Camry 2008-2009

Engine 2

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Removal & Installation



2.4L Engine
Non-hybrid

Specific to:

Toyota Camry 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Make sure wheels are pointing straight ahead.
  6.  
  7. Remove or disconnect the following:
    1. Front wheels.
    2.  
    3. Right and left hand engine under covers.
    4.  
    5. Front fender apron seal.
    6.  

  8.  
  9. Drain engine oil.
  10.  
  11. Drain and recycle the engine coolant.
  12.  
  13. If vehicle is equipped with an automatic transaxle, drain the transaxle fluid.
  14.  
  15. If the vehicle is equipped with a manual transaxle, drain the transaxle fluid.
  16.  
  17. Drain the brake fluid.
  18.  
  19. Remove or disconnect the following:


    1. Windshield wiper link assembly.
    2.  
    3. Cowl top panel.
    4.  
    5. Plastic engine cover.
    6.  
    7. Air cleaner assembly.
    8.  
    9. Battery.

      Click image to see an enlarged view

      Fig. Removing No. 2 engine mounting stay



      Click image to see an enlarged view

      Fig. Disconnecting the ground cable



      Click image to see an enlarged view

      Fig. Removing the engine mount and three bolts

    10.  
    11. No. 2 engine mounting stay
    12.  
    13. Ground cable.
    14.  
    15. Three bolts and the engine mount
    16.  
    17. Three bolts and No. 2 right hand mounting bracket.
    18.  
    19. No. 1 Vacuum hose clamp and disconnect the vacuum hose connector.

      Click image to see an enlarged view

      Fig. Removing the No. 2 right hand mounting bracket and three bolts



      Click image to see an enlarged view

      Fig. Removing the No. 1 Vacuum hose clamp and vacuum hose connector

    20.  
    21. Clamp and radiator inlet and outlet hose.
    22.  
    23. For automatic transaxle, oil cooler inlet and outlet hose.
    24.  
    25. Heater inlet and outlet hose.
    26.  
    27. ECM.

      Click image to see an enlarged view

      Fig. Removing the Engine wire from the engine room relay block



      Click image to see an enlarged view

      Fig. Removing the two bolts and clamp from the body

    28.  
    29. Engine wire from the engine room relay block.
    30.  
    31. Nut and separate the wire harness.
    32.  
    33. Using a screwdriver, unlock the engine room R/B. Pull the engine room R/B upward.
    34.  
    35. Engine wire connectors
    36.  
    37. Clamp from the bracket
    38.  
    39. Two bolts and clamp from the body
    40.  
    41. For automatic transaxle vehicles, clip and nut and separate the control lever. Separate the clamp and separate the cable from the transaxle
    42.  
    43. For manual transaxle vehicles, two clips and two washers. Disconnect the 2 cables from the transaxle. Remove the 2 clips and disconnect the 2 cables from the control cable bracket.
    44.  
    45. No. 1 oil reservoir to pump hose.
    46.  
    47. Return tube sub-assembly
    48.  
    49. For manual transaxle vehicles, clutch accumulator assembly. Clutch release cylinder assembly.
      NOTE
      Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector. Disconnect the connector by hand. Do not bend, fold or rotate the nylon tube. If the pipe and connector are stuck together, push and pull the connector until it becomes free. Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

    50.  
    51. No. 1 fuel pipe clamp. Disconnect the connector from the tube.
    52.  
    53. Generator assembly.
    54.  
    55. A/C compressor and magnetic clutch.
    56.  
    57. Front exhaust pipe assembly.
    58.  
    59. Left and right axle hub assembly.
    60.  
    61. Left and right front stabilizer link assembly.
    62.  
    63. Left and right front speed sensor.
    64.  
    65. Left and right tie rod assembly.
    66.  
    67. Left and right front suspension lower arm.
    68.  
    69. Left and right front axle assembly
    70.  
    71. Drive plate and torque converter clutch setting bolt (A/T).
    72.  
    73. Two bolts and exhaust pipe support bracket.
    74.  
    75. Separate steering sliding yoke.
    76.  
    77. Set the engine lifter.
    78.  
    79. Four bolts, two nuts and front suspension member brace rear RH and LH

      Click image to see an enlarged view

      Fig. Installing the 2 engine hangers

    80.  

  20.  
  21. Install the 2 engine hangers and tighten to 28 ft. lbs. (38 Nm):

    No. 1 engine hanger: Part No. 12281-28010
     
    No. 2 engine hanger: Part No. 12282-28010
     

  22.  
  23. Using a chain block and an engine sling device, hang the engine assembly.
  24.  
  25. Disconnect the oil pressure switch connector.
  26.  
  27. Loosen the 2 bolts and remove the vane pump from the engine.
  28.  
  29. Remove the front frame assembly by performing the following:

    Click image to see an enlarged view

    Fig. Removing the nut from the LH engine mounting insulator-A/T



    Click image to see an enlarged view

    Fig. Removing the nut from the LH engine mounting insulator-M/T



    Click image to see an enlarged view

    Fig. Removing the nut from the RH engine mounting insulator



    Click image to see an enlarged view

    Fig. Removing the nut from the FR engine mounting insulator




    1. For A/T vehicles, remove the nut from the LH engine mounting insulator.
    2.  
    3. For M/T vehicles, remove the bolt from the LH engine mounting insulator.
    4.  
    5. Remove the nut from the RH engine mounting insulator.
    6.  
    7. Remove the bolt from the FR engine mounting insulator.
    8.  
    9. For M/T vehicles, remove the bolt from the engine lateral control rod

      Click image to see an enlarged view

      Fig. Removing the bolt from the engine lateral control rod-M/T

    10.  

  30.  
  31. Raise the engine assembly and separate the front frame.
  32.  
  33. Remove or disconnect the following:


    1. LH and RH front drive shaft assembly.
    2.  
    3. Engine wire harness.
    4.  
    5. Starter assembly.
    6.  
    7. Separate A/T assembly or M/T assembly
    8.  
    9. Drive plate and ring gear for A/T.
    10.  
    11. Clutch cover, disc and flywheel assembly for M/T.
    12.  

  34.  
  35. Fix the engine on to a engine stand with the bolts.
  36.  
  37. Remove or disconnect the following:


    1. Fuel delivery pipe with injector.
    2.  
    3. Intake manifold.
    4.  
    5. IAT (for PZEV).
    6.  
    7. Ventilation hose
    8.  
    9. Intake manifold insulator.
    10.  
    11. Drive shaft bearing bracket.
    12.  
    13. Oil level tube and guide.
    14.  
    15. Manifold/catalytic bolt, nut and stay.
    16.  
    17. For PZEV vehicles, air-fuel ratio sensor connector
    18.  
    19. For PZEV vehicles, five nuts, manifold converter and gasket.
    20.  
    21. Except PZEV vehicles, four bolts and No. 1 insulator.
    22.  
    23. Except PZEV vehicles IAT.
    24.  
    25. Except PZEV five nuts, manifold converter and gasket.
    26.  
    27. Water inlet.
    28.  
    29. Thermostat.
    30.  
    31. Two nuts and water by-pass pipe with the gasket.
    32.  
    33. For vehicles with oil cooler pipe; bolt, 2 nuts and oil cooler pipe with the gasket.
    34.  
    35. Three bolts and RH engine mounting bracket.
    36.  
    37. Bolt, nut and belt tensioner.
    38.  
    39. Four bolts and four ignition coils.
    40.  
    41. Camshaft timing oil control valve assembly.
    42.  
    43. Knock sensor connector, nut and knock sensor.
    44.  
    45. Bolt and radio setting condenser.
    46.  
    47. Engine oil pressure switch assembly, using a 24 mm deep socket wrench.
    48.  
    49. ECT sensor and gasket using Special Tool: 09817-33190.
    50.  

