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Removal And Installation

  1. PREVENT GASOLINE FROM SPILLING OUT (See  FUEL SYSTEM  ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE HOOD SUB-ASSY 
  4. REMOVE V-BANK COVER 
  5. REMOVE AIR CLEANER INLET NO.1 
  6. REMOVE INTAKE AIR CONNECTOR PIPE 
  7. REMOVE AIR CLEANER ASSY 
  8. REMOVE ENGINE UNDER COVER 
  9. REMOVE ENGINE UNDER COVER NQ.2 
  10. DRAIN ENGINE OIL 
  11. DRAIN COOLANT (See  ENGINE COOLANT  ) 
  12. DRAIN AUTOMATIC TRANSMISSION FLUID 
  13. REMOVE RADIATOR ASSY (See  REPLACEMENT  .) 
  14. DISCONNECT FUEL PIPE SUB-ASSY NO. 2 (See  FUEL SYSTEM  ) 
  15. REMOVE FAN AND GENERATOR V BELT (See  REPLACEMENT  ) 
  16. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the ECM box.
    2. Remove the nut, and disconnect the generator wire from the generator.
    3. Disconnect the wire for generator wire from the wire clamp on generator.
    4. Remove the bolt, and disconnect the ground cable from the stay on generator.
    5. Remove the 2 bolts, and disconnect the PS oil hose from the No. 1 oil pan.
    6. Remove the bolt, and disconnect the ground strap from the body.
  17. DISCONNECT AIR HOSE NO.5 
  18. DISCONNECT FUEL VAPOR FEED HOSE NO.2 
  19. DISCONNECT HEATER WATER INLET HOSE A 
  20. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
  21. DISCONNECT VANE PUMP OIL RESERVOIR ASSY 
  22. DISCONNECT VANE PUMP ASSY 
    1. Disconnect the 2 PS air hoses.
    2. Remove the 2 screws and RH engine under cover.
    3. Disconnect the PS oil pressure switch connector.
    4. Remove the 2 bolts and nut, and disconnect the vane pump from the engine.
    5. Support the vane pump securely.
  23. DISCONNECT COOLER COMPRESSOR ASSY 
    1. Disconnect the compressor connector.
    2. Disconnect the wire clamp from the wire bracket on the compressor.
    3. Remove the bolt, nut and stay.
    4. Remove the bolt, and disconnect the wire bracket from the compressor.
    5. Remove the bolt, and disconnect the compressor from the engine.
    6. Support the cooler compressor securely.
  24. REMOVE FRONT FLOOR BRACE CENTER 
  25. REMOVE EXHAUST PIPE ASSY (See  EXHAUST SYSTEM  ) 
  26. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH 
  27. REMOVE W/CATALYST CONVERTER ASSY 
  28. REMOVE FRONT FLOOR HEAT INSULATOR NO. 1 
  29. REMOVE PARKING BRAKE CABLE HEAT INSULATOR 
  30. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (See  PROPELLER W/CENTER BEARING SHAFT ASSY  ) SST 09922-10010 
  31. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY 
  32. REMOVE STEERING SLIDING YOKE SUB-ASSY 
    1. Check the steering wheel at the straight-ahead position.
    2. Remove the 2 bolts and sliding yoke from the steering intermediate shaft.
    Fig 1: Removing Steering Sliding Yoke Sub-Assembly
    G01321443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT POWER STEERING GEAR HOUSING 
    1. Remove the bolt, and disconnect the 2 PS oil tubes from the front frame.
    2. Remove the 4 bolts, and disconnect the PS gear housing from the front frame.
    3. Suspend the PS gear housing securely.
    Fig 2: Disconnecting Power Steering Gear Housing
    G01321444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE ENGINE W/TRANSMISSION ASSEMBLY 
    1. Remove the nut and No. 1 V-bank cover bracket from the No. 2 engine hanger.
    2. Attach the engine chain hoist to the engine hangers.
      Fig 3: Attaching Engine Chain Hoist To Engine Hanger
      G01321445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 hole plugs.
    4. Remove the 4 nuts holding the engine mounting insulator to the front suspension crossmember.
    5. Remove the 4 bolts, 4 nuts and rear engine mounting member.
      Fig 4: Removing Rear Engine Mounting Member
      G01321446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 5: Removing Engine With Transmission Assembly
      G01321447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Lift the engine out of the vehicle slowly and carefully.

