nuts and adjusting bar.
    Fig 2: Removing Generator Belt Adjusting Bar
    G03033186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the 4 bolts and control rod.
    Fig 3: Removing Engine Moving Control Rod
    G03033187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE ENGINE MOUNTING STAY NO.2 RH 
    1. Remove the bolt, mounting stay No. 2 RH and mounting bracket No. 2 RH.
    Fig 4: Removing Engine Mounting Stay RH
    G03033188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Remove the bolt, nut and adjusting bar bracket.
    2. Remove the 3 bolts and disconnect the compressor.

    HINT:

    Hang up the hoses instead of detaching them.

    Fig 5: Removing Compressor And Magnetic Clutch
    G03033189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SEPARATE TRANSMISSION CONTROL CABLE ASSY (See  REPLACEMENT  ) 
  32. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Remove the vacuum hose for the brake booster.
  33. DISCONNECT FUEL PIPE SUB-ASSY NO.1 
    1. Remove the fuel pipe clamp.
      Fig 6: Removing Fuel Pipe Clamp
      G03033190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the tube while pinching part A with fingers as shown in the illustration.
    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.
    Fig 7: Disconnecting Connector From Tube
    G03033191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT HEATER INLET WATER HOSE 
  35. DISCONNECT HEATER OUTLET WATER HOSE 
  36. DISCONNECT RADIATOR HOSE INLET 
  37. DISCONNECT RADIATOR HOSE OUTLET 
  38. DISCONNECT OIL COOLER INLET TUBE NO.1 
  39. DISCONNECT OIL COOLER OUTLET TUBE NO.1 
  40. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1 
    Fig 8: Disconnecting Oil Reservoir To Pump Hose
    G03033192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. DISCONNECT STEERING GEAR OUTLET RETURN TUBE 
    Fig 9: Disconnecting Steering Gear Outlet Return Tube
    G03033193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE GLOVE COMPARTMENT DOOR ASSY 
  43. SEPARATE ENGINE WIRE 
    1. Disconnect the engine wire from the ECM and junction block.
    2. Disconnect the engine wire from the engine room junction block.
      1. Remove the nut and separate the wire harness.
      2. Using a screwdriver, release the engine room junction block. Disconnect the engine wire by pulling it upward.
    3. Remove the 2 nuts and pull out the engine wire.
    4. Remove the body ground.
    Fig 10: Disconnecting Engine Wire From ECM
    G03033194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE PROPELLER SHAFT ASSY (4WD TYPE) (See  OVERHAUL  ) 
  45. DISCONNECT EXHAUST PIPE SUB-ASSY FRONT NO.3 (See  REPLACEMENT  ) 
  46. DISCONNECT EXHAUST PIPE ASSY FRONT (See  REPLACEMENT  ) 
  47. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1 (See  REPLACEMENT  ) 
  48. 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.
  49. DISCONNECT FRONT STABILIZER LINK ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  50. REMOVE FRONT AXLE HUB LH NUT 
    1. Using SST and a hammer, strike the lock nut covering to remove it.
      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.
      Fig 11: Removing Front Axle Hub LH Nut
      G03033195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 30 mm socket wrench, remove the lock nut.
  51. REMOVE FRONT AXLE HUB RH NUT 

    HINT:

    Use the same procedures described for the LH side.

  52. 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 from foreign matter.
  53. DISCONNECT SPEED SENSOR FRONT RH 

    HINT:

    Use the same procedures described for the LH side.

  54. SEPARATE TIE ROD END SUB-ASSY LH 
    1. Remove the cotter pin and nut.
    2. Using SST, disconnect the tie rod end from the steering knuckle.
    NOTE: Do not damage the dust cover of the ball joint.
    Fig 12: Removing Tie Rod End From Steering Knuckle
    G03033196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. SEPARATE TIE ROD END SUB-ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  56. SEPARATE 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.
    2. Using a plastic hammer, disconnect the drive shaft from the axle hub.
    Fig 13: Removing Front Suspension Lower Assy
    G03033197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH 

    HINT:

    Use the same procedures described for the LH side.

  58. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft.

