Section 12 (Partial Engine Assembly - 2ZZ-GE): Replacement

WARNING: This page is about a different variant/trim than selected.

WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See PRECAUTION )
REMOVE FRONT WHEELS
REMOVE ENGINE UNDER COVER RH
REMOVE ENGINE UNDER COVER LH
DRAIN COOLANT (See REPLACEMENT )
DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
1. Using a 10 mm hexagon wrench, remove the drain plug and a gasket. Drain automatic transaxle fluid.
2. Install a new gasket and the drain plug.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
REMOVE CYLINDER HEAD COVER NO. 2
1. Remove the 3 bolts, the nut and the cylinder head cover No. 2.
REMOVE BATTERY
REMOVE AIR CLEANER ASSEMBLY WITH HOSE
1. Disconnect the MAF meter connector.
2. Place match marks on the vacuum hoses.
3. Disconnect the 5 vacuum hoses from the air cleaner cap.
4. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case.
5. Loosen the hose clamp bolt, and disconnect the air cleaner hose from the throttle body.
6. Remove the air cleaner assembly with hose.
7. Remove the air filter.
8. Disconnect the wire harness clamp, connector and hose.
9. Remove the 3 bolts and the air cleaner case.
REMOVE BATTERY CARRIER
1. Remove the 4 bolts and battery carrier.
  
  Fig 3: Removing Battery Carrier & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE ACCELERATOR CONTROL CABLE ASSY

Fig 4: Separating Accelerator Control Cable Assy
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
1. Disconnect the actuator connector.
2. Remove the 2 bolts, and disconnect the actuator from the body.
  
  Fig 5: Disconnecting Actuator Connector & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WIRE HARNESS CLAMP
1. Disconnect engine wire harness.
2. Remove the bolt and wiring harness clamp bracket.
  
  Fig 6: Removing Wire Harness Clamp Bracket & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT SUCTION HOSE SUB-ASSY
1. Remove the 2 nuts installing the suction hose sub-assy.
2. Disconnect the suction hose sub-assy.
  
  Fig 7: Removing Suction Hose Sub-Assy & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FAN AND GENERATOR V BELT
1. Turn the drive belt tensioner clockwise to relieve tension on the belt, and then remove the belt.
2. Carefully return the tensioner to the unloaded position.
  
  Fig 8: Removing Fan & Generator V Belt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EFI FUEL PIPE CLAMP (See PRECAUTION )
DISCONNECT FUEL TUBE SUB-ASSY (See PRECAUTION )
DISCONNECT RADIATOR HOSE INLET
1. Disconnect the radiator hose inlet from the radiator.
DISCONNECT RADIATOR HOSE OUTLET
1. Disconnect the radiator hose outlet from the radiator.
DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE) (See REPLACEMENT )
DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See REPLACEMENT )
DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See TRANSAXLE DISASSEMBLY )
DISCONNECT HEATER INLET WATER HOSE
1. Disconnect the heater inlet water hose from the air conditioner tube.
  
  Fig 9: Disconnecting Heater Inlet Water Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT HEATER OUTLET WATER HOSE
1. Disconnect the heater outlet water hose from the air conditioner tube.
  
  Fig 10: Disconnecting Heater Outlet Water Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT UNION TO CONNECTOR TUBE HOSE
1. Disconnect the union to check valve hose from the brake booster.
  
  Fig 11: Disconnecting Value Hose From Brake Booster
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GLOVE COMPARTMENT DOOR ASSY (See REPLACEMENT )
DISCONNECT ENGINE WIRE
1. Remove the engine room relay block cover.
2. Disconnect the 3 connectors.
  
  Fig 12: Disconnecting Engine Wire Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Disconnect the 2 wire harness clamps.
  
  Fig 13: Disconnecting Wire Harness Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Disconnect the 2 ground cables from the vehicle.
5. Disconnect the 2 ECM connectors.
6. Disconnect the 3 cowl wire connectors from connectors on bracket.
7. Pull out the engine wire from the cabin.
  
