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Engine Assembly: Installation

  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR  (See INSTALLATION )
  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
  3. INSTALL RADIO SETTING CONDENSER 
    1. Install the condenser with the bolt.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Fig 1: Identifying Condenser With Bolt
      G05538315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL KNOCK SENSOR  (See INSTALLATION )
  5. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY  (See INSTALLATION )
  6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY  (See INSTALLATION )
  7. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
  8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY  (See INSTALLATION  )
  9. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR  (See INSTALLATION )
  10. INSTALL INTAKE MANIFOLD ASSEMBLY  (See INSTALLATION )
  11. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Install a new gasket and the water by-pass pipe with the bolt and 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 2: Identifying No. 1 Water By-Pass Pipe Bolt And Nuts
      G05538314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL THERMOSTAT  (See INSTALLATION )
  13. INSTALL WATER INLET  (See INSTALLATION )
  14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY  (See INSTALLATION  )
  15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See INSTALLATION  )
  16. INSTALL NO. 2 MANIFOLD STAY  (See INSTALLATION  )
  17. INSTALL MANIFOLD STAY  (See INSTALLATION  )
  18. INSTALL OIL DIPSTICK GUIDE  (See INSTALLATION  )
  19. INSTALL OIL DIPSTICK  (See INSTALLATION  )
  20. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Fig 3: Identifying Drive Shaft Baring Bracket Bolts
      G05387330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Clean the 8 bolts and 8 bolt holes.
    2. Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    3. Using SST, hold the crankshaft.

      SST 09213-54015 (91651-60855), 09330-00021 

      Fig 4: Identifying Crankshaft Using SST
      G05538309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque: 130 N*m (1,326 kgf*cm, 96 ft.*lbf) 

      Fig 5: Identifying Flywheel Bolts In Sequence
      G05538320Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  23. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  24. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  25. INSTALL DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Clean the 8 bolts and 8 bolt holes.
    2. Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

    3. Using SST, hold the crankshaft.

      SST 09213-54015 (91651-60855), 09330-00021 

      Fig 6: Holding Crankshaft Using SST
      G05538309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front spacer, drive plate and rear spacer onto the crankshaft.
    5. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf) 

      Fig 7: Identifying Drive Plate Bolts In Sequence
      G05538322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  27. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY  (See INSTALLATION )
  28. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER 
    1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
    2. Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

      Fig 8: Identifying Rear Engine Mounting Insulator Through Bolt
      G05538308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt which is used to secure the front engine mounting bracket.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      Fig 9: Identifying Front Engine Mounting Bracket Bolt
      G05538307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. INSTALL VANE PUMP ASSEMBLY 
  33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.
      Fig 10: Identifying Suspension Crossmember With 2 Bolts And 2 Nuts
      G05538305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator LH with the through bolt and nut.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

      Fig 11: Identifying Engine Mounting Insulator LH With Through Bolt And Nut
      G05538303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting insulator RH with the 2 bolts and 2 nuts.

      Torque: 

      52 N*m (530 kgf*cm, 38 ft.*lbf) 

      113 N*m (1,152 kgf*cm, 83 ft.*lbf) for bolt A 

      Fig 12: Identifying Engine Mounting Insulator RH With 2 Bolts And 2 Nuts
      G05538327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the 2 bolts and 2 nuts.

      Torque: 

      45 N*m (459 kgf*cm, 33 ft.*lbf) for bolt 

      133 N*m (1,356 kgf*cm, 98 ft.*lbf) for nut 

      Fig 13: Identifying Suspension Crossmember With 2 Bolts And 2 Nuts
      G05538305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the front suspension member brace rear RH and LH with the 8 bolts.