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

    2. Remove the 2 bolts and flywheel housing under cover.
      Fig 14: Holding Crankshaft
      G03033198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 torque converter setting bolts.
    Fig 15: Removing Torque Converter Clutch Setting Bolt
    G03033199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Loosen the sliding yoke bolt.
      Fig 16: Loosing Sliding Yoke Bolt
      G03033200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place matchmarks on the steering intermediate shaft and control valve shaft.
    3. Remove the bolt and disconnect the steering intermediate haft.
    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: Placing Matchmarks On Steering Intermediate Shaft And Control Valve Shaft
    G03033201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 6 bolts, 2 nuts, and frame side rail plate subassembly LH and RH.
      Fig 18: Removing Frame Side Rail Plate Sub-Assy LH And RH
      G03033202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts, 2 nuts, and front suspension member brace rear LH and RH.
    4. Carefully, remove the engine assembly from the vehicle.
      Fig 19: Removing Front Suspension Member Brace Rear LH And RH
      G03033203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine hanger as shown in the illustration. Part No.:
      ENGINE HANGER CHART

      No. 2 engine hanger 12282-20020
      Bolt 91621-60822

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

    6. Using a chain block and an engine sling device, hang the engine assembly.
    Fig 20: Installing Engine Hanger
    G03033204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY 
    1. Disconnect the A/F sensor connector.
    2. Remove the 3 bolts and insulator.
      Fig 21: Removing Exhaust Manifold Convertor Insulator
      G03033205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 6 nuts in the sequence shown in the illustration.
    4. Remove the manifold and gasket.
    Fig 22: Removing Manifold And Gasket
    G03033206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY 
    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 23: Inspecting Exhaust Manifold Convertor Sub-Assy
    G03033207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. 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 24: Removing Vane Pump Assy
    G03033208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE STABILIZER BAR FRONT (See  STABILIZER BAR  ) 
  65. REMOVE POWER STEERING LINK ASSY (See  OVERHAUL  ) 
  66. REMOVE FRONT FRAME ASSY 
    1. Remove the 2 nuts and disconnect the engine mounting insulator RH and LH.
      Fig 25: Removing Engine Mounting Insulator RH and LH
      G03033209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and disconnect the engine mounting insulator FR.
      Fig 26: Removing Engine Mounting Insulator FR
      G03033210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and disconnect the engine mounting insulator RR.
    Fig 27: Removing Engine Mounting Insulator RR
    G03033211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE FRONT DRIVE SHAFT ASSY LH (See  REMOVAL & INSTALLATION  ) 
  68. REMOVE FRONT DRIVE SHAFT ASSY RH (2WD TYPE) (See  REMOVAL & INSTALLATION  ) 
  69. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See  REMOVAL & INSTALLATION  ) 
  70. REMOVE STARTER ASSY (See  STARTER  ) 
  71. REMOVE ENGINE MOUNTING BRACKET FR 
  72. REMOVE AUTOMATIC TRANSAXLE ASSY (2WD TYPE) (See  REPLACEMENT  ) 
  73. REMOVE TRANSFER STIFFENER PLATE RH (4WD TYPE) 
  74. REMOVE AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE) (See  REPLACEMENT  ) 
  75. REMOVE ENGINE MOUNTING BRACKET RR 
  76. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See  REPLACEMENT  ) 
  77. INSTALL ENGINE STAND 
  78. REMOVE ENGINE HANGER NO.2 
  79. REMOVE EMISSION CONTROL VALVE SET 
    1. Disconnect the 2 VSV connectors.
    2. Remove the wire harness clamp.
      Fig 28: Removing Wire Harness Clamp
      G03033212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the fuel vapor feed hose No. 1.
    4. Disconnect the fuel vapor feed hose No. 2.
    5. Disconnect the 2 vacuum hoses.
    6. Remove the clamp.
    7. Remove the 2 nuts and the emission control valve set.
    Fig 29: Removing Emission Control Valve Set
    G03033213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE INTAKE AIR SURGE TANK 
    1. Disconnect the throttle motor connector.
    2. Disconnect the water bypass hose No. 3
    3. Disconnect the water bypass hose No. 2.
    4. Disconnect the union to check valve hose.
      Fig 30: Disconnecting Throttle Motor Connector
      G03033214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the ventilation hose.
      Fig 31: Disconnect ventilation hose
      G03033215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 nuts and disconnect the pressure feed tube.
      Fig 32: Disconnect Pressure Feed Tube
      G03033216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts and engine hanger 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 33: Removing Engine Hanger And Surge Tank Stays
      G03033217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a socket hexagon wrench 8, remove the 4 bolts.
    11. Remove the 2 nuts, emission control valve bracket and intake air surge tank.
    12. Remove the gasket from the intake air surge tank.
    Fig 34: Removing Gasket From Intake Air Surge Tank
    G03033218Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. 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 35: Inspecting Intake Air Surge Tank
    G03033219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE INTAKE MANIFOLD 
    1. Remove the nut and disconnect the ground cable.
    2. Disconnect the 6 fuel injector connectors.
      Fig 36: Disconnecting Fuel Injector Connector
      G03033220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.
    Fig 37: Removal Sequence of Intake Manifold Bolts and Nuts
    G03033221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSPECT INTAKE MANIFOLD 
    1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head and intake air surge tank for warpage.