  38.  

To install:

  1. To install, reverse removal procedure.
  2.  
  3. Tighten the following to specification:

    Drive belt tensioner with the bolt and nut: 44 ft. lbs. (60 Nm)
     
    RH engine mounting bracket with the 3 bolts: 40 ft. lbs. (54 Nm)
     
    Oil cooler pipe: 80 inch lbs. (9 Nm)
     
    Water by-pass pipe bolt, two nuts and install a new gasket: 80 inch lbs. (9 Nm)
     
    Oil level gauge guide bolt: 80 inch lbs. (9 Nm)
     
    LH engine mounting insulator nut-A/T: 70 ft. lbs. (95 Nm)
     
    LH engine mounting insulator bolt-M/T: 105 ft. lbs. (143 Nm)
     
    RH engine mounting insulator nut: 70 ft. lbs. (95 Nm)
     
    FR engine mounting insulator bolt: 64 ft. lbs. (87 Nm)
     
    Engine lateral control rod bolt-M/T: 66 ft. lbs. (89 Nm)
     
    Engine room junction block nut: 74 inch lbs. (8.4 Nm)
     
    RH engine mountain bracket bolts: 38 ft. lbs. (52 Nm)
     
    Engine mount bolts: 47 ft. lbs. (64 Nm)
     
    Ground cable bolt: 74 inch lbs. (8.4 Nm)
     
    RH engine mounting stay bolts: 47 ft. lbs. (64 Nm).
     
    Front wheel: 76 ft. lbs. (103 Nm)
     

  4.  
  5. Add fluids and check for leaks.
  6.  
  7. Bleed power steering, brakes lines and clutch lines.
  8.  
  9. Check shift lever position.
  10.  
  11. Adjust front wheel alignment.
  12.  
  13. Check ignition timing.
  14.  
  15. Check engine idle speed.
  16.  
  17. Inspect CO/HC.
  18.  
  19. Check ABS speed sensor signal.
  20.  

3.5L Engine

Specific to:

Toyota Camry 2007-2008

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Prevent gasoline from spilling out.
  4.  
  5. Remove front wheels.
  6.  
  7. Remove the engine under covers.
  8.  
  9. Remove the right front fender apron seal.
  10.  
  11. Drain engine oil.
  12.  
  13. Drain engine coolant.
  14.  
  15. Drain automatic transaxle fluid.
  16.  
  17. Remove the windshield wiper link assembly.
  18.  
  19. Remove the cowl top panel outer sub-assembly.
  20.  
  21. Remove the 7 clips and intake duct seal.
  22.  
  23. Remove the V-bank cover sub-assembly.
  24.  
  25. Remove the drive belt.
  26.  
  27. Remove the 2 bolts, clamp and air cleaner inlet.
  28.  
  29. Remove air cleaner cap sub-assembly.
  30.  
  31. Remove the air cleaner assembly with hose, as follows:
    1. Disconnect the vacuum hoses and hose clamp.
    2.  
    3. Remove the 3 bolts and air cleaner case.
    4.  

  32.  
  33. Remove the bolt and No. 1 air cleaner inlet.
  34.  
  35. Loosen the bolt and nut, and remove the battery clamp.
  36.  
  37. Remove the clip, bolt and intake air resonator.
  38.  
  39. Remove the bolt, 2 nuts, and No. 2 RH mounting stay.
  40.  
  41. Remove the 4 bolts and engine moving control rod

    Click image to see an enlarged view

    Fig. Removing the 4 bolts and engine moving control rod

  42.  
  43. Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
  44.  
  45. Remove the clamp and disconnect the check valve to brake booster hose.
  46.  
  47. Remove the clamp and disconnect the radiator inlet and outlet hose.
  48.  
  49. Remove the oil cooler inlet and outlet hoses.
  50.  
  51. Disconnect the heater water inlet and outlet hose.
  52.  
  53. Remove the upper relay block cover.
  54.  
  55. Disconnect the engine wire from the engine room junction block, as follows:
    1. Remove the nut and separate the wire harness.
    2.  
    3. Using a screwdriver, unlock the engine room junction block. Pull the engine room junction block upward.
    4.  
    5. Disconnect the engine wire connectors.
    6.  
    7. Remove the 2 bolts and 2 clamps from the body.
    8.  
    9. Remove the bolt and clamp from the bracket.

      Click image to see an enlarged view

      Fig. Disconnecting the engine wire from the engine room junction block

    10.  

  56.  
  57. Disconnect the transmission control cable assembly. Remove the clip and nut, and separate the cable from the transaxle.
  58.  
  59. Separate the fuel tube sub-assembly, as follows:
    1. Remove the No. 1 fuel pipe clamp.
    2.  
    3. Disconnect the connector from the tube while pinching part A with your fingers.
      NOTE
      Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.


      NOTE
      Disconnect the connector by hand.


      NOTE
      Do not bend, fold or rotate the nylon tube.


      NOTE
      If the pipe and connector are stuck together, push and pull the connector until it comes free.


      NOTE
      Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

    4.  

  60.  
  61. Disconnect the oil reservoir to No. 1 pump hose.
  62.  
  63. Disconnect the return tube sub-assembly.
  64.  
  65. Remove the No. 1 exhaust pipe support bracket.
  66.  
  67. Remove the front exhaust pipe assembly.
  68.  
  69. Remove the left front axle shaft nut, as follows:
  70.  
  71. Using SST (SST: 09930-00010) or equivalent and a hammer, strike the lock nut covering to remove it.
    1. Set the drive shaft's groove so that it faces up. Then use the SST and a hammer.
    2.  
    3. Remove the covering from the lock nut completely. Otherwise the screw of the drive shaft may be damaged.
    4.  
    5. Do not sharpen the tip of the SST.
    6.  
    7. Using a 30 mm socket wrench, remove the lock nut.
    8.  

  72.  
  73. Remove the right front axle shaft nut.
  74.  
  75. Disconnect the left front stabilizer link assembly, as follows:
    1. Using a 6 mm socket hexagon wrench, hold the ball stud.
    2.  
    3. Remove the nut and disconnect the stabilizer link.
    4.  

