Partial Engine Assembly - 1ZZ-FE: Replacement

WORK TO PREVENT GASOLINE FROM SPILLING (See PRECAUTION )
REMOVE FRONT WHEELS
REMOVE ENGINE UNDER COVER RH
REMOVE ENGINE UNDER COVER LH
DRAIN COOLANT (See REPLACEMENT )
DRAIN AUTOMATIC TRANSAXLE FLUID (4WD DRIVE TYPE)
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)
DRAIN TRANSFER OIL (4WD DRIVE TYPE)
1. Install a new gasket and the drain plug.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
REMOVE CYLINDER HEAD COVER NO. 2

Fig 1: Removing Cylinder Head Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 2 nuts, 2 clips and cylinder head cover.
DISCONNECT RADIATOR HOSE INLET
1. Disconnect the radiator hose inlet from the radiator.
SEPARATE RADIATOR HOSE OUTLET
1. Disconnect the radiator hose outlet from the radiator.
DISCONNECT OIL COOLER INLET TUBE NO. 1 (A/T TRANSAXLE)
1. Disconnect the oil cooler inlet tube from the radiator.
DISCONNECT OIL COOLER OUTLET TUBE NO. 1 (A/T TRANSAXLE)
1. Disconnect the oil cooler outlet tube from the radiator.
REMOVE RADIATOR SUPPORT UPPER (W/ AIR CONDITIONER)
1. Remove the 2 bolts and 2 radiator support upper.
REMOVE RADIATOR ASSY (W/ AIR CONDITIONER)
1. Disconnect the connector and harness clamp, and remove the radiator.
REMOVE BATTERY
REMOVE BATTERY CARRIER

Fig 2: Removing Battery Carrier Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the 4 bolts and battery carrier.
REMOVE AIR CLEANER ASSEMBLY WITH HOSE
1. Separate an intake air flow meter connector.
2. Separate the VSV connector.
3. Disconnect 3 vacuum hoses, as shown in the illustration.
4. Loosen an air cleaner hose clump and separate an air cleaner hose.
5. Remove the air cleaner cap.
6. Remove the air filter.
7. Disconnect the wire harness clamp, connector and hose.
8. Remove the 3 bolts and the air cleaner case.
REMOVE EFI FUEL PIPE CLAMP (See FUEL RAILS & FUEL INJECTORS )
DISCONNECT FUEL TUBE SUB-ASSY (See FUEL RAILS & FUEL INJECTORS )
SEPARATE ACCELERATOR CONTROL CABLE ASSY
1. Loosen the nut, and remove the accelerator control cable.
REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)

Fig 5: Removing Actuator Connector
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the actuator connector.
2. Remove the 2 bolts, and disconnect the actuator from the body.
DISCONNECT UNION TO CONNECTOR TUBE HOSE
1. Disconnect the union to connector tube hose from the brake booster.
DISCONNECT HEATER INLET WATER HOSE
1. Disconnect the heater inlet water hose from the air conditioner tube.
  
  Fig 6: 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 7: Disconnecting Heater Outlet Water Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See REPLACEMENT )
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE) (See REPLACEMENT )
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See REPLACEMENT )
SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See REPLACEMENT )
REMOVE GLOVE COMPARTMENT DOOR ASSY (See REPLACEMENT )
DISCONNECT ENGINE WIRE

Fig 8: Removing Engine Room Relay Block Over & Disconnect Engine Wire
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Remove the engine room relay block cover.
2. Disconnect the 3 engine wire connectors from the engine room relay block.
3. Disconnect the 2 ground cables from the vehicle.
4. Disconnect the engine wire from the engine ECM and junction block.
5. Pull out the engine wire from the cabin.
REMOVE FAN AND GENERATOR V BELT

Fig 10: Removing Fan & Generator V Belt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER) (See REPLACEMENT )
NOTE: Hung up the hoses instead of detaching.
SEPARATE RETURN TUBE SUB-ASSY

Fig 11: Disconnecting Vane Pump Oil Reservoir
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the vane pump oil reservoir from the oil reservoir bracket.
2. 2WD
  1. Remove the 2 bolts installing the return tube.
3. 4WD
  