      HINT:

      Make sure the engine is clear of all wiring, hose and cable.

    7. Place the engine and transmission assembly onto the stand.
  35. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the transmission.
      1. Disconnect the VSV connector.
      2. Disconnect the PNP switch connector.
      3. Disconnect the solenoid connector.
      4. Disconnect the direct clutch speed sensor connector.
      5. Disconnect the engine wire from the 3 wire clamps.
      6. Disconnect the oil level sensor connector.
  36. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY 
  37. REMOVE OIL COOLER OUTLET TUBE NO. 1 
  38. REMOVE OIL COOLER INLET TUBE NO. 1 
  39. REMOVE AUTOMATIC TRANSMISSION ASSY 
    1. Remove the torque converter clutch bolts.
      1. Remove the 2 bolts and flywheel housing under cover.
      2. Turn the crankshaft pulley bolt to gain access to each bolt.
      3. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
        4. Fig 6: Identifying Crankshaft Pulley Bolt
        G01321448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 10 bolts and ground strap.
    3. Remove the transmission together with the torque converter clutch from the engine.
  40. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY 
  41. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY 

    HINT:

    The mounting bolts are tightened in 2 progressive steps: step (c) and (e).

    If any one of the mounting bolts is broken or deformed, replace it.

    1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

      Adhesive: 

      Part No. 08833-00070, THREE BOND 1324 or equivalent 

      Fig 7: Applying Adhesive To Mounting Bolt End Threads
      G01321449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front spacer, drive plate and rear spacer on the crankshaft.
    3. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.

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

      If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.

      Fig 8: Tightening Mounting Bolts In Sequence
      G01321450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the mounting bolt with paint.
    5. Retighten the mounting bolt by 90° in the numerical order shown.
    6. Check that the painted mark is now at a 90° angle to (e).
    Fig 9: Tightening Mounting Bolts An Additional 90 Degrees
    G01321451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL AUTOMATIC TRANSMISSION ASSY 
    1. Check the torque converter clutch installation (See TORQUE CONVERTER CLUTCH AND DRIVE PLATE ).
    2. Attach the transmission to the engine.
      3. Fig 10: Installing Bolts A & B
      G01321452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the ground strap and transmission-to-engine bolts.

      Torque: 

      Bolt A: 72 N.m (730 kgf.cm, 53 ft.lbf) for 17 mm head 

      Bolt B: 37 N.m (380 kgf.cm, 27 ft.lbf) for 14 mm head 

    4. Install the torque converter clutch bolts.
      1. Apply adhesive to 2 or 3 threads of the bolt end.

        Adhesive: 

        Part No. 08833-00070, THREE BOND 1324 or equivalent 

      2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolt evenly.

        Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) 

        Fig 11: Identifying Crankshaft Pulley Bolt
        G01321453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT:

        First install the black colored bolt, then install the other bolt.

      3. Install the flywheel housing under cover with the 2 bolts.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

  43. INSTALL OIL COOLER INLET TUBE NO. 1 
  44. INSTALL OIL COOLER OUTLET TUBE NO. 1 
  45. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY 
  46. CONNECT ENGINE WIRE 
    1. Connect the engine wire to the transmission.
      1. Connect the VSV connector.
      2. Connect the PNP switch connector.
      3. Connect the solenoid connector.
      4. Connect the direct clutch speed sensor connector.
      5. Connect the engine wire from the 3 wire clamps.
      6. Connect the oil level sensor connector.
  47. INSTALL ENGINE W/TRANSMISSION ASSEMBLY 
    1. Attach the engine chain hoist to the engine hangers.
    2. Slowly lower the engine and transmission assembly into the engine compartment.
    3. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
      Fig 12: Attaching Engine Chain Hoist To Engine Hanger
      G01321454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Keep the engine level.
      Fig 13: Keeping Engine Level
      G01321455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the rear engine mounting member with the 4 bolts and 4 nuts.

      Torque: 

      25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolts 

      13.5 N.m (135 kgf.cm, 10 ft.lbf) for nuts 

      NOTE: Be careful of installation direction.
      Fig 14: Installing Rear Engine Mounting Member
      G01321456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.