  76.  
  77. Disconnect the right front stabilizer link assembly.
  78.  
  79. Remove the bolts and disconnect the right and left front speed sensors from the steering knuckle.
  80.  
  81. Disconnect the left and right tie rod assemblies, as follows:
    1. Remove the cotter pin and nut.
    2.  
    3. Using SST (SST: 09628-62011) or equivalent, disconnect the tie rod ends from the steering knuckle.
      NOTE
      Do not damage the dust cover of the ball joint.

    4.  

  82.  
  83. Disconnect the lower No. 1 left and right front suspension arm sub-assemblies, as follows:
    1. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
    2.  
    3. Using a plastic hammer, disconnect the drive shaft from the axle hub.
    4.  

  84.  
  85. Separate left and right front axle assembly.
  86.  
  87. Remove the No. 1 exhaust pipe support bracket with the 2 bolts.
  88.  
  89. Remove the drive plate and torque converter clutch setting bolt, as follows:
    1. Using SST (SST: 09213-70011, SST: 09330-00021) or equivalent, hold the crankshaft.
    2.  
    3. Remove the 2 bolts and flywheel housing under cover.
    4.  
    5. Remove the 6 torque converter clutch setting bolts.
    6.  

  90.  
  91. Disconnect steering sliding yoke.
  92.  
  93. Remove generator assembly.
  94.  
  95. Separate the cooler compressor assembly, as follows:
    1. Remove the 2 connector clamps.
    2.  
    3. Remove the 4 bolts and separate the compressor.
      NOTE
      Hang up the hoses instead of detaching them.

    4.  

  96.  
  97. Remove the engine assembly with transaxle, as follows:
    1. Set the engine lifter.
    2.  
    3. Remove the 4 bolts, 2 nuts, and right and left frame side rail plates.
    4.  
    5. Remove the 4 bolts, 2 nuts, front suspension member right and left rear brace.
    6.  
    7. Operate the engine lifter, then remove the engine assembly from the vehicle.
      NOTE
      Make sure the engine is clear of all wiring and hoses.

    8.  

  98.  
  99. Remove the vane pump assembly, as follows:
    1. Remove the pressure feed tube clamp bolt.
    2.  
    3. Remove the 2 bolts, nut and vane pump.
    4.  

  100.  
  101. Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part numbers: Engine hanger No. 1 12281-31120, Engine hanger No. 2 12282-31100, Bolts 91671-10825. Torque to 24 ft. lbs. (33 Nm).

    Click image to see an enlarged view

    Fig. Install the 2 engine hangers

    1. Attach the engine sling device and hang the engine with the chain block.
    2.  

  102.  
  103. Remove the front frame assembly, as follows:
    1. Disconnect the connector and clamp.
    2.  
    3. Disconnect the 2 clamps.
    4.  
    5. Remove the 2 nuts and disconnect the right and left engine mounting insulators.
    6.  
    7. Remove the bolt and disconnect the engine mounting insulator FR.
    8.  

  104.  
  105. Remove the right and left front drive shaft assemblies.
  106.  
  107. Remove the engine wire.
  108.  
  109. Remove the starter assembly.
  110.  
  111. Remove the automatic transaxle assembly.
  112.  
  113. Remove the drive plate and ring gear sub-assembly.
  114.  
  115. Install engine stand.
  116.  
  117. Remove intake air surge tank assembly, as follows:
    1. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly
    2.  
    3. Disconnect the vapor feed hose.
    4.  
    5. Disconnect the throttle with motor body assembly connector and clamp.
    6.  
    7. Disconnect the No. 1 ventilation hose.
    8.  
    9. Remove the bolt and vacuum hose clamp.
    10.  
    11. Disconnect the connector.
    12.  
    13. Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket.
    14.  
    15. Using a 5 mm socket hexagon wrench, remove the 4 bolts. Remove the 2 nuts and intake air surge tank. Remove the gasket from the intake air surge tank.
    16.  

  118.  
  119. Remove the ignition coil assembly.
  120.  
  121. Remove the bolt and the No. 2 RH engine mounting stay.
  122.  
  123. Remove the intake manifold, as follows:
    1. Uniformly loosen and remove the 6 bolts and 4 nuts.
    2.  
    3. Remove the intake manifold and 2 gaskets.
    4.  

  124.  
  125. Remove the right exhaust manifold sub-assembly, as follows:
    1. Disconnect the A/F sensor connector clamp.
    2.  
    3. Uniformly loosen and remove the 6 nuts.
    4.  
    5. Remove the manifold and gasket.
    6.  

  126.  
  127. Remove the oil level gauge guide sub-assembly, as follows:
    1. Remove the oil level gauge.
    2.  
    3. Remove the 2 bolts, and No. 1 and No. 2 oil level gauge guides.
    4.  
    5. Remove the O-rings from the oil level gauge guide.
    6.  

  128.  
  129. Remove the 2 bolts and the No. 2 manifold stay.
  130.  
  131. Remove the 3 bolts and the No. 2 exhaust manifold heat insulator.
  132.  
  133. Remove the left exhaust manifold sub-assembly, as follows:
    1. Uniformly loosen and remove the 6 nuts.
    2.  
    3. Remove the manifold and gasket.
    4.  

  134.  
  135. Remove the 3 bolts and the right engine mounting bracket.
  136.  
  137. Remove the 3 bolts and drive shaft bearing bracket.
  138.  
  139. Remove the 5 bolts and V-ribbed belt tensioner assembly.
  140.  
  141. Remove the 2 bolts and the No. 2 timing gear cover.
  142.  
  143. Remove the bolt, plate and No. 2 idler pulley sub-assembly.
  144.  
  145. Remove the water pump pulley.
  146.  
  147. Remove the 6 bolts and No. 1 left front engine mounting bracket.
  148.  
  149. Remove the 2 bolts and 2 radio setting condensers.
  150.  
  151. Remove the bolt and No. 1 vacuum switching valve.
  152.  
  153. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
  154.  
  155. Remove 2 bolts and 2 knock control sensors.
  156.  
  157. Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket.
  158.  
  159. Replace partial engine assembly as necessary.
  160.  

To install:

  1. Using a 19 mm deep socket wrench, install the EFI engine coolant temperature sensor and a new gasket and tighten to 14 ft. lbs. (20 Nm).
  2.  
  3. Install the knock control sensor.
  4.  
  5. Install the engine oil pressure switch assembly, as follows:
    1. Clean the threads of the oil pressure switch. Apply adhesive (Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent) to 2 or 3 threads of the oil pressure switch.
    2.  
    3. Using a 24 mm deep socket wrench install the oil pressure switch and tighten to 15 ft. lbs. (21 Nm). Install the left front No. 1 engine mounting bracket with the 6 bolts and tighten to 40 ft. lbs. (54 Nm).
    4.  