  Fig 12: Installing Return Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Remove the 3 bolts installing the return tube.
REMOVE FRONT DOOR SCUFF PLATE RH (See REPLACEMENT )
REMOVE COWL SIDE TRIM BOARD RH (See REPLACEMENT )
REMOVE REAR DOOR SCUFF PLATE RH (4WD DRIVE TYPE) (See REPLACEMENT )
REMOVE CENTER PILLAR GARNISH LOWER RH (4WD DRIVE TYPE) (See REPLACEMENT )
REMOVE FRONT SEAT ASSY RH (4WD DRIVE TYPE) (See OVERHAUL )
REMOVE COLUMN HOLE COVER SILENCER SHEET
1. Remove the 2 clips and column hole cover silencer sheet.
SEPARATE STEERING INTERMEDIATE SHAFT (See OVERHAUL )
REMOVE FLOOR PANEL BRACE FRONT (2WD DRIVE TYPE)
1. Remove the 2 nuts and floor panel brace front.
REMOVE EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See FUEL PUMP )
REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE) (See OVERHAUL )
REMOVE EXHAUST PIPE ASSY FRONT (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
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 AXLE SHAFTS - FRONT )
SST 09628-6201 1
SEPARATE TIE ROD END SUB-ASSY RH
SST 09628-6201 1

NOTE: Perform the same procedure as above on the opposite side.
SEPARATE FRONT STABILIZER LINK ASSY LH (See OVERHAUL )
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 AXLE SHAFTS - FRONT )
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

Fig 13: Removing Bolts, Nuts & Engine Mounting Insulator
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Set the engine lifter.
2. Remove the 4 bolts, 2 nuts and engine mounting insulator.
3. Remove the through bolt and nut, detach the engine mounting insulator from the vehicle.
  
  Fig 14: Removing Through Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 6 bolts, as shown in the illustration.
5. Carefully, remove the engine with transaxle from the vehicle.
  
  Fig 15: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 2 engine hangers with the 2 bolts.
  Part No.:
  
  No. 1 engine hanger 12281-15040
  
  No. 2 engine hanger 12281-22021
  
  Bolt 91512-B1016
  
  Torque: 38 N.m (387 kgf.cm, 28 ft.lbf)
  
  HINT:
  
  Be sure to install engine hanger (12281-22021) to the front side of the engine and engine hanger (12281-15040) to the rear side.
  
  Fig 16: Removing Front & Rear Side Hanger Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using the chain block and engine sling device, hang the engine assembly.
SEPARATE VANE PUMP ASSY (See OVERHAUL )
NOTE: Do not disconnect the hose.
REMOVE RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE) (See OVERHAUL )
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.
  
  Fig 17: Removing Front Suspension Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the through bolt, detach the engine mounting insulator RR from the suspension crossmember.
3. Separate the engine and transaxle assembly from the suspension crossmember and engine mounting member.
  
  Fig 18: Separating Engine & Transaxle Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANIFOLD STAY (4WD DRIVE TYPE)
1. Remove the 2 bolt and manifold stay.
  
  Fig 19: Removing Manifold Stay & Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OXYGEN SENSOR (4WD DRIVE TYPE)
1. Using SST, remove the oxygen sensor.
  SST 09224-00010
  
  Fig 20: Removing Oxygen Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (4WD DRIVE TYPE)
1. Remove the 4 bolts and exhaust manifold heat insulator.
  
  Fig 21: Remove Exhaust Manifold Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD (4WD DRIVE TYPE)
1. Remove the 5 nuts, exhaust manifold and gasket.
  
  Fig 22: Removing Nuts, Exhaust Manifold & Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. REMOVE STARTER ASSY (See REMOVAL & INSTALLATION )
REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See REPLACEMENT )
REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See REMOVAL )
TRANSVERSE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE) (See REMOVAL )
REMOVE TRANSFER STIFFENER PLATE CENTER (4WD DRIVE TYPE) (See REMOVAL )
REMOVE TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) (See REMOVAL )
REMOVE TRANSFER ASSY (4WD DRIVE TYPE) (See REMOVAL )
REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE, 2WD DRIVE TYPE) (See TRANSAXLE DISASSEMBLY )
REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE, 4WD DRIVE TYPE) (See TRANSAXLE DISASSEMBLY )
REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See OVERHAUL )
REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See OVERHAUL )
REMOVE FLYWHEEL SUB-ASSY (M/T TRANSAXLE)

Fig 23: Removing Flywheel
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Fix the crankshaft with SST, then remove the 8 bolts and flywheel.
  SST 09960-10010 (09962-01000, 09963-01000)
REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE)

Fig 24: Removing Drive Plate & Ring Gear
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Fix the crankshaft with SST, then remove the 8 bolts and drive plate & ring gear.
  SST 09960-10010 (09962-01000, 09963-01000)
REMOVE GENERATOR ASSY (See GENERATOR ) .
REMOVE IGNITION COIL ASSY
1. Disconnect the 4 ignition coil connectors.
  