  Fig 14: Disconnecting Cowl Wire Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RADIATOR ASSY (W/ AIR CONDITIONER) (See REPLACEMENT )
DISCONNECT CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See REPLACEMENT )
REMOVE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER) (See REPLACEMENT )
NOTE: Hung up the hoses instead of detaching.
SEPARATE RETURN TUBE SUB-ASSY
1. Remove the 2 clamp bolts, and separate the return tube sub-assy.
  
  Fig 15: Removing Clamp Bolts & Separating Return Tube Sub Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE VANE PUMP OIL RESERVOIR ASSY
1. Remove the 2 bolts and the oil reservoir assy.
REMOVE FLOOR PANEL BRACE FRONT (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
REMOVE EXHAUST PIPE ASSY FRONT (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
REMOVE STEERING INTERMEDIATE SHAFT (See OVERHAUL )
REMOVE FRONT AXLE HUB LH NUT (See AXLE SHAFTS - FRONT )
SST 09930-00010
REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010

NOTE: Perform the same procedure as above on the opposite side.
SEPARATE TIE ROD END SUB-ASSY LH (See OVERHAUL )
SST 09628-62011
SEPARATE TIE ROD END SUB-ASSY RH
SST 09628-62011

NOTE: Perform the same procedure as above on the opposite side.
SEPARATE FRONT STABILIZER LINK ASSY LH (See page FRONT )
SEPARATE FRONT STABILIZER LINK ASSY RH
NOTE: Perform the same procedure as above on the opposite side.
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See )
SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH
NOTE: Perform the same procedure as above on the opposite side.
SEPARATE FRONT AXLE ASSY LH (See AXLE SHAFTS - FRONT )
SEPARATE FRONT AXLE ASSY RH
NOTE: Perform the same procedure as above on the opposite side.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine lifter.
2. Remove the 5 bolts, 2 nuts and engine mounting insulator RH.
  
  Fig 16: Removing Engine Mounting Insulator RH Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the through bolt and nut, detach the engine mounting insulator LH from the vehicle.
  
  Fig 17: Removing Engine Mounting Insulator LH Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 6 bolts, as shown in the illustration.
5. Carefully, remove the engine assembly from the vehicle.
  
  Fig 18: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 2 engine hangers as shown in the illustration.
  
  Fig 19: Installing Engine Hangers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Parts No.:
  
  No. 1 engine hanger 12281-88600
  
  No. 2 engine hanger 12282-88600
  
  Bolt: 91512-61020
  
  Torque: 38 N.m (387 kgf.cm, 28 ft.lbf)
  
  HINT:
  
  Be sure to install engine hanger (12281-88600) to the front side of the engine, and engine hanger (12282-88600) to the rear side.
7. Using the chain block and engine sling device, hang the engine assembly.
REMOVE FRONT SUSPENSION CROSS MEMBER W/CENTER MEMBER
1. Remove the through bolt and a nut, detach the engine mounting insulator FR from the engine mounting bracket.
2. Remove the through bolt, detach the engine mounting insulator RR from the suspension crossmember.
3. Separate the engine and transaxle assembly from the front suspension crossmember w/center member.
  
  Fig 21: Detaching Engine Mounting Insulator RR From Suspension Crossmember
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE STARTER ASSY (See STARTER )
REMOVE FRONT DRIVE SHAFT ASSY RH (See AXLE SHAFTS - FRONT )
SST 09520-01010, 09520-24010 (09520-32040)
SEPARATE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See REPLACEMENT )
SEPARATE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See TRANSAXLE DISASSEMBLY )
REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See OVERHAUL )
REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See OVERHAUL )
REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL
1. Fix the crankshaft with SST, then remove the drive plate and ring gear or the flywheel.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Fig 22: Removing Drive Plate & Ring Gear Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE STAND
REMOVE OIL LEVEL GAGE SUB-ASSY
REMOVE OIL LEVEL GAGE GUIDE
REMOVE SURGE TANK STAY NO. 1
1. Remove the 2 bolts, the nut and the surge tank stay.
  
  Fig 23: Removing Surge Tank Stay & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE MANIFOLD
1. Remove the 4 bolts, the 2 nuts, the intake manifold and the gasket.
  
  Fig 24: Removing Intake Manifold Bolts & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE V-RIBBED BELT TENSIONER ASSY
1. Remove the bolt, the nut and the v-ribbed belt tensioner assy.
REMOVE MANIFOLD STAY
1. Remove the 2 bolts, the nut and exhaust manifold stay.
  