  6.  
  7. Install the bolt and No. 1 vacuum switching valve and tighten to 7 ft. lbs. (10 Nm).
  8.  
  9. Install the 2 bolts and 2 radio setting condensers and tighten to 7 ft. lbs. (10 Nm).
  10.  
  11. Install the No. 1 engine mounting bracket front LH with the 6 bolts and tighten to 40 ft. lbs. (54 Nm).
  12.  
  13. Install the water pump pulley.
  14.  
  15. Install the No. 2 idler pulley sub-assembly and cover plate with the bolt and tighten to 32 ft. lbs. (43 Nm).
  16.  
  17. Install the No. 2 timing gear cover with the 2 bolts and tighten to 53 inch lbs. (6 Nm).
  18.  
  19. Install the V-ribbed belt tensioner assembly, as follows:
    1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
    2.  
    3. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration to 32 ft. lbs. (43 Nm).

      Click image to see an enlarged view

      Fig. V-ribbed belt tensioner bolt tightening sequence

    4.  
    5. Tighten the other bolts to 32 ft. lbs. (43 Nm). Bolt length: A: 70 mm (2.76 in.), B: 33 mm (1.30 in.)
    6.  

  20.  
  21. Install the drive shaft bearing bracket with the 3 bolts and tighten to 47 ft. lbs. (64 Nm).
  22.  
  23. Install the engine mounting bracket RH with the 3 bolts and tighten to 40 ft. lbs. (54 Nm).
  24.  
  25. Install the left exhaust manifold sub-assembly, as follows:
    1. Install a new gasket.
    2.  
    3. Install the exhaust manifold sub-assembly with the 6 nuts and tighten to 15 ft. lbs. (21 Nm).
    4.  

  26.  
  27. Install the No. 2 exhaust manifold heat insulator with the 3 bolts and tighten to 75 inch lbs. (8.5 Nm).
  28.  
  29. Install the No. 2 manifold stay with the 2 bolts and tighten to 25 ft. lbs. (34 Nm).
  30.  
  31. Install the oil level gauge guide sub-assembly, as follows:
    1. Install 2 new O-rings to the oil level gauge guide.
    2.  
    3. Apply a coat of engine oil lightly to the O-rings.
    4.  
    5. Push in the oil level gauge guide end into the guide hole.
    6.  
    7. Install the No. 1 oil level gauge guide with the bolt and tighten to 15 ft. lbs. (21 Nm).
    8.  
    9. Install the No. 2 oil level gauge guide with the bolt and tighten to 15 ft. lbs. (21 Nm).
    10.  
    11. Install the oil level gauge.
    12.  

  32.  
  33. Install the right exhaust manifold sub-assembly, as follows:
    1. Install a new gasket.
    2.  
    3. Install the exhaust manifold sub-assembly with the 6 nuts and tighten to 15 ft. lbs. (21 Nm).
    4.  

  34.  
  35. Install the intake manifold.
  36.  
  37. Install the right No. 2 mounting stay with the bolt and tighten to 15 ft. lbs. (21 Nm).
  38.  
  39. Install the 6 ignition coil assemblies with the 6 bolts and tighten to 7 ft. lbs. (10 Nm).
    CAUTION
    DO NOT apply oil to the following bolts: surge tank and intake manifold, No. 1 surge tank stay and cylinder head cover, No. 1 surge tank stay and surge tank, throttle body bracket and cylinder head cover, throttle body bracket and surge tank.

    1. Install a new gasket to the intake air surge tank.
    2.  
    3. Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts. Tighten the bolts to 13 ft. lbs. (18 Nm). Tighten the nuts to 12 ft. lbs. (16 Nm).
    4.  
    5. Install the throttle body bracket, No. 1 surge tank stay and 4 bolts and tighten to 15 ft. lbs. (21 Nm).
    6.  
    7. Connect the connector.
    8.  
    9. Install the vacuum hose clamp with the bolt and tighten to 48 inch lbs. (5.4 Nm).
    10.  
    11. Connect the No. 1 ventilation hose.
    12.  
    13. Install the clamp and connect the throttle with motor body assembly connector.
    14.  
    15. Connect the vapor feed hose.
    16.  
    17. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
    18.  

  40.  
  41. Remove the engine stand.
  42.  
  43. Install the drive plate and ring gear sub-assembly.
  44.  
  45. Install the automatic transaxle assembly.
  46.  
  47. Install the starter assembly.
  48.  
  49. Install the engine wire.
  50.  
  51. Install the right and left front drive shaft assemblies.
  52.  
  53. Install the front frame assembly, as follows:
    1. Install the right and left engine mounting insulators and with the 2 nuts and tighten 70 ft. lbs. (95 Nm).
    2.  
    3. Install the engine mounting insulator FR with the bolt and tighten 64 ft. lbs. (87 Nm).
    4.  
    5. Connect the connector and clamp.
    6.  
    7. Connect the 2 clamps.
    8.  

  54.  
  55. Install the vane pump assembly, as follows:
    1. Install the vane pump with the 2 bolts and nut and tighten 32 ft. lbs. (43 Nm).
    2.  
    3. Install the pressure feed tube clamp bolt and tighten 87 inch lbs. (9.8 Nm).
    4.  
    5. Connect the power steering oil pressure switch connector.
    6.  

  56.  
  57. Install the engine assembly with transaxle, as follows:
    1. Set the engine assembly with transaxle on the engine lifter.
    2.  
    3. Install the engine assembly to the vehicle.
    4.  
    5. Install the right and left frame side rail plates and with the 4 bolts and 2 nuts. Tighten A to 63 ft. lbs. (85 Nm) and B to 24 ft. lbs. (32 Nm).
    6.  
    7. Install the right and left front suspension member rear braces with the 4 bolts and 2 nuts. Tighten C to 63 ft. lbs. (85 Nm) and D to 24 ft. lbs. (32 Nm).

      Click image to see an enlarged view

      Fig. Installing suspension braces

    8.  

  58.  
  59. Install the cooler compressor assembly.
  60.  
  61. Install generator assembly.
  62.  
  63. Install the steering intermediate shaft assembly.
  64.  
  65. Install drive plate and torque converter clutch setting bolt, as follows:
    1. Using SST (SST: 09213-70011, SST: 09330-00021) or equivalent, hold the crankshaft.
    2.  
    3. Using kerosene or gasoline, clean the bolts thoroughly.
    4.  
    5. Apply adhesive (Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent) to 2 or 3 threads of the bolt end.
    6.  
    7. Install the 6 torque converter set bolts and tighten 30 ft. lbs. (41 Nm). First tighten the green colored bolt, then the other 5 bolts.
    8.  
    9. Install the flywheel housing under cover with the 2 bolts and tighten 69 inch lbs. (7.8 Nm).
    10.  

  66.  
  67. Install the No. 1 exhaust pipe support bracket with the 2 bolts and tighten 15 ft. lbs. (21 Nm).
  68.  
  69. Install both front axle assemblies.
  70.  
  71. Install the lower right and left No. 1 suspension arm sub-assemblies, as follows:
    1. Install the drive shaft to the steering knuckle.
    2.  
    3. Install the suspension lower arm with the bolt and 2 nuts and tighten 55 ft. lbs. (75 Nm).
    4.  