      Maximum warpage: 

      MAXIMUM WARPAGE CHART

      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.

      Fig 38: Inspecting Intake Manifold
      G03033222Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE WATER OUTLET 
    1. Disconnect the radiator hose inlet.
    2. Disconnect the engine coolant temperature sensor connector.
    3. Remove the clamp.
    4. Remove the 2 bolts, 2 nuts and 2 washers.
    5. Lock the hose clamp as shown in the illustration and remove the water outlet together with the water bypass hose No. 1.
    6. Remove the 2 gaskets from the 2 cylinder heads.
    Fig 39: Removing Water Outlet
    G03033223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE IGNITION COIL ASSY 
  86. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 
    1. Disconnect the A/F sensor connector.
    2. Remove the bolt, nut and insulator No. 3.
      Fig 40: Removing Exhaust Manifold Convertor Insulator No 3
      G03033224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and insulator No. 2.
      Fig 41: Removing Exhaust Manifold Convertor Insulator No.2
      G03033225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration.
    5. Remove the converter and gasket.
      Fig 42: Removing Converter and Gasket
      G03033226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 bolts and manifold stay.
    Fig 43: Removing Manifold Stay
    G03033227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. 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 44: Inspecting Exhaust Manifold Converter Sub-Assy No.2
    G03033228Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE ENGINE MOUNTING BRACKET RH 
  89. REMOVE PUMP BRACKET 
    1. Remove the 3 bolts and pump bracket.
    Fig 45: Removing Pump Bracket
    G03033229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE GENERATOR BRACKET NO.1 
  91. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 
  92. REMOVE WATER INLET PIPE (See  REPLACEMENT  ) 
  93. REMOVE WATER INLET (See  REPLACEMENT  ) 
  94. REMOVE THERMOSTAT (See  REPLACEMENT  ) 
  95. REMOVE ENGINE OIL PRESSURE SWITCH ASSY 
    1. Remove the oil pressure switch. Oil Pressure Switch
    Fig 46: Removing Oil Pressure Switch
    G03033230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. REMOVE KNOCK SENSOR 
    1. Remove the 2 nuts and 2 sensors.
  97. REPLACE PARTIAL ENGINE ASSY Upper 
  98. INSTALL KNOCK SENSOR 
    1. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.

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

    Fig 47: Installing Knock Sensor
    G03033231Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. 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 (153 kgfVcm, 11 ft.lbf) 

  100. INSTALL THERMOSTAT (See  REPLACEMENT  ) 
  101. INSTALL WATER INLET (See  REPLACEMENT  ) 
  102. INSTALL WATER INLET PIPE (See  REPLACEMENT  ) 
  103. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 
  104. INSTALL GENERATOR BRACKET NO.1 
  105. INSTALL PUMP BRACKET 
  106. INSTALL ENGINE MOUNTING BRACKET RH 
  107. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2 
    1. Install the manifold stay with the 2 bolts, as shown in the illustration.

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

      Fig 48: Installing Manifold Stay
      G03033232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket and the converter sub-assy No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration.

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

    3. Retighten nuts 1 and 2 as shown in the illustration.
      Fig 49: Tightening Sequence of Convertor Sub-Assy No.2 Nuts
      G03033233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the insulator No. 2 with the bolt and nut, as shown in the illustration.

      Torque: 9.0 N.m (92 kgfVcm, 80 in.Vlbf) 

      Fig 50: Installing Insulator No.2
      G03033234Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the insulator No. 3 with the bolt and nut, as shown in the illustration.

      Torque: 9.0 N.m (92 kgfVcm, 80 in.Vlbf) 

    6. Connect the A/F sensor connector.
    Fig 51: Installing Insulator No.3
    G03033235Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. INSTALL IGNITION COIL ASSY 

    Torque: 8.0 N.m (82 kgfVcm, 71 in.Vlbf) 

  109. INSTALL WATER OUTLET 
    1. Install 2 new gaskets to the 2 cylinder heads.
    2. Install the water outlet together with the water bypass hose No. 1 and unlock the hose clamp.
    3. Tighten the 2 bolts, 2 nuts and 2 washers.

