Starter Reinstallation
1. Install Starter
(a) Install a new 0-ring to the water bypass pipe, lightly coat 0-ring with 0-ring lubricant and place the pipe onto the shelf at the right front corner of the engine valley. The rear end of the water bypass pipe must be positioned behind the passenger side valve cover.
(b) Place the nose of the starter gear partially into the starter hole on cylinder block, connect the starter cable with the nut, tighten the nut until finger tight.
(c) Install the wire clamp to the starter housing with the bolt.
Torque: 8.83 N-m (90 kg-cm, 78 in-lb)
(d) Torque the starter cable nut and close plastic cover over starter cable mounting stud.
Torque: 8.83 N-m (90 kg-cm, 78 in-lb)
(e) Connect the starter connector.
NOTE:
Be careful not to damage the connector and be sure the lock tab is engaged.
(f) Reinstall the starter with the 2 bolts.
Torque: 39 N-m (400 kg-cm, 29 ft-lb)
NOTE:
Upon tightening the starter bolts, the torque wrench may contact the No.1 EGR pipe, be careful not to deform the pipe as it will become difficult to reinstall.
(g) Install a new gasket on the No.1 EGR pipe.
(h) Install 2 new rear water bypass gaskets to the cylinder heads and install the rear water bypass to the heads with 4 nuts.
Torque: 18 N-m (185 kg-cm, 13 ft-lb)
(i) Using the SST wrench set, reinstall the No.1 EGR pipe to the rear water bypass with the 2 bolts.
(j) Push the water bypass pipe into the pipe hole at the back of the water pump.
(k) Install the water bypass pipe mounting bolt.
Torque: 18 N-m (185 kg-cm, 13 ft-lb)
NOTE:
Be sure the correct length bolt is used (13 mm). If the bolt is too long it will not secure the water bypass pipe mounting bracket properly.
(l) Connect the wire clamp to the bracket on the water bypass pipe.
2. Reinstall Intake Manifold Assembly
(a) Remove protective covers from the intake ports, visually inspect all intake ports for any foreign material and clean up prior to reinstallation.
(b) Place 2 new intake gaskets on the cylinder heads with the white painted mark facing upwards.
NOTE:
Align the port holes of the gasket and cylinder head. Be careful of the installation direction.
(c) Place the intake manifold on the cylinder heads with the arrow mark facing forward.
NOTE:
First, lower the rear of the intake manifold onto the rear studs being sure to clear the engine wire harness and fuel return pipe. Second, lower the front of the manifold being sure to clear the wire harness at the right front and the wire bridge at the left front. Be careful not to pinch any portion of harness or connectors under the manifold.
(d) Be sure that the intake manifold ports are still covered to prevent any dirt from entering.
(e) Install and uniformly tighten the 6 bolts and 4 nuts in several passes.
Start from center and work outward.
Torque: 18 N-m (185 kg-cm, 13 ft-lb)
(f) Connect the 8 injector connectors.
3. Reinstall Fuel Return Pipe
(a) Apply loc-tite to the first fuel return pipe mounting bolt and reinstall the fuel return pipe onto the rear water bypass under the wire harness.
(b) Apply loc-tite to the thread of the second fuel return pipe mounting bolt between the bracket and the cylinder head, then tighten the bolt.
4. Reconnect fuel return hose
(a) Reconnect the fuel return hose to the fuel pressure regulator.
5. Reconnect the Heater Hoses
(a) Reconnect the heater water hose to the water bypass pipe.
(b) Reconnect the heater water hose from the rear water bypass to the heater water valve assembly.
6. Reinstall Engine Wire harness to Fuel Rail and Rear Water Bypass
(a) Reinstall the following:
^ 2 engine wire connectors (EA1 & EA2 for LS400, EC1 & EC2 for SC400) to connector bracket on LH fuel rail.
^ DLC1 to bracket on LH fuel rail.
^ Engine wire clamp to wire bracket on LH fuel rail.
(b) Reinstall the left hand side of the engine wire harness to the rear water bypass with one bolt.
(c) Reinstall the A/T throttle cable to the clamps on the engine wire protector and engine hanger.
(d) Reinstall the right hand side of the engine wire harness to the rear water bypass with one bolt.
(e) Reinstall the engine wire harness to the RH fuel rail with the 2 bolts.
(f) Using new gaskets, place No.2 EGR pipe on rear water bypass with nuts threaded at top of studs.