  72.  
  73. Install the left and right tie rod assemblies, as follows:
    1. Connect the tie rod end to the steering knuckle with the castle nut and tighten 36 ft. lbs. (49 Nm).
      NOTE
      Do not allow lubricants to contact the thread and taper portions.


      NOTE
      After tightening the castle nut, tighten additional 60° so that a cotter pin can be inserted.

    2.  
    3. Insert a new cotter pin.
    4.  

  74.  
  75. Install the right and left front speed sensors.
  76.  
  77. Install the right and left front stabilizer link assemblies, as follows:
    1. Using a 6 mm socket hexagon wrench, hold the ball stud and install the nut and tighten 55 ft. lbs. (74 Nm).
    2.  

  78.  
  79. Install the right and left front axle shaft hub nuts, as follows:
    1. Using a 30 mm socket wrench, install a new hub nut and tighten 217 ft. lbs. (294 Nm).
    2.  
    3. Using a chisel and hammer, tap the hub nut.
    4.  

  80.  
  81. Install the front exhaust pipe assembly.
  82.  
  83. Install the No. 1 exhaust pipe support bracket.
  84.  
  85. Connect the oil reservoir to the No. 1 pump hose.
  86.  
  87. Connect the steering gear outlet return tube.
  88.  
  89. Connect the fuel tube sub-assembly, as follows:
    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. Check if the pipe and the connector are securely connected by trying to pull them apart.

    2.  
    3. Install the No. 1 fuel pipe clamp .
    4.  

  90.  
  91. Connect the transmission control cable assembly. Install the clip and nut, and connect the cable to the transaxle. Tighten the nut to 9 ft. lbs. (13 Nm).
  92.  
  93. Connect engine wire, as follows:
    1. Install the bolt and clamp to the bracket. Tighten 74 inch lbs. (8.4 Nm).
    2.  
    3. Install the 2 bolts and 2 clamps to the body.
    4.  
    5. Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors. Tighten to 74 inch lbs. (8.4 Nm).
    6.  

  94.  
  95. Install upper relay block cover upper.
  96.  
  97. Connect the heater water outlet and inlet hose.
  98.  
  99. Connect the oil cooler inlet and outlet hoses.
  100.  
  101. Install the radiator inlet and outlet hoses.
  102.  
  103. Install the clamp and connect the check valve to brake booster hose.
  104.  
  105. Install the clamp and connect the No. 1 fuel vapor feed hose.
  106.  
  107. Install the engine moving control rod, as follows:
    1. Temporarily install the moving control rod with the 4 bolts.
    2.  
    3. Tighten the bolt A to 28 ft. lbs. (38 Nm).
    4.  
    5. Tighten the bolt B in the order shown in the illustration to 28 ft. lbs. (38 Nm).

      Click image to see an enlarged view

      Fig. Engine moving control rod bolt tightening sequence

    6.  

  108.  
  109. Temporarily install the right No. 2 mounting stay with the bolts and 2 nuts. Tighten to 17 ft. lbs. (23 Nm).
  110.  
  111. Install the intake air resonator with the bolt and clip and tighten to 44 inch lbs. (5 Nm).
  112.  
  113. Install the battery and battery tray.
  114.  
  115. Install the No. 1 air cleaner inlet with the bolt and tighten 44 inch lbs. (5 Nm).
  116.  
  117. Install the air cleaner case sub-assembly, as follows:
    1. Install the air cleaner case with the 3 bolts and tighten 44 inch lbs. (5 Nm).
    2.  
    3. Connect the vacuum hose and hose clamp.
    4.  

  118.  
  119. Install the air cleaner cap sub-assembly.
  120.  
  121. Install the air cleaner inlet with the clamp and 2 bolts and tighten to 44 inch. lbs. (5 Nm).
  122.  
  123. Connect vacuum hoses.

    Click image to see an enlarged view

    Fig. Connecting vacuum hoses

  124.  
  125. Install drive belt.
  126.  
  127. Install the outer cowl top panel.
  128.  
  129. Install the windshield wiper link assembly.
  130.  
  131. Install the front wheels.
  132.  
  133. Add automatic transaxle fluid.
  134.  
  135. Add engine oil.
  136.  
  137. Add engine coolant.
  138.  
  139. Add power steering fluid.
  140.  
  141. Bleed power steering system.
  142.  
  143. Inspect for oil leak, coolant leak, fuel leak, and exhaust gas leak.
  144.  
  145. Inspect and adjust front wheel alignment.
  146.  
  147. Inspect ignition timing and engine idle speed.
  148.  
  149. Check function of throttle body.
  150.  
  151. Install the V-bank cover sub-assembly.
  152.  
  153. Inspect CO/HC.
  154.  
  155. Check ABS speed sensor signal.
  156.  
  157. Perform initialization.
  158.  

Specific to:

Toyota Camry 2009-2010

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Prevent gasoline from spilling out.
  4.  
  5. Remove front wheels.
  6.  
  7. Remove the engine under covers.
  8.  
  9. Remove the right front fender apron seal.
  10.  
  11. Drain engine oil.
  12.  
  13. Drain engine coolant.
  14.  
  15. Drain automatic transaxle fluid.
  16.  
  17. Remove the windshield wiper link assembly.
  18.  
  19. Remove the cowl top panel outer sub-assembly.
  20.  
  21. Remove the 7 clips and intake duct seal.
  22.  
  23. Remove the V-bank cover sub-assembly.
  24.  
  25. Remove the drive belt.
  26.  
  27. Remove the 2 bolts, clamp and air cleaner inlet.
  28.  
  29. Remove air cleaner cap sub-assembly.
  30.  
  31. Remove the air cleaner assembly with hose, as follows:
    1. Disconnect the vacuum hoses and hose clamp.
    2.  
    3. Remove the 3 bolts and air cleaner case.
    4.  

  32.  
  33. Remove the bolt and No. 1 air cleaner inlet.
  34.  
  35. Loosen the bolt and nut, and remove the battery clamp.
  36.  
  37. Remove the clip, bolt and intake air resonator.
  38.  
  39. Remove the bolt, 2 nuts, and No. 2 RH mounting stay.
  40.  
  41. Remove the 4 bolts and engine moving control rod

    Click image to see an enlarged view

    Fig. Removing the 4 bolts and engine moving control rod

  42.  
  43. Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
  44.  
  45. Remove the clamp and disconnect the check valve to break booster hose.
  46.  
  47. Remove the clamp and disconnect the radiator inlet and outlet hose.
  48.  
  49. Remove the oil cooler inlet and outlet hoses.
  50.  
  51. Disconnect the heater water inlet and outlet hose.
  52.  
  53. Remove the upper relay block cover.
  54.  
  55. Disconnect the engine wire from the engine room junction block, as follows:
    1. Remove the nut and separate the wire harness.
    2.  
    3. Using a screwdriver, unlock the engine room junction block. Pull the engine room junction block upward.
    4.  
    5. Disconnect the engine wire connectors.
    6.  
    7. Remove the 2 bolts and 2 clamps from the body.
    8.  
    9. Remove the bolt and clamp from the bracket.