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

    4. Install the clamp.
    5. Connect the engine coolant temperature sensor connector.
    6. Connect the radiator hose inlet.
  110. 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 the illustration.

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

    2. Retighten the water outlet mounting bolts and nuts.

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

    3. Install the ground cable with the nut.

      Torque: 8.0 N.m (82 kgfVcm, 71 in.Vlbf) 

    4. Connect the heater inlet water hose.
    Fig 52: Installing Sequence of Intake Manifold Bolts and Nuts
    G03033236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  111. 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 kgfVcm, 21 ft.lbf) 

    3. Using a socket hexagon wrench 8, tighten the 4 bolts.

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

      Fig 53: Installing Intake Air Surge Tank
      G03033237Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the surge tank stay No. 2 with the 2 bolts.

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

    5. Install the surge tank stay No. 1 with the 2 bolts.

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

    6. Install the engine hanger No. 1 with the 2 bolts.

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

      Fig 54: Installing Engine Hanger And Surge Tank Stay
      G03033238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the pressure feed tube with the 3 nuts.

      Torque: 8.0 N.m (82 kgfVcm, 71 in.Vlbf) 

      Fig 55: Installing Pressure Feed tube
      G03033239Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the ventilation hose.
      Fig 56: Connecting Ventilation Hose
      G03033240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the union to the check valve hose.
    10. Connect the water bypass hose No. 2.
    11. Connect the water bypass hose No. 3.
    12. Connect the throttle motor connector.
    Fig 57: Connecting Throttle Motor Connector
    G03033241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  112. INSTALL EMISSION CONTROL VALVE SET 
    1. Install the emission control valve set with the 2 nuts.

      Torque: 8.0 N.m (82 kgfVcm, 71 in.Vlbf) 

    2. Install the clamp.
    3. Connect the 2 vacuum hoses.
    4. Connect the fuel vapor feed hose No. 2.
    5. Connect the fuel vapor feed hose No. 1.
      Fig 58: Installing Emission Control Valve Set
      G03033242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the wire harness clamp.
    7. Connect the 2 VSV connectors.
      Fig 59: Connecting 2VSV Connector
      G03033243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  113. INSTALL ENGINE HANGER NO.2 

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

  114. REMOVE ENGINE STAND 
  115. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See  REPLACEMENT  ) 
  116. INSTALL ENGINE MOUNTING BRACKET RR 
  117. INSTALL AUTOMATIC TRANSAXLE W/TRANSFER (4WD TYPE) (See  REPLACEMENT  ) 
  118. INSTALL TRANSFER STIFFENER PLATE RH (4WD TYPE) 
  119. INSTALL AUTOMATIC TRANSAXLE ASSY (2WD TYPE) (See  REPLACEMENT  ) 
  120. INSTALL ENGINE MOUNTING BRACKET FR 
  121. INSTALL STARTER ASSY (See  STARTER  ) 
  122. INSTALL FRONT DRIVE SHAFT ASSY LH (See  REMOVAL & INSTALLATION  ) 
  123. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD TYPE) (See  REMOVAL & INSTALLATION  ) 
  124. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See  REMOVAL & INSTALLATION  ) 
  125. INSTALL FRONT FRAME ASSY 
    1. Install the engine mounting insulator RH and LH with the 2 nuts.

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

      Fig 60: Installing Engine Mounting Insulator RH And LH
      G03033244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine mounting insulator FR with the nut.

      Torque: 87 N.m (887 kgfVcm, 64 ft.lbf) 

      Fig 61: Installing Engine Mounting Insulator FR
      G03033245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator RR with the 2 bolts.

      Torque: 75 N.m (765 kgfVcm, 55 ft.lbf) 

    Fig 62: Installing Engine Mounting Insulator RR
    G03033246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  126. INSTALL POWER STEERING LINK ASSY (See  OVERHAUL  ) 
  127. INSTALL STABILIZER BAR FRONT (See  STABILIZER BAR  ) 
  128. INSTALL VANE PUMP ASSY 
    1. Install the vane pump with the 2 bolts.

      Torque: 43 N.m (438 kgfVcm, 32 ft.lbf) 

      HINT:

      After adjusting the V-ribbed belt, tighten bolt A.