  Fig 25: Removing Exhaust Manifold Stay Nut & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
REMOVE EXHAUST MANIFOLD
1. Remove the 3 bolts, 2 nuts, exhaust manifold and gasket.
REMOVE GENERATOR BRACKET NO. 1 (See GENERATOR )
REMOVE GENERATOR ASSY (See GENERATOR )
REMOVE FUEL DELIVERY PIPE SUB-ASSY (See FUEL RAILS & FUEL INJECTORS )
REMOVE IGNITION COIL ASSY
1. Remove the 3 bolts, the nut and the 4 ignition coils.
  
  Fig 26: Removing Ignition Coils, Bolts & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THERMOSTAT (See THERMOSTAT )
REMOVE WATER BY-PASS PIPE NO. 1
1. Remove the 2 bolts, the 2 nuts, the water by-pass pipe No. 1 and the gasket.
REMOVE ENGINE OIL PRESSURE SWITCH ASSY
1. Using the SST, remove the oil pressure switch. SST 09268-46021
REMOVE UNION TO CONNECTOR TUBE HOSE
1. Remove the clamp and tube.
REMOVE CRANK POSITION SENSOR
REMOVE CAM POSITION SENSOR
REMOVE KNOCK CONTROL SENSOR
1. Remove the nut and the knock control sensor.
  
  Fig 27: Removing Knock Control Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
1. Using a SST, remove the water temperature sensor.
  SST 09817-33190
REPLACE PARTIAL ENGINE ASSY
INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
1. Install a new gasket to the water temperature sensor.
2. Using a SST, install the water temperature sensor.
  SST 09817-33190
  
  Torque: 20 N.m (208 kgf.cm, 15 ft.lbf)
INSTALL KNOCK CONTROL SENSOR
1. Install the nut and the knock control sensor.
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
  
  Fig 28: Installing Knock Control Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CAM POSITION SENSOR
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL CRANK POSITION SENSOR
1. Install the crank position sensor and cord wiring clamp.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL UNION TO CONNECTOR TUBE HOSE
Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
INSTALL ENGINE OIL PRESSURE SWITCH ASSY
1. Clean the threads of the oil pressure switch, apply adhesive there.
  Adhesive:
  
  Part No. 08833-00080, THREE BOND 1344,
2. Using a SST, install the oil pressure switch.
  SST 09268-46021
  
  Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
INSTALL WATER BY-PASS PIPE NO. 1
1. Install the 2 bolts, the 2 nuts, the new gasket and the water by-pass pipe.
  Torque:
  
  8.5 N.m (87 kgf.cm, 75 in.lbf) for M6
  
  21 N.m (214 kgf.cm, 15 ft.lbf) for M8
  
  10 N.m (102 kgf.cm, 7 ft.lbf) for Nut
INSTALL THERMOSTAT (See REPLACEMENT )
INSTALL IGNITION COIL ASSY
1. Install the 3 bolts, the nut and the 4 ignition coils.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 29: Installing Ignition Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL DELIVERY PIPE SUB-ASSY (See FUEL RAILS & FUEL INJECTORS )
INSTALL EXHAUST MANIFOLD
1. Install a new gasket.
2. Install and uniformly tighten the 3 bolts and 2 nuts in several passes and in the sequence shown.
  Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
INSTALL MANIFOLD STAY
Torque: 50 N.m (510 kgf.cm, 37 ft.lbf)

Fig 31: Installing Manifold Stay
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-RIBBED BELT TENSIONER ASSY
1. Install the bolt, the nut and v-ribbed belt tensioner assy.
  Torque:
  
  Nut: 29 N.m (296 kgf.cm, 21 ft.lbf)
  
  Bolt: 100 N.m (1,020 kgf.cm, 74 ft.lbf)
INSTALL INTAKE MANIFOLD
1. Install the new gasket, the intake manifold with the 4 bolts and 2 nuts.
  