      Click image to see an enlarged view

      Fig. Disconnecting the engine wire from the engine room junction block

    10.  

  56.  
  57. Disconnect the transmission control cable assembly. Remove the clip and nut, and separate the cable from the transaxle.
  58.  
  59. Separate the fuel tube sub-assembly, as follows:
    1. Remove the No. 1 fuel pipe clamp.
    2.  
    3. Disconnect the connector from the tube while pinching part A with your fingers.
      NOTE
      Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.


      NOTE
      Disconnect the connector by hand.


      NOTE
      Do not bend, fold or rotate the nylon tube.


      NOTE
      If the pipe and connector are stuck together, push and pull the connector until it comes free.


      NOTE
      Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

    4.  

  60.  
  61. Disconnect the oil reservoir to No. 1 pump hose.
  62.  
  63. Disconnect the return tube sub-assembly.
  64.  
  65. Remove the No. 1 exhaust pipe support bracket.
  66.  
  67. Remove the front exhaust pipe assembly.
  68.  
  69. Remove the left front axle shaft nut, as follows:
  70.  
  71. Using SST (SST: 09930-00010) or equivalent and a hammer, strike the lock nut covering to remove it.
    1. Set the drive shaft's groove so that it faces up. Then use the SST and a hammer.
    2.  
    3. Remove the covering from the lock nut completely. Otherwise the screw of the drive shaft may be damaged.
    4.  
    5. Do not sharpen the tip of the SST.
    6.  
    7. Using a 30 mm socket wrench, remove the lock nut.
    8.  

  72.  
  73. Remove the right front axle shaft nut.
  74.  
  75. Disconnect the left front stabilizer link assembly, as follows:
    1. Using a 6 mm socket hexagon wrench, hold the ball stud.
    2.  
    3. Remove the nut and disconnect the stabilizer link.
    4.  

  76.  
  77. Disconnect the right front stabilizer link assembly.
  78.  
  79. Remove the bolts and disconnect the right and left front speed sensors from the steering knuckle.
  80.  
  81. Disconnect the left and right tie rod assemblies, as follows:
    1. Remove the cotter pin and nut.
    2.  
    3. Using SST (SST: 09628-62011) or equivalent, disconnect the tie rod ends from the steering knuckle.
      NOTE
      Do not damage the dust cover of the ball joint.

    4.  

  82.  
  83. Disconnect the lower No. 1 left and right front suspension arm sub-assemblies, as follows:
    1. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
    2.  
    3. Using a plastic hammer, disconnect the drive shaft from the axle hub.
    4.  

  84.  
  85. Separate left and right front axle assembly.
  86.  
  87. Remove the No. 1 exhaust pipe support bracket with the 2 bolts.
  88.  
  89. Remove the drive plate and torque converter clutch setting bolt, as follows:
    1. Using SST (SST: 09213-70011, SST: 09330-00021) or equivalent, hold the crankshaft.
    2.  
    3. Remove the 2 bolts and flywheel housing under cover.
    4.  
    5. Remove the 6 torque converter clutch setting bolts.
    6.  

  90.  
  91. Disconnect steering sliding yoke.
  92.  
  93. Remove generator assembly.
  94.  
  95. Separate the cooler compressor assembly, as follows:
    1. Remove the 2 connector clamps.
    2.  
    3. Remove the 4 bolts and separate the compressor.
      NOTE
      Hang up the hoses instead of detaching them.

    4.  

  96.  
  97. Remove the engine assembly with transaxle, as follows:
    1. Set the engine lifter.
    2.  
    3. Remove the 4 bolts, 2 nuts and right and left frame side rail plates.
    4.  
    5. Remove the 4 bolts, 2 nuts, front suspension member right and left rear brace.
    6.  
    7. Operate the engine lifter, then remove the engine assembly from the vehicle.
      NOTE
      Make sure the engine is clear of all wiring and hoses.

    8.  

  98.  
  99. Remove the vane pump assembly, as follows:
    1. Remove the pressure feed tube clamp bolt.
    2.  
    3. Remove the 2 bolts, nut and vane pump.
    4.  

  100.  
  101. Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part numbers: Engine hanger No. 1 12281-31120, Engine hanger No. 2 12282-31100, Bolts 91671-10825. Torque to 24 ft. lbs. (33 Nm).

    Click image to see an enlarged view

    Fig. Install the 2 engine hangers

    1. Attach the engine sling device and hang the engine with the chain block.
    2.  

  102.  
  103. Remove the front frame assembly, as follows:
    1. Disconnect the connector and clamp.
    2.  
    3. Disconnect the 2 clamps.
    4.  
    5. Remove the 2 nuts and disconnect the right and left engine mounting insulators.
    6.  
    7. Remove the bolt and disconnect the engine mounting insulator FR.
    8.  

  104.  
  105. Remove the right and left front drive shaft assemblies.
  106.  
  107. Remove the engine wire.
  108.  
  109. Remove the starter assembly.
  110.  
  111. Remove the automatic transaxle assembly.
  112.  
  113. Remove the drive plate and ring gear sub-assembly.
  114.  
  115. Install engine stand.
  116.  
  117. Remove intake air surge tank assembly, as follows:
    1. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly
    2.  
    3. Disconnect the vapor feed hose.
    4.  
    5. Disconnect the throttle with motor body assembly connector and clamp.
    6.  
    7. Disconnect the No. 1 ventilation hose.
    8.  
    9. Remove the bolt and vacuum hose clamp.
    10.  
    11. Disconnect the connector.
    12.  
    13. Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket.
    14.  
    15. Using a 5 mm socket hexagon wrench, remove the 4 bolts. Remove the 2 nuts and intake air surge tank. Remove the gasket from the intake air surge tank.
    16.  

  118.  
  119. Remove the ignition coil assembly.
  120.  
  121. Remove the bolt and the No. 2 RH engine mounting stay.
  122.  
  123. Remove the intake manifold, as follows:
    1. Uniformly loosen and remove the 6 bolts and 4 nuts.
    2.  
    3. Remove the intake manifold and 2 gaskets.
    4.  

  124.  
  125. Remove the right exhaust manifold sub-assembly, as follows:
    1. Disconnect the A/F sensor connector clamp.
    2.  
    3. Uniformly loosen and remove the 6 nuts.
    4.  
    5. Remove the manifold and gasket.
    6.  

  126.  
  127. Remove the oil level gauge guide sub-assembly, as follows:
    1. Remove the oil level gauge.
    2.  
    3. Remove the 2 bolts, and No. 1 and No. 2 oil level gauge guides.
    4.  
    5. Remove the O-rings from the oil level gauge guide.
    6.  