    Fig 63: Installing Vane Pump Assy
    G03033247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  129. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY 
    1. Install a new gasket and the exhaust manifold RH. Uniformly tighten the 6 nuts in the sequence shown in the illustration.

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

      Fig 64: Tightening Sequence of Exhaust Manifold RH Nuts
      G03033248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Retighten nuts 1 and 2 shown in the illustration.
    3. Install the insulator with the 3 bolts, as shown in the illustration.

      Torque: 9.0 N.m (92 kgfVcm, 80 in.Vlbf) 

    4. Connect the A/F sensor connector.
    Fig 65: Installing Insulator
    G03033249Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  130. 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 6 bolts and 2 nuts.

      Torque: 

      85 N.m (867 kgfVcm, 63 ft.lbf) for bolt A 

      32 N.m (326 kgfVcm, 24 ft.lbf) for bolt B and nut C 

      Fig 66: Installing Frame Side Rail Plate RH and LH
      G03033250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.

      Torque: 

      85 N.m (867 kgfVcm, 63 ft.lbf) for bolt A 

      32 N.m (326 kgfVcm, 24 ft.lbf) for bolt B and nut C 

    Fig 67: Installing Front Suspension Member Brace Rear RH and LH
    G03033251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  131. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSY 
    1. Align the matchmarks on the intermediate shaft and the control valve shaft, and install the bolt.

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

      Fig 68: Aligning Matchmarks on Intermediate Shaft and Control Valve Shaft
      G03033252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the sliding yoke bolt.

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

    Fig 69: Tightening Sliding Yoke Bolt
    G03033253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  132. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft.

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

    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 

      Fig 70: Holding Crankshaft
      G03033254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 6 torque converter set bolts.

      Torque: 41 N.m (418 kgfVcm, 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: 8.0 N.m (82 kgfVcm, 70 in.Vlbf) 

    Fig 71: Installing Torque Converter Clutch Setting Bolt
    G03033255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  133. 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: 127 N.m (1,295 kgfVcm, 94 ft.lbf) 

    Fig 72: Installing Suspension Lower Arm
    G03033256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  134. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH 

    HINT:

    Use the same procedures described for the LH side.

  135. INSTALL TIE ROD END SUB-ASSY LH 
    1. Connect the tie rod end to the steering knuckle and install a new castle nut.

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

    NOTE:
    • Prevent any lubricant from contacting the thread and the taper portions.
    • After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin.
  136. INSTALL TIE ROD END SUB-ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  137. INSTALL SPEED SENSOR FRONT LH (See  REPLACEMENT  ) 
  138. INSTALL SPEED SENSOR FRONT RH (See  REPLACEMENT  ) 
  139. INSTALL FRONT AXLE HUB RH NUT 
    1. Using a 30 mm socket wrench, install a new hub nut.

      Torque: 294 N.m (2, 998 kgf.cm, 217 ft.lbf) 

    2. Using a chisel and hammer, tap the front axle hub LH nut.
    Fig 73: Installing Front Axle Hub LH Nut
    G03033257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  140. INSTALL FRONT AXLE HUB LH NUT 

    HINT:

    Use the same procedures described for the LH side.

  141. 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 kgfVcm, 55 ft.lbf) 

  142. INSTALL FRONT STABILIZER LINK ASSY RH 

    HINT:

    Use the same procedures described for the LH side.

  143. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1 (See  REPLACEMENT  ) 
  144. CONNECT EXHAUST PIPE ASSY FRONT (See  REPLACEMENT  ) 
  145. CONNECT EXHAUST PIPE SUB-ASSY FRONT NO.3 (See  REPLACEMENT  ) 
  146. INSTALL PROPELLER SHAFT (4WD TYPE) (See  OVERHAUL  ) 
  147. CONNECT ENGINE WIRE 
  148. INSTALL GLOVE COMPARTMENT DOOR ASSY 
  149. CONNECT STEERING GEAR OUTLET RETURN TUBE 
  150. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1 
  151. CONNECT OIL COOLER OUTLET TUBE NO.1 
  152. CONNECT OIL COOLER INLET TUBE NO.1 
  153. CONNECT RADIATOR HOSE OUTLET 
  154. CONNECT RADIATOR HOSE INLET 
  155. CONNECT HEATER OUTLET WATER HOSE 
  156. CONNECT HEATER INLET WATER HOSE 
  157. CONNECT FUEL PIPE SUB-ASSY NO.1 
    1. Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.
      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.
      Fig 74: Connecting Fuel Pipe Sub-Assy No.1
      G03033258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fuel pipe clamp.
  158. CONNECT UNION TO CHECK VALVE HOSE 
  159. INSTALL TRANSMISSION CONTROL CABLE ASSY (See  REPLACEMENT  ) 
  160. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 
    1. Install the compressor with the 3 bolts.

