Page 1308 of 2389
POST ASSEMBLY
1. INSTALL OIL PUMP AND OIL PAN
(See page LU±14)
2. INSTALL WATER PUMP (See page CO±7)
3. INSTALL CYLINDER HEAD (See page EM±67)
4. INSTALL PULLEYS AND TIMING BELT
(See page EM±29)
5. INSTALL ALTERNATOR (See page CH±14)
6. INSTALL DISTRIBUTOR (See page IG±16)
7. REMOVE ENGINE STAND
8. INSTALL REAR END PLATE
Torque: 95 kg±cm (82 ft±Ib, 9.3 N±m)
9. (M/T)
INSTALL FLYWHEEL
(a) Apply adhesive to two or three threads of the mount bolt
end.
Adhesive: Part No.08833±00070, THREE BOND 1324
or equivalent
10. (A/T)
INSTALL DRIVE PLATE
(See procedure step 9)
Torque: 850 kg±cm (61 ft±Ib, 83 N±m)
11. (M/T)
INSTALL CLUTCH DISC AND COVER (b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the mount bolts in several
passes in the sequence shown.
Torque: 900 kg±cm (65 ft±Ib. 88 N±m)
± ENGINE MECHANICALCylinder Block (3S±FE)EM±131
Page 1323 of 2389
PREPARATION FOR DISASSEMBLY
1. (M/T)
REMOVE CLUTCH COVER AND DISC
2. (M/T)
REMOVE FLYWHEEL
3. (A/T)
REMOVE DRIVE PLATE
4 REMOVE REAR END PLATE
Remove the bolt and end plate.
5. INSTALL ENGINE TO ENGINE STAND FOR
DISASSEMBLY
6. REMOVE DISTRIBUTOR (See page IG±18)
7. REMOVE TIMING BELT AND PULLEYS
(See page EM±34)
8. REMOVE CYLINDER HEADS (See page EM±76)
9. REMOVE WATER PUMP (See page CO±9)
10. REMOVE OIL PAN AND OIL PUMP
(See page LU±17)
11. REMOVE OIL FILTER (See page LU±7)
12. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816±30010
13. REMOVE WATER BY±PASS PIPE
Remove the two bolts, two nuts and by±pass pipe.
14. REMOVE NO.2 IDLER PULLEY BRACKET
Remove the three bolts and mounting bracket.
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±146
Page 1345 of 2389
4. INSTALL OIL FILTER (See page LU±7)
5. INSTALL OIL PUMP AND OIL PAN
(See page LU±14)
6. INSTALL WATER PUMP (See page CO±6)
7. INSTALL CYLINDER HEADS
(See pages EM±96 to 106)
8. INSTALL PULLEYS AND TIMING BELT
(See pages EM±42 to 47)
9. INSTALL DISTRIBUTOR (See page IG±19)
10. REMOVE ENGINE STAND
11. INSTALL REAR END PLATE
Install the end plate with the bolt.
Torque: 75 kg±cm (65 in.±Ib, 7.4 N±m)
12. (M/T)
INSTALL FLYWHEEL
(a) Apply adhesive to two or three threads of the mount bolt
end.
Adhesive: Part No. 08833±00070, THREE BOND
1324 or equivalent
13. (A/T)
INSTALL DRIVE PLATE (See procedure step 12)
Torque: 854 kg±cm (61 ft±Ib, 83 N±m)
14. (M/T)
INSTALL CLUTCH DISC AND COVER (b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the eight mount bolts in
several passes, in the sequence shown.
Torque: 850 kg±cm (61 ft±Ib, 83 N±m)
± ENGINE MECHANICALCylinder Block (2VZ±FE)EM±168
Page 1397 of 2389
9. INSTALL BEARING LOCK NUT, LOCK NUT CAP AND
NEW COTTER PIN
(a) Torque the bearing lock nut while depressing the brake
pedal.
Torque: 1,900 kg±cm (137 ft±Ib, 186 N±m)
(b) Install the lock nut cap and, using pliers, install a new
cotter pin. 8. TIGHTEN SIX HEXAGON BOLTS
Using SST, tighten the six hexagon bolts while depress-
ing the brake pedal.
SST 09043±88010
Torque: 660 kg±cm (48 ft±Ib, 65 N±m)
10. FILL TRANSAXLE WITH GEAR OIL
(See page MT±45)
11. INSTALL ENGINE UNDER COVERS
12. CHECK FRONT WHEEL ALIGNMENT7. CONNECT STEERING KNUCKLE TO LOWER ARM
Torque: 1,150 kg±cm (83 ft±Ib, 113 N±m)
± FRONT AXLE AND SUSPENSIONFront Drive Shaft (FWD VZV21 )FA±40
Page 1416 of 2389
4. INSTALL SUSPENSION LOWER CROSSMEMBER
Temporarily install the two bolts and two nuts by hand,
and then torque the bolts and nuts.
Torque: 2,110 kg±cm (153 ft±Ib, 207 N±m)
HINT: Temporarily first install the lower arm shaft to the
body with lower arm shaft installation bolt and nut and
then temporarily install the suspension lower cross-
member. 3. CONNECT LOWER BALL JOINT TO STEERING
KNUCKLE
Connect the steering knuckle to the lower ball joint and
torque the two bolts.
Torque: 1,150 kg±cm (83 ft±Ib, 113 N ± m )
5. INSTALL WHEELS AND LOWER VEHICLE
(a) Install the wheels.
