Engine Assembly, Intake Manifold, Exhaust Manifold: Installation
- INSTALL ENGINE COOLANT TEMPERATURE SENSOR
- Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.
Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
- Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.
- INSTALL KNOCK CONTROL SENSOR (See INSTALLATION )
- INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
- 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
- Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
NOTE: Do not start the engine within 1 hour after installation to prevent oil leaks.
- Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.
- INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
- Install the bolt and No. 1 vacuum switching valve.
Torque: 10 N*m (102 kgf cm, 7 ft.*lbf)
- Install the bolt and No. 1 vacuum switching valve.
- INSTALL RADIO SETTING CONDENSER
- Install the 2 bolts and 2 radio setting condensers.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the 2 bolts and 2 radio setting condensers.
- INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH
- Install the No. 1 engine mounting bracket front LH with the 6 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
- Install the No. 1 engine mounting bracket front LH with the 6 bolts.
- INSTALL WATER PUMP PULLEY (See INSTALLATION )
- INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
- Install the No. 2 idler pulley sub-assembly and cover plate with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Install the No. 2 idler pulley sub-assembly and cover plate with the bolt.
- INSTALL NO. 2 TIMING GEAR COVER
- Install the No. 2 timing gear cover with the 2 bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
- Install the No. 2 timing gear cover with the 2 bolts.
- INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
- Temporarily install the V-ribbed belt tensioner with the 5 bolts.
HINT:
Each bolt length is as follows:
- A: 70 mm (2.76 in.)
- B: 33 mm (1.30 in.)
- 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.*lbf)
- Tighten the other bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Temporarily install the V-ribbed belt tensioner with the 5 bolts.
- INSTALL DRIVE SHAFT BEARING BRACKET
- Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf)
- Install the drive shaft bearing bracket with the 3 bolts.
- INSTALL ENGINE MOUNTING BRACKET RH
- Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
- Install the engine mounting bracket RH with the 3 bolts.
- INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
- Install a new gasket as shown in the illustration.
- Install the exhaust manifold sub-assembly LH with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
- Install the No. 2 insulator with the 3 bolts.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
- Install the No. 2 insulator with the 3 bolts.
- INSTALL NO. 2 MANIFOLD STAY
- Install the No. 2 manifold stay with the 2 bolts.
Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
- Install the No. 2 manifold stay with the 2 bolts.
- INSTALL OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY
- Install 2 new O-rings to the oil level gauge guide.
- Apply a light coat of engine oil to the O-rings.
- Push in the oil level gauge guide end into the guide hole.
- Install the oil level gauge guide No. 1 with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the oil level gauge guide No. 2 with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the oil level gauge.
- INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
- Install a new gasket as shown in the illustration.
- Install the exhaust manifold sub-assembly RH with the 6 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- INSTALL INTAKE MANIFOLD
- Set a new gasket on each cylinder head.NOTE:
- Align the port holes of the gasket and cylinder head.
- Make sure that the gasket is installed in the correct direction.
- Set the intake manifold on the cylinder heads.
- Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Set a new gasket on each cylinder head.
- INSTALL NO. 2 ENGINE MOUNTING STAY RH
- Install the No. 2 mounting stay RH with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the No. 2 mounting stay RH with the bolt.
- INSTALL IGNITION COIL ASSEMBLY
- Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the 6 ignition coil assemblies with the 6 bolts.
- INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTE: DO NOT apply oil to the bolts as listed belowINTAKE AIR SURGE TANK ASSEMBLY
Tightening Parts Torque N*m (kgf*cm, ft.*lbf) QTY Surge Tank and Intake Manifold 18 (184, 13) 4 No. 1 Surge Tank Stay and Cylinder Head Cover 21 (214,1 5) 1 Ho. 1 Surge Tank Stay and Surge Tank 21 (214, 15) 1 Throttle Body Bracket and Cylinder Head Cover 21 (214, 15) 1 Throttle Body Bracket and Surge Tank 21 (214, 15) 1 - Install a new gasket to the intake air surge tank.
- Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.
Torque:
Bolt
18 N*m (184 kgf*cm, 13 ft.*lbf)
Nut
16 N*m (163 kgf*cm, 12 ft.*lbf)
- Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Connect the connector.
- Install the vacuum hose clamp with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Connect the No. 1 ventilation hose.
- Install the clamp and connect the throttle with motor body assembly connector.
- Connect the vapor feed hose.
- Connect the 2 water by-pass hoses to the throttle with motor body assembly.
- REMOVE ENGINE STAND
- INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See INSTALLATION )
- INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
HINT:
See INSTALLATION .
- INSTALL STARTER ASSEMBLY (See INSTALLATION )
- INSTALL ENGINE WIRE
- INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See INSTALLATION )
- INSTALL FRONT FRAME ASSEMBLY
- Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
- Install the engine mounting insulator FR with the bolt.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)
- Connect the connector and clamp.
- Connect the 2 clamps.
- Install the engine mounting insulators RH and LH with the 2 nuts.
- INSTALL VANE PUMP ASSEMBLY
- Install the vane pump with the 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
- Install the pressure feed tube clamp bolt.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- Connect the power steering oil pressure switch connector.
- Install the vane pump with the 2 bolts.
- INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
- Set the engine assembly with transaxle on the engine lifter.
- Install the engine assembly to the vehicle.
- 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.*lbf)
B
32 N*m (329 kgf*cm, 24 ft.*lbf)
- Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
C
85 N*m (867 kgf*cm, 63 ft.*lbf)
D
32 N*m (329 kgf*cm, 24 ft.*lbf)
- INSTALL COOLER COMPRESSOR ASSEMBLY
- Temporarily install the cooler compressor with the 4 bolts.
- Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
- Install the 2 connector clamps.
- INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
- INSTALL STEERING SLIDING YOKE (See INSTALLATION )
- INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See INSTALLATION )
- INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
- Install the No. 1 exhaust pipe support bracket with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
- Install the No. 1 exhaust pipe support bracket with the bolt.
- INSTALL FRONT AXLE ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT AXLE ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See INSTALLATION )
- INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT:
Use the same procedures described for the LH side.
- INSTALL TIE ROD ASSEMBLY LH (See INSTALLATION )
- INSTALL TIE ROD ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT SPEED SENSOR LH (See INSTALLATION )
- INSTALL FRONT SPEED SENSOR RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT AXLE HUB NUT LH (See INSTALLATION )
- INSTALL FRONT AXLE HUB NUT RH
HINT:
Use the same procedures described for the LH side.
- INSTALL EXHAUST PIPE ASSEMBLY FRONT (See INSTALLATION )
- INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See INSTALLATION )
- CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
- Connect the No. 1 oil reservoir to pump hose.
- CONNECT RETURN TUBE SUB-ASSEMBLY
- Connect the return tube sub-assembly.
- CONNECT FUEL TUBE SUB-ASSEMBLY
- Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.NOTE:
- 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.
- Install the No. 1 fuel pipe clamp.
- Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
- CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
- Install the clip and nut, and connect the cable to the transaxle.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
- Install the clip and nut, and connect the cable to the transaxle.
- CONNECT ENGINE WIRE
- Install the bolt and clamp to the bracket.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
- Install the 2 bolts and 2 clamps to the body.
Torque:
Bolt A
12 N*m (123 kgf*cm, 9 ft.*lbf)
Bolt B
8.4 N*m (85 kgf*cm, 74 in.*lbf)
- Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
- Install the bolt and clamp to the bracket.
- INSTALL RELAY BLOCK COVER UPPER
- INSTALL ECM (See INSTALLATION )
- CONNECT HEATER INLET WATER HOSE
- Connect the heater inlet water hose.
- CONNECT HEATER OUTLET WATER HOSE
- Connect the heater outlet water hose.