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

    2. Install the adjusting bar bracket with the bolt and nut.

      Torque: 

      25 N.m (255 kgfVcm, 18 ft.lbf) for bolt 

      26 N.m (265 kgfVcm, 19 ft.lbf) for nut 

    Fig 75: Installing Adjusting Bar Bracket
    G03033259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  161. INSTALL ENGINE MOUNTING STAY NO.2 RH 
    1. Install the mounting stay and mounting bracket with the bolt.
    Fig 76: Installing Engine Mounting Stay No.2 RH
    G03033260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  162. INSTALL ENGINE MOVING CONTROL ROD 
    1. Install the control rod and bracket with the 4 bolts.

      Torque: 

      64 N.m (653 kgfVcm, 47 ft.lbf) for bolt A 

      23 N.m (235 kgfVcm, 17 ft.lbf) for bolt B 

    Fig 77: Installing Engine Moving Control Rod
    G03033261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  163. INSTALL GENERATOR BELT ADJUSTING BAR 
    1. Install the adjusting bar with the 2 bolts and 2 nuts.

      Torque: 

      43 N.m (438 kgfVcm, 32 ft.lbf) for nut A 

      18 N.m (184 kgfVcm, 13 ft.lbf) for bolt B 

      8.0 N.m (82 kgfVcm, 71 in.Vlbf) for bolt C 

    Fig 78: Installing Generator Belt Adjusting Bar
    G03033262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  164. INSTALL GENERATOR BRACKET NO.2 

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

  165. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
  166. INSTALL VANE PUMP V BELT (See  REPLACEMENT  ) 
  167. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (See  REPLACEMENT  ) 
  168. INSPECT DRIVE BELT TENSION (See  INSPECTION  ) 
  169. INSTALL AIR CLEANER CASE 
  170. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSY 
  171. INSTALL AIR CLEANER CAP SUB-ASSY 
  172. CONNECT VACUUM HOSES 
    Fig 79: Locating Vacuum Hose Routing Diagram
    G03033263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  173. INSTALL BATTERY 
  174. INSTALL V-BANK COVER SUB-ASSY 
    1. Fit the 2 retainers and install the V-bank cover.
    2. Using a socket hexagon wrench 5, tighten the 3 nuts.

      Torque: 8.0 N.m (82 kgfVcm, 71 in.Vlbf) 

    Fig 80: Installing V-Bank Cover Sub-Assy
    G03033264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  175. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER 

    Torque: 80 N.m (816 kgfVcm, 59 ft.lbf) 

  176. INSTALL COWL PANEL SUB-ASSY 
  177. INSTALL WINDSHIELD WIPER LINK ASSY (See  REPLACEMENT  ) 
  178. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSY (See  REPLACEMENT  ) 
  179. INSTALL FR WIPER ARM LH (See  REPLACEMENT  ) 
  180. INSTALL FR WIPER ARM RH (See  REPLACEMENT  ) 
  181. INSTALL FRONT WHEELS 
  182. ADD TRANSFER OIL (4WD TYPE) 
  183. INSPECT TRANSFER OIL (4WD TYPE) 
  184. ADD AUTOMATIC TRANSAXLE FLUID 
  185. ADD ENGINE OIL 
  186. ADD ENGINE COOLANT (See  REPLACEMENT  ) 
  187. ADD POWER STEERING FLUID 
  188. BLEED POWER STEERING FLUID (See  ON-VEHICLE INSPECTION  ) 
  189. INSPECT AUTOMATIC TRANSAXLE FLUID 
  190. CHECK FOR ENGINE OIL LEAKS 
  191. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION  ) 
  192. CHECK POWER STEERING FLUID LEAKAGE 
  193. INSPECT FOR FUEL LEAKS 
  194. CHECK FOR EXHAUST GAS LEAKS 
  195. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See  ADJUSTMENT  ) 
  196. INSPECT IGNITION TIMING (See  INSPECTION  ) 
  197. INSPECT ENGINE IDLE SPEED (See  INSPECTION  ) 
  198. INSPECT CO/HC (See  INSPECTION  ) 
  199. CHECK ABS SPEED SENSOR SIGNAL (See  PRE-CHECK  ) 
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