      Torque: 

      133 N*m (1,356 kgf*cm, 98 ft.*lbf) for bolt A 

      80 N*m (816 kgf*cm, 59 ft.*lbf) for bolt B 

      NOTE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
      Fig 14: Identifying Front Suspension Member Brace Rear RH And LH With 8 Bolts
      G05538329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the return tube.
      Fig 15: Identifying Return Tube
      G05538301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the oil reservoir to No. 1 pump hose.
      Fig 16: Identifying Oil Reservoir To No. 1 Pump Hose
      G05538300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the No. 1 and No. 2 engine hangers.
    Fig 17: Identifying No. 1 And No. 2 Engine Hangers With Bolts
    G05538121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL FRONT AXLE HUB SUB-ASSEMBLY  (See INSTALLATION )
  35. INSTALL FRONT AXLE HUB HOLE SNAP RING  (See INSTALLATION )
  36. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH  (See INSTALLATION )
  37. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY RH  (See INSTALLATION )
  38. INSTALL TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  39. INSTALL TIE ROD END SUB-ASSEMBLY RH  (See INSTALLATION )
  40. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  41. INSTALL FRONT SPEED SENSOR RH  (See INSTALLATION )
  42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH  (See INSTALLATION )
  44. INSTALL FRONT AXLE HUB NUT LH  (See INSTALLATION )
  45. INSTALL FRONT AXLE HUB NUT RH  (See INSTALLATION )
  46. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See INSTALLATION )
  47. INSTALL COLUMN HOLE COVER SILENCER SHEET 
  48. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  49. CONNECT ENGINE WIRE 
    1. Install the ground cable with the bolt.
      Fig 18: Identifying Ground Cable With Bolt
      G05538299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire to the battery positive terminal with the nut.
      Fig 19: Identifying Engine Wire To Battery Positive Terminal With Nut
      G05538298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 clamps of the engine wire.
      Fig 20: Identifying Engine Wire Clamps
      G05538297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire harness with the 2 claws.
      Fig 21: Identifying Engine Wire Harness With 2 Claws
      G05538296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 connectors.
  50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  51. INSTALL COOLER COMPRESSOR ASSEMBLY  (See INSTALLATION )
  52. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  53. INSTALL FAN AND GENERATOR V BELT  (See INSTALLATION  )
  54. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  55. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  57. CONNECT HEATER WATER OUTLET HOSE 
    1. Connect the heater outlet hose to the air conditioner tube.
      Fig 22: Identifying Heater Water Outlet Hose
      G05538295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT HEATER WATER INLET HOSE 
    1. Connect the heater inlet hose to the air conditioner tube.
      Fig 23: Identifying Heater Water Inlet Hose
      G05538294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the union to connector tube to the booster vacuum tube.
    Fig 24: Identifying Union To Connector Tube Hose
    G05538293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. CONNECT FUEL MAIN TUBE  (See INSTALLATION )
  61. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 4 bolts.

      Torque: 12.8 N*m (131 kgf*cm, 9 ft.*lbf) 

      Fig 25: Identifying Battery Carrier Bolts
      G05538292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the clamp of the engine wire.
  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Connect the air cleaner case to the No. 1 air cleaner inlet.
    2. Install the air cleaner case with the 3 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 26: Identifying Air Cleaner Case Bolts
      G05538291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the clamp of the engine wire.
  63. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY  (See INSTALLATION )
  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
  65. INSTALL RADIATOR ASSEMBLY  (See INSTALLATION )
  66. CONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) 
  67. CONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) 
  68. CONNECT RADIATOR HOSE OUTLET 
  69. CONNECT RADIATOR HOSE INLET 
  70. INSTALL BATTERY TRAY 
  71. INSTALL BATTERY 
  72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  73. ADD MANUAL TRANSAXLE OIL  (See INSTALLATION )
  74. ADD AUTOMATIC TRANSAXLE FLUID  (See INSTALLATION )
  75. ADD ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  76. CHECK FOR FUEL LEAKAGE  (See ON-VEHICLE INSPECTION )
  77. CHECK FOR ENGINE COOLANT LEAKS 
    1. Check for the engine coolant leaks (See ON-VEHICLE INSPECTION ).
  78. CHECK FOR MANUAL TRANSAXLE OIL LEAKS 
  79. CHECK FOR AUTOMATIC TRANSAXLE FLUID LEAKS 
  80. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY  (See INSTALLATION  )
  81. INSTALL FRONT FENDER APRON SEAL RH  (See INSTALLATION )
  82. INSTALL ENGINE UNDER COVER LH 
  83. INSTALL ENGINE UNDER COVER RH 
  84. INSTALL FRONT WHEEL  (See INSTALLATION )
  85. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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