  Fig 25: Removing Ignition Coil Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt and nut installing the engine wire.
  
  Fig 26: Installing Engine Wire, Bolt & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 4 bolts and 4 ignition coils.
  
  Fig 27: Removing Ignition & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FUEL DELIVERY PIPE SUB-ASSY (See FUEL RAILS & FUEL INJECTORS ) .
REMOVE INTAKE MANIFOLD

Fig 28: Removing Intake Manifold
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Disconnect the 2 water hoses from the throttle body.
2. Disconnect the 2 vacuum hoses from the intake manifold.
3. Remove the 4 bolts, 2 nut, 2 wire brackets, the intake manifold and throttle body assembly.
4. Remove the gasket from the intake manifold and throttle body assembly.
REMOVE OIL LEVEL GAGE SUB-ASSY
1. Remove the oil level gage guide from the oil level gage guide.
REMOVE OIL LEVEL GAGE GUIDE
1. Remove the bolt and oil level gage guide.
  
  Fig 29: Removing Oil Level Gage Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER BY-PASS PIPE NO. 1
1. Remove the 2 bolts, 2 nuts, water by-pass pipe and gasket.
  
  Fig 30: Removing Water By-Pass Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER INLET
1. Remove the 2 nuts and water inlet.
  
  Fig 31: Removing Water Inlet & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE THERMOSTAT
REMOVE ENGINE OIL PRESSURE SWITCH ASSY (See LUBRICATION SYSTEM - 1ZZ-FE ).
SST 09268-46021
REMOVE CRANK POSITION SENSOR NO. 1
1. Remove the bolt and cam position sensor.
  
  Fig 32: Removing Crank Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CRANK POSITION SENSOR
1. Remove the 2 bolts and crank position sensor.
  
  Fig 33: Disassembling Crank Position Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE KNOCK CONTROL SENSOR
1. Remove the nut and knock control sensor.
  
  Fig 34: Removing Knock Control Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE V-RIBBED BELT TENSIONER ASSY
1. Remove the bolts, nut and V-ribbed belt tensioner.
  
  Fig 35: Removing V-Ribbed Belt Tensioner Assembling
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TRANSVERSE ENGINE MOUNTING BRACKET
1. Remove the 3 bolts and transverse engine mounting bracket.
  
  Fig 36: Removing Transverse Mounting Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MANIFOLD STAY (2WD DRIVE TYPE)
1. Remove the 3 bolts and manifold stay.
  
  Fig 37: Removing Bolts & Manifold Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (2WD DRIVE TYPE)
1. Remove the 4 bolts and exhaust manifold heat insulator.
  
  Fig 38: Removing Exhaust Manifold Heat Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE EXHAUST MANIFOLD (2WD DRIVE TYPE)
1. Remove the 5 nuts, exhaust manifold and gasket.
  
  Fig 39: Removing Nuts, Gasket & Exhaust Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
1. Using SST, remove the E.F.I. engine coolant temperature sensor.
  SST 09817-33190
  
  Fig 40: Removing E.F.I. Engine Coolant Temperature Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RADIO SETTING CONDENSER
1. Remove the bolt and condenser.
  
  Fig 41: Removing Condenser
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE WATER BY-PASS HOSE NO. 2
REMOVE RADIATOR HOSE INLET
REMOVE HEATER INLET WATER HOSE
REPLACE ENGINE ASSY, PARTIAL
INSTALL RADIO SETTING CONDENSER
1. Install the condenser with the bolt.
  Torque: 10 N.m (102 kgf.cm, 7 ft.lbf)
  
  Fig 42: Installing Radio Setting Condenser
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR

Fig 43: Installing E.F.I. Engine Coolant Temperature
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Install a new gasket to the E.F.I. engine coolant temperature sensor.
2. Using SST, install the E.F.I. engine coolant temperature sensor.
  SST 09817-33190
  
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
INSTALL EXHAUST MANIFOLD (2WD DRIVE TYPE)
1. Install a new gasket and the exhaust manifold with the 5 nuts.
  Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
  
  Fig 44: Installing New Gasket & Exhaust Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (2WD DRIVE TYPE)
1. Install the exhaust manifold heat insulator with the 4 bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
  
