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Starting System: Starter: Installation

  1. INSTALL STARTER ASSEMBLY 
    1. Install the starter with the 2 bolts.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

    2. Connect the engine wire protector with the bolt.
    3. Connect the starter cable with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 86 in.*lbf) 

    4. Connect the starter connector.
  2. INSTALL AIR SWITCHING VALVE ASSEMBLY (See  INSTALLATION  ) 
  3. INSTALL AIR PUMP ASSEMBLY WITH BRACKET (See  INSTALLATION  ) 
  4. INSTALL REAR WATER BY-PASS JOINT 
    1. Install 2 new gaskets to the cylinder head.
    2. Install the 4 nuts holding the water by-pass joint to the cylinder heads. Alternately tighten the nuts.

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

  5. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Install a new O-ring to the water by-pass pipe.
    2. Apply soapy water to the O-ring.
      Fig 1: Installing Starter With Bolts
      G04436381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Push the water by-pass pipe end into the pipe hole of the water pump.
    4. Install the water by-pass pipe with the nut.

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

    5. Install the wire clamp to the bracket of the water by-pass pipe.
  6. INSTALL INTAKE MANIFOLD ASSEMBLY 
    1. Install 2 new gaskets to the cylinder head.
    2. Install the intake manifold with the 4 bolts and 2 nuts.

      Torque: 

      • 18 N*m (185 kgf*cm, 13 ft.*lbf) for bolt 
      • 18 N*m (185 kgf*cm, 13 ft.*lbf) for nut 
  7. CONNECT WATER BY-PASS HOSE 
  8. CONNECT NO. 7 WATER BY-PASS HOSE 
    Fig 2: Installing Intake Manifold
    G04436382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE WIRE 
    1. Install the 3 bolts and connect the engine wire.

      Torque: 8.2 N*m (83 kgf*cm, 72 in.*lbf) 

    2. Connect the engine coolant temperature sensor connector.
    3. Connect the throttle position sensor and control motor connector.
    4. Connect the 8 fuel injector connectors.
    Fig 3: Installing Engine Wire
    G04436383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL VACUUM CONTROL VALVE SET (See  INSTALLATION  ) 
  11. INSTALL PURGE VSV (See  INSTALLATION  ) 
  12. CONNECT VENTILATION HOSE (See  INSTALLATION  ) 
  13. CONNECT NO. 2 FUEL HOSE (See  INSTALLATION  ) 
  14. CONNECT FUEL HOSE (See  INSTALLATION  ) 
  15. INSTALL INTAKE AIR CONNECTOR (See  INSTALLATION  ) 
  16. ADD ENGINE COOLANT 
  17. CHECK FOR ENGINE COOLANT LEAKS (See  INSTALLATION  ) 
  18. CHECK FOR FUEL LEAKS 
  19. INSTALL V-BANK COVER SUB-ASSEMBLY (See  INSTALLATION  ) 
  20. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
    NOTE: Certain systems need to be initialized after disconnecting the cable from negative (-) battery terminal.
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