  128.  
  129. Remove the 2 bolts and the No. 2 manifold stay.
  130.  
  131. Remove the 3 bolts and the No. 2 exhaust manifold heat insulator.
  132.  
  133. Remove the left exhaust manifold sub-assembly, as follows:
    1. Uniformly loosen and remove the 6 nuts.
    2.  
    3. Remove the manifold and gasket.
    4.  

  134.  
  135. Remove the 3 bolts and the right engine mounting bracket.
  136.  
  137. Remove the 3 bolts and drive shaft bearing bracket.
  138.  
  139. Remove the 5 bolts and V-ribbed belt tensioner assembly.
  140.  
  141. Remove the 2 bolts and the No. 2 timing gear cover.
  142.  
  143. Remove the bolt, plate and No. 2 idler pulley sub-assembly.
  144.  
  145. Remove the water pump pulley.
  146.  
  147. Remove the 6 bolts and No. 1 left front engine mounting bracket.
  148.  
  149. Remove the 2 bolts and 2 radio setting condensers.
  150.  
  151. Remove the bolt and No. 1 vacuum switching valve.
  152.  
  153. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
  154.  
  155. Remove 2 bolts and 2 knock control sensors.
  156.  
  157. Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket.
  158.  
  159. Replace partial engine assembly as necessary.
  160.  

To install:

  1. Using a 19 mm deep socket wrench, install the EFI engine coolant temperature sensor and a new gasket and tighten to 14 ft. lbs. (20 Nm).
  2.  
  3. Install the knock control sensor.
  4.  
  5. Install the engine oil pressure switch assembly, as follows:
    1. Clean the threads of the oil pressure switch. Apply adhesive (Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent) to 2 or 3 threads of the oil pressure switch.
    2.  
    3. Using a 24 mm deep socket wrench install the oil pressure switch and tighten to 15 ft. lbs. (21 Nm). Install the left front No. 1 engine mounting bracket with the 6 bolts and tighten to 40 ft. lbs. (54 Nm).
    4.  

  6.  
  7. Install the bolt and No. 1 vacuum switching valve and tighten to 7 ft. lbs. (10 Nm).
  8.  
  9. Install the 2 bolts and 2 radio setting condensers and tighten to 7 ft. lbs. (10 Nm).
  10.  
  11. Install the No. 1 engine mounting bracket front LH with the 6 bolts and tighten to 40 ft. lbs. (54 Nm).
  12.  
  13. Install the water pump pulley.
  14.  
  15. Install the No. 2 idler pulley sub-assembly and cover plate with the bolt and tighten to 32 ft. lbs. (43
  16.  
  17. Nm).
  18.  
  19. Install the No. 2 timing gear cover with the 2 bolts and tighten to 53 inch lbs. (6 Nm).
  20.  
  21. Install the V-ribbed belt tensioner assembly, as follows:
    1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
    2.  
    3. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration to 32 ft. lbs. (43 Nm).

      Click image to see an enlarged view

      Fig. V-ribbed belt tensioner bolt tightening sequence

    4.  
    5. Tighten the other bolts to 32 ft. lbs. (43 Nm). Bolt length: A: 70 mm (2.76 in.), B: 33 mm (1.30 in.)
    6.  

  22.  
  23. Install the drive shaft bearing bracket with the 3 bolts and tighten to 47 ft. lbs. (64 Nm).
  24.  
  25. Install the engine mounting bracket RH with the 3 bolts and tighten to 40 ft. lbs. (54 Nm).
  26.  
  27. Install the left exhaust manifold sub-assembly, as follows:
    1. Install a new gasket.
    2.  
    3. Install the exhaust manifold sub-assembly with the 6 nuts and tighten to 15 ft. lbs. (21 Nm).
    4.  

  28.  
  29. Install the No. 2 exhaust manifold heat insulator with the 3 bolts and tighten to 75 inch lbs. (8.5 Nm).
  30.  
  31. Install the No. 2 manifold stay with the 2 bolts and tighten to 25 ft. lbs. (34 Nm).
  32.  
  33. Install the oil level gauge guide sub-assembly, as follows:
    1. Install 2 new O-rings to the oil level gauge guide.
    2.  
    3. Apply a coat of engine oil lightly to the O-rings.
    4.  
    5. Push in the oil level gauge guide end into the guide hole.
    6.  
    7. Install the No. 1 oil level gauge guide with the bolt and tighten to 15 ft. lbs. (21 Nm).
    8.  
    9. Install the No. 2 oil level gauge guide with the bolt and tighten to 15 ft. lbs. (21 Nm).
    10.  
    11. Install the oil level gauge.
    12.  

  34.  
  35. Install the right exhaust manifold sub-assembly, as follows:
    1. Install a new gasket.
    2.  
    3. Install the exhaust manifold sub-assembly with the 6 nuts and tighten to 15 ft. lbs. (21 Nm).
    4.  

  36.  
  37. Install the intake manifold.
  38.  
  39. Install the right No. 2 mounting stay with the bolt and tighten to 15 ft. lbs. (21 Nm).
  40.  
  41. Install the 6 ignition coil assemblies with the 6 bolts and tighten to 7 ft. lbs. (10 Nm).
    CAUTION
    DO NOT apply oil to the following bolts: surge tank and intake manifold, No. 1 surge tank stay and cylinder head cover, No. 1 surge tank stay and surge tank, throttle body bracket and cylinder head cover, throttle body bracket and surge tank.

    1. Install a new gasket to the intake air surge tank.
    2.  
    3. Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts. Tighten the bolts to 13 ft. lbs. (18 Nm). Tighten the nuts to 12 ft. lbs. (16 Nm).
    4.  
    5. Install the throttle body bracket, No. 1 surge tank stay and 4 bolts and tighten to 15 ft. lbs. (21 Nm).
    6.  
    7. Connect the connector.
    8.  
    9. Install the vacuum hose clamp with the bolt and tighten to 48 inch lbs. (5.4 Nm).
    10.  
    11. Connect the No. 1 ventilation hose.
    12.  
    13. Install the clamp and connect the throttle with motor body assembly connector.
    14.  
    15. Connect the vapor feed hose.
    16.  
    17. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
    18.  

  42.  
  43. Remove the engine stand.
  44.  
  45. Install the drive plate and ring gear sub-assembly.
  46.  
  47. Install the automatic transaxle assembly.
  48.  
  49. Install the starter assembly.
  50.  
  51. Install the engine wire.
  52.  
  53. Install the right and left front drive shaft assemblies.
  54.  
  55. Install the front frame assembly, as follows:
    1. Install the right and left engine mounting insulators and with the 2 nuts and tighten 70 ft. lbs. (95 Nm).
    2.  
    3. Install the engine mounting insulator FR with the bolt and tighten 64 ft. lbs. (87 Nm).
    4.  
    5. Connect the connector and clamp.
    6.  
    7. Connect the 2 clamps.
    8.  

  56.  
  57. Install the vane pump assembly, as follows:
    1. Install the vane pump with the 2 bolts and nut and tighten 32 ft. lbs. (43 Nm).
    2.  
    3. Install the pressure feed tube clamp bolt and tighten 87 inch lbs. (9.8 Nm).
    4.  
    5. Connect the power steering oil pressure switch connector.
    6.  