  Fig 32: Installing Intake Manifold & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  A: 34 N.m (347 kgf.cm, 25 ft.lbf)
  
  B: 46 N.m (469 kgf.cm, 34 ft.lbf)
INSTALL SURGE TANK STAY NO. 1
1. Install the surge tank stay with the 2 bolts and nut.
  Torque:24 N.m (245 kgf.cm, 18 ft.lbf)
  
  Fig 33: Installing Surge Tank Stay No. 1
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL LEVEL GAGE GUIDE
1. Apply a light coat of engine oil to a new O-ring, install it to the oil level gage guide.
2. Install the oil level gage and guide with the bolt.
  Torque: 24 N.m (245 kgf.cm, 18 ft.lbf)
INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
1. Fix the crankshaft with SST.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Fig 34: Fixing Crankshaft With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Clean the bolt and bolt hole.
3. Apply adhesive to the bolts.
  Adhesive:
  
  Part No. 09330-00070, THREE BOND or equivalent.
4. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  
  Fig 35: Installing Fly Wheel Sub-Assy In Sequence (M/T Transaxle)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Mark the bolts with paint.
6. Retighten the bolts by an additional 90°.
7. Check that the point marked bolts are moved at 90°C angle.
  
  Fig 36: Checking Point Marked Bolts Are Moved At 90°C Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE)
1. Fix the crankshaft with SST.
  SST 09213-70011 (09213-70020), 09330-00021
  
  Fig 37: Installing Crankshaft With SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Clean the bolt and bolt hole.
3. Apply adhesive to the bolts.
  Adhesive:
  
  Part No. 09330-00070, THREE BOND or equivalent.
4. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
  Torque: 88 N.m (897 kgf.cm, 65 ft.lbf)
  
  Fig 38: Installing Bolts In Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See OVERHAUL )
SST 09301-00210
INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See OVERHAUL )
SST 09301-00210
INSTALL FRONT DRIVE SHAFT ASSY LH (See AXLE SHAFTS - FRONT )
INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See REPLACEMENT )
INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See TRANSAXLE DISASSEMBLY )
INSTALL STARTER ASSY (See STARTER )
INSTALL FRONT SUSPENSION CROSS MEMBER W/CENTER MEMBER
1. Attach the engine and transaxle assembly to the suspension crossmember w/center member.
2. Install the bolt holding the rear engine mounting bracket to the mounting insulator.
  Torque: 87 N.m (887 kgf.cm, 64 ft.lbf)
  
  Fig 39: Installing Rear Engine Mounting Bracket To Mounting Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bolt holding the front engine mounting bracket to the mounting insulator.
  Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
  
  Fig 40: Installing Front Engine Mounting Bracket To Mounting Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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. Temporarily, install the suspension crossmember and 6 bolts.
  
  Fig 41: Installing Suspension Crossmember & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the engine mounting insulator LH.
  Torque: 80 N.m (816 kgf.cm, 60 ft.lbf)
  
  Fig 42: Installing Engine Mounting Insulator LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the engine mounting insulator RH.
  Torque: 52 N.m (531 kgf.cm, 38 ft.lbf)
  
  Fig 43: Installing Engine Mounting Insulator RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Insert SST to the positioning holes on the right handle crossmember and on the right-handle of the vehicle.
  SST 09670-00010
7. Temporarily tighten the bolt A first, then bolt B.
  
  Fig 44: Temporarily Tightening Bolt A & B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Insert SST to the positioning holes on the left-handle crossmember and on the left-handle of the vehicle.
  
  Fig 45: Inserting SST To Positioning Holes On Left Handle Crossmember
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09670-00010
9. Temporarily tighten the bolt A first, then bolt B.
10. Insert SST to the positioning holes on the right-handle crossmember and the right-handle of the vehicle, then the bolts with a specified torque.
  SST 09670-00010
  
  Torque:
  
  Bolt A: 157 N.m (1,601 kgf.cm, 116 ft.lbf)
  
  Bolt B: 113 N.m (1,152 kgf.cm, 83 ft.lbf)
11. Insert SST to the positioning holes on the left-handle crossmember and the left-handle of the vehicle, then tighten the bolts with a specified torque.
  SST 09670-00010
  
  Torque:
  
  Bolt A: 157 N.m (1,601 kgf.cm, 116 ft.lbf)
  
  Bolt B: 113 N.m (1,152 kgf.cm, 83 ft.lbf)
  1. Tighten the 2 bolts as shown in the illustration.
    