      Torque: 68 N.m (700 kgf.cm, 50 ft.lbf) 

    7. Install the 2 hole plugs.
    8. Remove the engine chain hoist.
    9. Install the V-bank cover bracket No. 1 to the engine hanger No. 2 with the nut.
    Fig 15: Installing Engine Mounting Brackets To Front Suspension Crossmember
    G01321457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL POWER STEERING GEAR HOUSING ASSY 
    Fig 16: Installing Power Steering Gear Housing Assembly
    G01321458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the sliding yoke to the PS gear housing and intermediate shaft.
    2. Install the PS gear housing with the 4 bolts.

      Torque: 65 N.m (660 kgf.cm, 48 ft.lbf) 

    3. Install the 2 PS oil tube with the bolt.
  49. INSTALL STEERING SLIDING YOKE SUB-ASSY 
    1. Tighten the 2 bolts for sliding yoke.

      Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

    Fig 17: Installing Steering Sliding Yoke Sub-Assembly
    G01321459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY 
  51. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (See  PROPELLER W/CENTER BEARING SHAFT ASSY  ) 
  52. INSTALL PARKING BRAKE CABLE HEAT INSULATOR 
  53. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 
  54. INSTALL W/CATALYST CONVERTER ASSY 
  55. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH 

    Torque: 58 N.m (590 kgf.cm, 43 ft.lbf) for nuts 

  56. INSTALL EXHAUST PIPE ASSY (See  EXHAUST SYSTEM  ) 
  57. INSTALL FRONT FLOOR BRACE CENTER 
  58. INSTALL COOLER COMPRESSOR ASSY 
    1. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.

      Torque: 

      49 N.m (500 kgf.cm, 36 ft.lbf) for bolts 

      29 N.m (300 kgf.cm, 21 ft.lbf) for nut 

    2. Connect the compressor connector.
    3. Install the wire clamp.
    Fig 18: Installing Cooler Compressor Assembly
    G01321460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. INSTALL VANE PUMP ASSY 
    1. Install the vane pump with the 2 bolts and nut. Alternately tighten the bolts and nut.

      Torque: 

      39.2 N.m (400 kgf.cm, 29 ft.lbf) for bolts 

      43.1 N.m (440 kgf.cm, 32 ft.lbf) for nut 

    2. Connect the PS oil pressure switch connector.
    3. Install the RH engine under cover with the 2 screws.
    4. Connect the 2 PS air hoses to the vane pump.
    Fig 19: Installing Vane Pump Assembly
    G01321461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL VANE PUMP OIL RESERVOIR ASSY 
  61. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
  62. CONNECT HEATER WATER INLET HOSE A 
  63. CONNECT FUEL VAPOR FEED HOSE NO. 2 
  64. CONNECT AIR HOSE NO. 5 
  65. CONNECT ENGINE WIRE 
    1. Connect the engine wire from the ECM box.
    2. Install the nut, and connect the generator wire to the generator.
    3. Connect the wire for generator wire to the wire clamp on generator.
    4. Install the bolt, and disconnect the ground cable to the stay on generator.
    5. Install the 2 bolt, and connect the PS oil hose to the No. 1 oil pan.
    6. Install the 2 bolts, and connect the ground strap to the body.
  66. INSTALL FAN AND GENERATOR V BELT (See  FAN AND GENERATOR V BELT  ) 
  67. CONNECT FUEL PIPE SUB-ASSY NO. 2 (See  FUEL SYSTEM  ) 
  68. INSTALL RADIATOR ASSY (See  RADIATOR ASSY  ) 
  69. INSTALL ENGINE UNDER COVER NO. 2 
  70. INSTALL ENGINE UNDER COVER 
  71. INSTALL AIR CLEANER ASSY 
  72. INSTALL INTAKE AIR CONNECTOR PIPE 
  73. INSTALL AIR CLEANER INLET NO. 1 
  74. INSTALL V-BANK COVER 
  75. INSTALL HOOD SUB-ASSY 
  76. INSTALL BATTERY NEGATIVE TERMINAL 
  77. ADD AUTOMATIC TRANSMISSION FLUID 
  78. ADD COOLANT (See  ENGINE COOLANT  ) 
  79. ADD ENGINE OIL 
  80. CHECK FOR ENGINE COOLANT LEAKS (See  ENGINE COOLANT  ) 
  81. INSPECT FUEL LEAK (See  FUEL SYSTEM  ) 
  82. INSPECT AUTOMATIC TRANSMISSION FLUID (See  LUBRICATION  ) 
  83. INSPECT ENGINE OIL LEAKS 
  84. DRIVING TEST 
  85. ADJUST ENGINE (See  ENGINE ADJUSTMENT  ) 
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