(b) Remove the stands and bounce the vehicle up and
down to stabilize the suspension.
6. TORQUE LOWER SUSPENSION ARM INSTALLATION
NUT
Torque: Stabilizer bar X Lower suspension arm
2,160 kg±cm (156 ft±Ib, 212 N±m)
Torque: Lower arm shaft x Lower suspension arm
2,160 kg±cm (156 ft±lb , 212 N±m)
7. CHECK FRONT WHEEL ALIGNMENT
± FRONT AXLE AND SUSPENSIONFront SuspensionFA±59
Page 1860 of 2389

6. Precoated parts
Precoated parts are bolts and nuts, etc. that are coated with a
seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused to
move in any way, it must be recoated with the specified
adhesive.
(b) Recoating of precoated parts
(1) Clean off the old adhesive from the bolt, nut or threads.
(2) Dry with compressed air.
(3) Apply the specified sea! lock adhesive to the bolt or nut
threads.
(e) Precoated parts are indicated in the. component illustra-
tions by the ºrº symbol.
7. When necessary, use a sealer on gaskets to prevent leaks.
8. Carefully observe all specifications for bolt tightening torques. Al-
ways use a torque wrench.
9. Use of special service tools (SST) and special service materials
(SSM) may be required, depending on the nature of the repair.
Be sure to use SST and SSM where specified and follow the
proper work procedure. A list of SST and
SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse has the correct am-
perage rating. DO NOT exceed the rating or use one with a low-
er rating.
11. Care must be taken when jacking up and supporting the vehicle.
Be sure to lift and support the vehicle at the proper locations.
(See page IN±27)
(a) If the vehicle is to be jacked up only at the front or rear end,
be sure to block the wheels at the apposite end in order
to ensure safety.
(b) After the vehicle is jacked up, be sure to support it on stands.
It is extremely dangerous to do any work on a vehicle
raised on a jack alone, even for a small job that can be fin-
ished quickly.
12. Observe the following precautions 'to avoid damage to the parts:
(a) Do not open the cover or case of the ECU unless abso-
lutely necessary. (If the IC terminals are touched, the
IC may be destroyed by static electricity.)
(b) When replacing the internal mechanism (computer
part) of the digital meter, be careful that no
part of your body or clothing comes in contact with the
terminals of the leads from the IC, etc. of the replace-
ment part (spare part).
(c) To disconnect vacuum hoses, pull on the end, not the middle
of the hose.
M To pull apart electrical connectors, pull on the connector
itself, not the wires.
(e) Be careful not to drop electrical components, such as sen-
sors or relays. If they are dropped on a hard floor, they
should be replaced and not reused.
± INTRODUCTIONGeneral Repair InstructionsIN±5
Page 1927 of 2389

23. FINAL INSPECTION
(a) Check the operation of the body parts:
wHood
Auxiliary catch operation properly
Hood locks securely when closed
wFront and rear doors
Door locks operate properly
Doors close properly
wLuggage compartment door and back door
Door sock operates properly
wSeats
Seat adjusts easily and locks securely in any position
Front seat back locks securely in any position
Folding±down rear seat backs lock securely
(b) Road test
wCheck the engine and chassis for abnormal noises.
wCheck that the vehicle does not wander or pull to one side.
wCheck that the brakes work properly and do not drag.
wPerform bedding down of the parking brake shoes and drum.
(See page MA±8)
(c) Be sure to deliver a clean car especially check:
wSteering wheel
wShift lever knob
wAll switch knobs
wDoor handles
wSeatswStrut/stabilizer bar bracket±to±body mount bolts
(LH and RH)
Torque: 620 kg±cm (45 ft±lb, 61 N±m)
wEngine mounting center member±to±body mount bolts
Torque: 400 kg±cm 129 ft±lb, 39 N±m)
wFront suspension lower cross member±to±body mount
bolts
Torque: 2,110 kg±cm (153 ft±Ib, 206 N±m)
wRear suspension lower crossmember±to±body mount
bolts
Torque: 2WD 710 kg±cm (51 ft±lb, 70 N±m)
4WD 1,620 kg±cm (117 ft±Ib, 159 N±m)
± MAINTENANCEMaintenance OperationsMA±15
Page 2156 of 2389
5. INSTALL WHEELS AND LOWER VEHICLE
(a) Install the wheels.
(b) Remove the stands and bounce the vehicle up and
down to stabilize the suspension.
6. TORQUE AXLE CARRIER MOUNTING BOLTS
Torque the axle carrier mounting blots with the vehicle
weight on the suspension.
Torque:
Strut rod x Axle carrier
1,150 kg±cm (83 ft±Ib, 113 N±m)
No. 1 and No. 2 suspension arm x Axle carrier
1,850 kg±cm (134 ft±Ib, 181 N±m)
7. BLEED BRAKE SYSTEM
(See page BR±7)
8. CHECK REAR WHEEL ALIGNMENT
(See page RA±3) 3. TORQUE BRAKE TUBE
Using SST, torque the brake tube union.
SST 09751±36011
4. INSTALL BRAKE DRUM(b) Temporarily connect the brake tube to the backing
plate.
(c) Install the axle hub and torque the four
bolts.
Torque: 820 kg±cm (59 ft±Ib, 80 N ± m )
± REAR AXLE AND SUSPENSIONRear Axle Hub and Carrier (FWD)RA±10