- CONNECT NO. 1 OIL COOLER INLET HOSE
- Install the clamp and connect the oil cooler inlet hose.
- CONNECT NO. 1 OIL COOLER OUTLET HOSE
- Install the clamp and connect the oil cooler outlet hose.
- INSTALL RADIATOR HOSE INLET
- Install the clamp and connect the radiator hose inlet.
- INSTALL RADIATOR HOSE OUTLET
- Install the clamp and connect the radiator hose outlet.
- CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE
- Install the clamp and connect the check valve to brake booster hose.
- CONNECT NO. 1 FUEL VAPOR FEED HOSE
- Install the clamp and connect the No. 1 fuel vapor feed hose.
- INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
- Temporarily install the engine moving control rod with the 4 bolts.
- First install the bolts A, and then the remaining bolt B.
Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf)
- INSTALL NO. 2 ENGINE MOUNTING STAY RH
- Temporarily install the No. 2 engine mounting stay RH with the bolt.
Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf)
- Tighten the 2 nuts.
Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf)
- Temporarily install the No. 2 engine mounting stay RH with the bolt.
- INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
- Install the intake air resonator with the bolt and clip.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the intake air resonator with the bolt and clip.
- INSTALL BATTERY
- Install the battery and battery tray.
- Install the battery clamp with the bolt and nut.
Torque:
Bolt
9.0 N*m (92 kgf*cm, 80 in.*lbf)
Nut
3.5 N*m (36 kgf*cm, 31 in.*lbf)
- INSTALL NO. 1 AIR CLEANER INLET
- Install the No. 1 air cleaner inlet with the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the No. 1 air cleaner inlet with the bolt.
- INSTALL AIR CLEANER CASE SUB-ASSEMBLY
- Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Connect the vacuum hose and hose clamp.
- Install the air cleaner case with the 3 bolts.
- INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See INSTALLATION )
- INSTALL AIR CLEANER INLET ASSEMBLY
- Install the air cleaner inlet with the clamp and 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the air cleaner inlet with the clamp and 2 bolts.
- CONNECT VACUUM HOSES
- INSTALL V-RIBBED BELT (See INSTALLATION )
- INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY (See INSTALLATION )
- INSTALL WINDSHIELD WIPER LINK ASSEMBLY
HINT:
See INSTALLATION .
- INSTALL FRONT WHEELS
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
- ADD ENGINE OIL
- CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
- ADD ENGINE COOLANT (See ON-VEHICLE INSPECTION )
- ADD AUTOMATIC TRANSAXLE FLUID (See INSTALLATION )
- ADD POWER STEERING FLUID
- BLEED POWER STEERING FLUID (See BLEEDING )
- CHECK FOR FUEL LEAKS (See ON-VEHICLE INSPECTION )
- CHECK FOR ENGINE OIL LEAKS
- CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
- CHECK FOR EXHAUST GAS LEAKS
- CHECK SHIFT LEVER POSITION (See INSPECTION )
- CHECK AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
See ADJUSTMENT .
- CHECK IGNITION TIMING (See ON-VEHICLE INSPECTION )
- CHECK ENGINE IDLE SPEED (See ON-VEHICLE INSPECTION )
- CHECK CO/HC (See ON-VEHICLE INSPECTION )
- CHECK FUNCTION OF THROTTLE BODY (See ON-VEHICLE INSPECTION )
- INSTALL FRONT FENDER APRON SEAL RH
- INSTALL ENGINE UNDER COVER LH
- INSTALL ENGINE UNDER COVER RH
- INSTALL V-BANK COVER SUB-ASSEMBLY
- Fit the 3 retainers and install the V-bank cover.
- INSTALL COOL AIR INTAKE DUCT SEAL
- Install the intake duct seal with the 7 clips.
- CHECK ABS SPEED SENSOR SIGNAL
- ABS: See TEST MODE PROCEDURE
- VSC (for BOSCH): See TEST MODE PROCEDURE
- VSC (for ADVICS): See TEST MODE PROCEDURE