NOTE:
When placing the EGR pipe on the rear water bypass, the convoluted part of the EGR pipe is on top.
(g) Move the No.2 EGR pipe toward the firewall and tie it back to provide clearance for the air intake chamber during reinstallation.
7. Reinstall Air Intake Chamber Assembly
(a) Remove intake manifold port covers, place 4 new gaskets on the intake manifold.
(b) Reconnect the following hoses:
^ PCV hose from RH cylinder head to throttle body.
^ Water bypass hose to throttle body from rear water bypass.
(c) Place the air intake chamber assembly on the intake manifold, install forward end first, guide the IAC coolant hose onto thermostat housing and reinstall the clamp.
(d) Reconnect the EGR gas temperature sensor connector.
(e) Reinstall the air intake chamber fasteners along with the mounting brackets for the VSV for fuel pressure control and VSV for EVAP. Uniformly tighten the 4 bolts and 8 nuts using several passes.
Torque: 18 N-m (185 kg-cm, 13 ft-lb)
(f) Install No.2 EGR pipe to rear of air intake chamber with the 2 bolts. Tighten the 2 nuts and 2 bolts.
Torque: 22.5 N-m (230 kg-cm, 17 ft-lb)
8. Reconnect Hoses and Connectors
(a) Reconnect the following hoses:
^ Brake booster vacuum hose to union on the air intake chamber.
^ Vacuum hose for the fuel pressure VSV to the rear of the air intake chamber.
^ PCV hose to PCV valve on LH cylinder head.
^ Hose from the rear water bypass to EGR valve.
^ EVAP hose to the VSV for the EVAP
(b) Reconnect these connectors:
^ EGR valve connector.
^ VSV connector for fuel pressure control.
^ VSV connector for EVAP
^ Throttle position sensor connector.
^ w/TRAC: Sub-throttle position sensor connector and Sub-throttle actuator connector.
^ IAC valve connector.
(c) Install the accelerator bracket with the 2 bolts.
(d) Reconnect these cables.
^ Accelerator cable.
^ A/T throttle control cable.
^ Cruise control actuator cable.
(e) Reinstall intake air connector assembly.
(f) Reconnect P/S air control hoses, the IAC valve air supply hose, the EVAP hose for canister, and the hose retaining clamp.
(g) Reinstall V-bank cover with the bolt and 2 cap nuts.
(h) Reinstall air cleaner inlet and the battery clamp cover.
(i) Reconnect the negative battery terminal.
(j) With the ignition key "ON" and the shift lever in the "PARK" position, press the "SET" and seat memory "No.1" buttons to reestablish the "No.1" seating position memory.
(k) Tighten fuel tank fuel cap and close fuel door.
9. Refill Coolant into Engine
(a) Remove the water filler plug from the water inlet housing.
(b) Slowly pour coolant into the water inlet housing until it is full.
(c) Reinstall the water filler plug to the water inlet housing.
Torque: 44 N-m (450 kg-cm, 33 ft-lb)
(d) Remove radiator reservoir cap and slowly pour coolant into the radiator reservoir until it is full. Then reinstall the cap.
(e) Bleed the cooling system.
^ Start the engine and turn on the heater to open the heater water valve.
^ Maintain the engine speed between 2,000 to 2,500 rpm until the engine is warm.
(f) Monitor the coolant level, temperature gauge and check for any leaks.
(g) Test drive vehicle to check for leaks and make sure the low coolant level warning light does not turn on.
(h) Upon returning, stop the engine and let it cool down. Then check the coolant level and add additional coolant until the reservoir is full. If the level is below specification, top up with "Toyota Long Life Antifreeze Coolant".
10. Reset Clock and Radio
(a) Reset the clock and radio stations as originally preset by customer.
11. Scan for Trouble Codes
(a) Using the scan tool, check for any diagnostic trouble codes which may be set.
If any codes are found, correct as necessary.
12. SSC Completion Label Installation
(a) After completing repair and before returning vehicle to the owner, a SSC completion label that is enclosed in the owner's notification must be affixed to the left front door hinge post near the check strap.
(b) The label is to be filled out as follows:
Write in SSC WL1
Write in date of repair
Write in your Dealer Code
(c) Additional SSC completion labels, in sheets of 50 (P/N 00410-01917), may be ordered through the non-parts system on a 1450 order form or through the TDN system.