    Fig 46: Tightening Bolts
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
    
    NOTE: After installing the crossmember, check that the positioning holes on the crossmember and the vehicle are aligned with each other.
INSTALL FRONT AXLE ASSY LH (See AXLE SHAFTS - FRONT )
INSTALL FRONT AXLE ASSY RH
NOTE: Perform the same procedure as above on the opposite side.
INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See FRONT )
INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH
NOTE: Perform the same procedure as above on the opposite side.
INSTALL FRONT STABILIZER LINK ASSY LH (See page FRONT )
INSTALL FRONT STABILIZER LINK ASSY RH
NOTE: Perform the same procedure as above on the opposite side.
INSTALL TIE ROD END SUB-ASSY LH (See OVERHAUL )
INSTALL TIE ROD END SUB-ASSY RH
NOTE: Perform the same procedure as above on the opposite side.
INSTALL FRONT AXLE HUB LH NUT (See AXLE SHAFTS - FRONT )
INSTALL FRONT AXLE HUB RH NUT
NOTE: Perform the same procedure as above on the opposite side.
INSTALL STEERING INTERMEDIATE SHAFT (See OVERHAUL )
INSTALL EXHAUST PIPE ASSY FRONT (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
INSTALL FLOOR PANEL BRACE FRONT (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
INSTALL RETURN TUBE SUB-ASSY
1. Install the return tube with the 2 bolts.
  
  Fig 47: Installing Return Tube With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque:
  
  Bolt A: 5.0 N.m (51 kgf.cm, 44 in.lbf)
  
  Bolt B: 7.8 N.m (80 kgf.cm, 69 in.lbf)
INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER) (See REPLACEMENT )
INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See CLUTCH RELEASE CYLINDER )
INSTALL GENERATOR ASSY (See GENERATOR )
INSTALL GENERATOR BRACKET NO. 1 (See GENERATOR )
INSTALL RADIATOR ASSY (W/ AIR CONDITIONER) (See REPLACEMENT )
INSTALL GLOVE COMPARTMENT DOOR ASSY (See REPLACEMENT )
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE) (See REPLACEMENT )
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See REPLACEMENT )
INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See TRANSAXLE DISASSEMBLY )
CONNECT FUEL TUBE SUB-ASSY (See PRECAUTION )
INSTALL EFI FUEL PIPE CLAMP (See PRECAUTION )
INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 N.m (100 kgf.cm, 7 ft.lbf)

Fig 48: Installing Suction Hose Sub-Assy With Nut
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WIRE HARNESS CLAMP
Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)

Fig 49: Installing Wire Harness Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY CARRIER
1. Install the battery carrier with the 4 bolts.
  Torque: 13 N.m (132 kgf.cm, 10 ft.lbf)
  
  Fig 50: Installing Battery Carrier With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
- Install the actuator with the 2 bolts.
  
  Fig 51: Install Actuator With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
- Connect the actuator connector.
INSTALL AIR CLEANER ASSEMBLY WITH HOSE
1. Install the air cleaner case with the 3 bolts.
  
  Fig 52: Install Air Cleaner Case With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
2. Connect the wire harness clamp, connector and hose.
3. Install the air filter.
4. Connect the air cleaner hose to the throttle body.
5. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps.
6. Tighten the air cleaner hose clamp.
7. Connect the 5 vacuum hoses for the air cleaner cap.
8. Connect the MAF meter connector.
INSTALL CYLINDER HEAD COVER NO. 2
Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE) (See REPLACEMENT )
ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
ADD ENGINE OIL
ADD COOLANT (See REPLACEMENT )
CHECK ENGINE OIL LEAK
CHECK ENGINE COOLANT LEAK (See REPLACEMENT )
CHECK FUEL LEAK
INSTALL FRONT WHEELS
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
CHECK EXHAUST GAS LEAK
INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See INSPECTION )
SST 09843-18040
INSPECT CO/HC (See INSPECTION )
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See ADJUSTMENT )
CHECK ABS SPEED SENSOR SIGNAL (See PRE-CHECK )