  Fig 45: Installing Exhaust Manifold Heat Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANIFOLD STAY (2WD DRIVE TYPE)
1. Install the manifold stay with the 3 bolts.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  
  Fig 46: Installing Manifold Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL TRANSVERSE ENGINE MOUNTING BRACKET
1. Install the transverse engine mounting bracket with the 3 bolts.
  Torque: 47 N.m (479 kgf.cm, 35 ft.lbf)
  
  Fig 47: Installing Transverse Engine
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL V-RIBBED BELT TENSIONER ASSY
1. Install the V-ribbed belt tensioner with the bolt and nut.
  Torque:
  
  Nut 29 N.m (296 kgf.cm, 21 ft.lbf)
  
  Bolt 69 N.m (704 kgf.cm, 51 ft.lbf)
  
  Fig 48: Assembling V-Ribbed Belt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KNOCK CONTROL SENSOR
1. Install the knock control sensor with the nut.
  Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
  
  Fig 49: Installing Knock Control Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANK POSITION SENSOR
1. Install the crank position sensor with the 2 bolts.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 50: Installing Crank Position With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL CRANK POSITION SENSOR NO. 1
1. Install the cam position sensor with the bolts.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 51: Assembling Crank Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE OIL PRESSURE SWITCH ASSY (See LUBRICATION SYSTEM - 1ZZ-FE ).
Adhesive: Part No.08833 - 00080, THREE BOND 1344.

SST 09268-46021
INSTALL THERMOSTAT (See REPLACEMENT )
INSTALL WATER INLET
1. Install the water inlet with the 2 nuts.
  Torque: 11 N.m (112 kgf.cm, 8 ft.lbf)
  
  Fig 52: Installing Water Inlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER BY-PASS PIPE NO. 1
1. Install a new gasket and water by-pass with the 2 nuts and 2 bolts.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 53: Assembling New Gasket & Water By-Pass
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL LEVEL GAGE GUIDE
1. Apply a light coat of a new O-ring and install it to the oil level gage guide.
2. Install the oil level gage guide with the bolt.
  Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
  
  Fig 54: Installing Oil Level Gage Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL INTAKE MANIFOLD
1. Install a new gasket to the intake manifold.
2. Install the intake manifold and throttle body assembly with the 2 brackets, 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
  Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
3. Connect the 2 vacuum hoses to the intake manifold.
4. Connect the 2 water hoses to the throttle body.
  
  Fig 55: Assembling Intake Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FUEL DELIVERY PIPE SUB-ASSY (See FUEL RAILS & FUEL INJECTORS )
INSTALL IGNITION COIL ASSY
1. Install the 4 ignition coils with the 4 bolts.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 56: Installing Ignition Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the engine wire with the bolt and nut.
  Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf)
  
  Fig 57: Assembling Engine Wire With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ASSY (See GENERATOR )
INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
1. Fix the crankshaft with SST.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Fig 58: Assembling Flywheel Sub-Assy
  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 59: Installing Bolt & Tightening In Sequence
  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° angle.
  
  Fig 60: Checking Point Marked Bolts Are Moved 90° Angle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE)
1. Fix the crankshaft with SST.
  SST 09960-10010 (09962-01000, 09963-01000)
  
  Fig 61: Installing Crankshaft
  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 62: Installing & Bolt
  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 MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See REPLACEMENT )
INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE, 2WD DRIVE TYPE) (See TRANSAXLE DISASSEMBLY )
INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE, 4WD DRIVE TYPE) (See TRANSAXLE DISASSEMBLY )
INSTALL TRANSFER ASSY (4WD DRIVE TYPE) (See REMOVAL )
INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) (See REMOVAL )
INSTALL TRANSFER STIFFENER PLATE CENTER (4WD DRIVE TYPE) (See REMOVAL )
INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE) (See REMOVAL )
INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See REMOVAL )
INSTALL STARTER ASSY (See REMOVAL & INSTALLATION )
INSTALL EXHAUST MANIFOLD (4WD DRIVE TYPE)
1. Install a new gasket and the exhaust manifold with the 5 nuts.
  Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
  
  Fig 63: Installing Exhaust Manifold (4WD Drive Type)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (4WD DRIVE TYPE)
1. Install the exhaust manifold heat insulator with the 4 bolts.
  Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
  
  Fig 64: Installing Exhaust Manifold Heat Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OXYGEN SENSOR (4WD DRIVE TYPE)
1. Using SST, install the oxygen sensor.
  SST 09224-00010
  