  58.  
  59. Install the engine assembly with transaxle, as follows:
    1. Set the engine assembly with transaxle on the engine lifter.
    2.  
    3. Install the engine assembly to the vehicle.
    4.  
    5. Install the right and left frame side rail plates and with the 4 bolts and 2 nuts. Tighten A to 63 ft. lbs. (85 Nm) and B to 24 ft. lbs. (32 Nm).
    6.  
    7. Install the right and left front suspension member rear braces with the 4 bolts and 2 nuts. Tighten C to 63 ft. lbs. (85 Nm) and D to 24 ft. lbs. (32 Nm).

      Click image to see an enlarged view

      Fig. Installing suspension braces

    8.  

  60.  
  61. Install the cooler compressor assembly.
  62.  
  63. Install generator assembly.
  64.  
  65. Install the steering intermediate shaft assembly.
  66.  
  67. Install drive plate and torque converter clutch setting bolt, as follows:
    1. Using SST (SST: 09213-70011, SST: 09330-00021) or equivalent, hold the crankshaft.
    2.  
    3. Using kerosene or gasoline, clean the bolts thoroughly.
    4.  
    5. Apply adhesive (Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent) to 2 or 3 threads of the bolt end.
    6.  
    7. Install the 6 torque converter set bolts and tighten 30 ft. lbs. (41 Nm). First tighten the green colored bolt, then the other 5 bolts.
    8.  
    9. Install the flywheel housing under cover with the 2 bolts and tighten 69 inch lbs. (7.8 Nm).
    10.  

  68.  
  69. Install the No. 1 exhaust pipe support bracket with the 2 bolts and tighten 15 ft. lbs. (21 Nm).
  70.  
  71. Install both front axle assemblies.
  72.  
  73. Install the lower right and left No. 1 suspension arm sub-assemblies, as follows:
    1. Install the drive shaft to the steering knuckle.
    2.  
    3. Install the suspension lower arm with the bolt and 2 nuts and tighten 55 ft. lbs. (75 Nm).
    4.  

  74.  
  75. Install the left and right tie rod assemblies, as follows:
    1. Connect the tie rod end to the steering knuckle with the castle nut and tighten 36 ft. lbs. (49 Nm).
      NOTE
      Do not allow lubricants to contact the thread and taper portions.


      NOTE
      After tightening the castle nut, tighten additional 60° so that a cotter pin can be inserted.

    2.  
    3. Insert a new cotter pin.
    4.  

  76.  
  77. Install the right and left front speed sensors.
  78.  
  79. Install the right and left front stabilizer link assemblies, as follows:
    1. Using a 6 mm socket hexagon wrench, hold the ball stud and install the nut and tighten 55 ft. lbs. (74 Nm).
    2.  

  80.  
  81. Install the right and left front axle shaft hub nuts, as follows:
    1. Using a 30 mm socket wrench, install a new hub nut and tighten 217 ft. lbs. (294 Nm).
    2.  
    3. Using a chisel and hammer, tap the hub nut.
    4.  

  82.  
  83. Install the front exhaust pipe assembly.
  84.  
  85. Install the No. 1 exhaust pipe support bracket.
  86.  
  87. Connect the oil reservoir to the No. 1 pump hose.
  88.  
  89. Connect the steering gear outlet return tube.
  90.  
  91. Connect the fuel tube sub-assembly, as follows:
    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. Check if the pipe and the connector are securely connected by trying to pull them apart.

    2.  
    3. Install the No. 1 fuel pipe clamp.
    4.  

  92.  
  93. Connect the transmission control cable assembly. Install the clip and nut, and connect the cable to the transaxle. Tighten the nut to 9 ft. lbs. (13 Nm).
  94.  
  95. Connect engine wire, as follows:
    1. Install the bolt and clamp to the bracket. Tighten 74 inch lbs. (8.4
    2.  
    3. Nm).
    4.  
    5. Install the 2 bolts and 2 clamps to the body.
    6.  
    7. Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors. Tighten to 74 inch lbs. (8.4 Nm).
    8.  

  96.  
  97. Install upper relay block cover upper.
  98.  
  99. Connect the heater water outlet and inlet hose.
  100.  
  101. Connect the oil cooler inlet and outlet hoses.
  102.  
  103. Install the radiator inlet and outlet hoses.
  104.  
  105. Install the clamp and connect the check valve to brake booster hose.
  106.  
  107. Install the clamp and connect the No. 1 fuel vapor feed hose.
  108.  
  109. Install the engine moving control rod, as follows:
    1. Temporarily install the moving control rod with the 4 bolts.
    2.  
    3. Tighten the bolt A to 28 ft. lbs. (38 Nm).
    4.  
    5. Tighten the bolt B in the order shown in the illustration to 28 ft. lbs. (38 Nm).

      Click image to see an enlarged view

      Fig. Engine moving control rod bolt tightening sequence

    6.  

  110.  
  111. Temporarily install the right No. 2 mounting stay with the bolts and 2 nuts. Tighten to 17 ft. lbs. (23 Nm).
  112.  
  113. Install the intake air resonator with the bolt and clip and tighten to 44 inch lbs. (5 Nm).
  114.  
  115. Install the battery and battery tray.
  116.  
  117. Install the No. 1 air cleaner inlet with the bolt and tighten 44 inch lbs. (5 Nm).
  118.  
  119. Install the air cleaner case sub-assembly, as follows:
    1. Install the air cleaner case with the 3 bolts and tighten 44 inch lbs. (5 Nm).
    2.  
    3. Connect the vacuum hose and hose clamp.
    4.  

  120.  
  121. Install the air cleaner cap sub-assembly.
  122.  
  123. Install the air cleaner inlet with the clamp and 2 bolts and tighten to 44 inch. lbs. (5 Nm).
  124.  
  125. Connect vacuum hoses.

    Click image to see an enlarged view

    Fig. Connecting vacuum hoses

  126.  
  127. Install drive belt.
  128.  
  129. Install the outer cowl top panel.
  130.  
  131. Install the windshield wiper link assembly.
  132.  
  133. Install the front wheels.
  134.  
  135. Add automatic transaxle fluid.
  136.  
  137. Add engine oil.
  138.  
  139. Add engine coolant.
  140.  
  141. Add power steering fluid.
  142.  
  143. Bleed power steering system.
  144.  
  145. Inspect for oil leak, coolant leak, fuel leak, and exhaust gas leak.
  146.  
  147. Inspect and adjust front wheel alignment.
  148.  
  149. Inspect ignition timing and engine idle speed.
  150.  
  151. Check function of throttle body.
  152.  
  153. Install the V-bank cover sub-assembly.
  154.  
  155. Inspect CO/HC.
  156.  
  157. Check ABS speed sensor signal.
  158.  
  159. Perform initialization.
  160.  

 
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