  Torque: 44 N.m (450 kgf.cm, 33 ft.lbf)
  
  Fig 65: Assembling Oxygen Sensor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANIFOLD STAY (4WD DRIVE TYPE)
1. Install the manifold stay with the 2 bolts.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
  
  Fig 66: Installing Manifold Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting 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 67: Installing Front Suspension Crossmember
  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 68: Installing Bolt Holding Front Engine Mounting Bracket To Mounting Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE) (see OVERHAUL )
SST 09023-38200
INSTALL VANE PUMP ASSY (See OVERHAUL )

Fig 69: Installing Vane Pump Assemble
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine with transaxle on the engine lifter.
2. Install the engine with transaxle to the vehicle.
3. Temporarily, install the suspension crossmember and 6 bolts.
4. Install the engine mounting insulator LH.
  Torque: 80 N.m (816 kgf.cm, 59 ft.lbf)
5. Install the engine mounting insulator RH.
  Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
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 70: 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.
  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 right-handle of the vehicle, then tighten the bolts with a specified torque.
11. Insert SST to the positioning holes on the right-handle crossmember and left-handle of the vehicle, then tighten the bolts with a specified torque.
  SST 09670-00010
  
  Torque:
  
  Bolt A 157N.m (1,601 kgf.cm, 116 ft.lbf)
  
  Bolt B 113N.m (1,152 kgf.cm, 83 ft.lbf)
  
  Fig 71: Installing Crossmember & Left-Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Tighten the 2 bolts, as shown in the illustration.
  Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
  
  NOTE: After installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
  
  Fig 72: Tightening Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See AXLE SHAFTS - 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 OVERHAUL )
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 AXLE SHAFTS - FRONT )
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.
TEMPORARY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE) (See OVERHAUL )
INSTALL EXHAUST PIPE ASSY FRONT (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
INSTALL EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See FUEL PUMP )
INSTALL FLOOR PANEL BRACE FRONT
1. Install front floor panel brace with the 2 nuts.
  Torque: 30 N.m (306 kgf.cm, 22 ft.lbf)
INSTALL FRONT SEAT ASSY RH (4WD DRIVE TYPE) (See OVERHAUL )
INSTALL STEERING INTERMEDIATE SHAFT (See OVERHAUL )
INSTALL RETURN TUBE SUB-ASSY
1. 2WD
  
  Fig 73: Installing Return Type Sub Assy 2WD
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the return tube with 2 bolts.
    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)
2. 4WD
  
  Fig 74: Installing Return Type 4WD
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  1. Install the return tube with 3 bolts.
    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 REPLACEMENT ).
INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
1. Install the actuator with the 2 bolts.
  Torque: 6.0 N.m (61 kgf.cm, 53 in.lbf)
2. Connect the actuator connector.
  
  Fig 75: Installing Actuator With & Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY WITH HOSE
1. Install the air cleaner case with the 3 bolts.
  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. Install the air cleaner cap.
5. Connect the air cleaner hose.
  
  Fig 76: Assembling Air Cleaner & Hose Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect 3 vacuum hoses, as shown in the illustration.
7. Connect the VSV connector.
8. Connect the intake air flow meter connector.
  
  Fig 77: Connecting Vacuum Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY CARRIER
1. Install the battery carrier with the 4 bolts.
  Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
  
  Fig 78: Installing Battery Carrier
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY
Torque:

Bolt 5.0 N.m (51 kgf.cm, 44 in.lbf)

Nut 3.0 - 4.0 N.m (31 - 41 kgf.cm, 27 - 35 in.lbf)
INSTALL RADIATOR SUPPORT UPPER (W/ AIR CONDITIONER)
1. Install the 2 radiator support uppers with the 2 bolts.
  Torque: 19 N.m (194 kgf.cm, 14 ft.lbf)
INSTALL CYLINDER HEAD COVER NO. 2
1. Install the cylinder head cover with the 2 nuts and 2 clips.
  Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf)
  
  Fig 79: Assembling Cylinder Head Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WHEELS
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
ADD TRANSFER OIL (4WD DRIVE TYPE)
1. Install a new gasket and the filler plug.
  Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
ADD AUTOMATIC TRANSAXLE FLUID (4WD DRIVE TYPE)
ADD ENGINE OIL
ADD COOLANT (See REPLACEMENT )
CHECK ENGINE OIL LEAK
CHECK ENGINE COOLANT LEAK (See REPLACEMENT )
CHECK FUEL LEAK
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