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Engine Assembly: Installation

  1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Using SST, hold the crankshaft.

      SST 09213-58013 (91651-60855), 09330-00021 

      Fig 1: Holding Crankshaft With SST
      G05399116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the bolt and the bolt hole.
    3. Apply adhesive to 2 or 3 threads of the bolt end.

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

    4. Install the front spacer, drive plate and rear spacer with the 8 bolts.

      Uniformly tighten the 8 bolts.

      Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) 

      Fig 2: Locating Bolts And Drive Plate
      G05399117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  3. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  4. INSTALL TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle) 
  5. INSTALL NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)  (See INSTALLATION )
  6. INSTALL NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)  (See INSTALLATION )
  7. INSTALL NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle)  (See INSTALLATION )
  8. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Hold the crankshaft with SST.

      SST 09213-58013 (91651-60855), 09330-00021 

      Fig 3: Holding Crankshaft With SST
      G05399116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the 8 bolts and their holes.
    3. Apply adhesive to the 2 or 3 end threads of the bolts.

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

      Fig 4: Applying Adhesive To 2 Or 3 End Threads Of Bolts
      G04828778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the flywheel with the 8 bolts in the order shown in the illustration.

      Torque: 49 N*m (500 kgf*cm, 38 ft.*lbf) 

      Fig 5: Locating Flywheel And Bolts
      G05399124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Mark paint marks on the upper edge of the bolt heads.
      6. Fig 6: Identifying Paint Marks On Upper Edge Of Bolt Heads
      G05399125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Tighten the bolts 90° in the sequence order shown in the illustration.
      NOTE: Do not start the engine for at least 1 hour after performing the installation.
  9. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  10. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  11. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  12. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  13. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transaxle) 
    1. Install the control cable bracket with 2 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      Fig 7: Locating Bolts And Control Cable Bracket
      G04831660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  15. INSTALL FLYWHEEL HOUSING SIDE COVER  (See INSTALLATION )
  16. INSTALL ENGINE MOVING CONTROL ROD (for Automatic Transaxle)  (See INSTALLATION )
  17. INSTALL ENGINE MOVING CONTROL ROD (for Manual Transaxle)  (See INSTALLATION )
  18. INSTALL ENGINE MOVING CONTROL ROD COVER  (See INSTALLATION )
  19. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the engine moving control rod with the through bolt.

      Torque: 120 N*m (1224 kgf*cm, 89 ft.*lbf) 

    2. Remove the 2 bolts and remove the 2 engine hangers.
    3. Install the air fuel ratio sensor bracket with bolt.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

  20. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR 
    1. Install the transverse engine mounting insulator with the 5 bolts.

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

      Fig 8: Locating Bolts And Transverse Engine Mounting Insulator
      G05399113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
      2. Fig 9: Identifying Engine Lifter
      G05399108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator RH and transverse engine mounting insulator can be installed.
    3. Install the transverse engine mounting insulator with the through bolt and nut.

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

      Fig 10: Locating Through Bolt And Nut
      G05399129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting insulator RH with the 6 bolts and nut.

      Torque: 88 N*m (897 kgf*cm, 65 ft.*lbf) for Bolt A 

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

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

      Fig 11: Locating Engine Mounting Insulator RH And Bolts
      G05399130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine mounting stay RH with the 2 bolts.

      Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf) 

      Fig 12: Locating Bolts And Engine Mounting Stay RH
      G05399109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts.
    7. Insert SST into the datum holes in the front suspension crossmember RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.

      SST 09670-00010 

      Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) for Bolt A 

      160 N*m (1631 kgf*cm, 118 ft.*lbf) for Bolt B 

      95 N*m (969 kgf*cm, 70 ft.*lbf) for Bolt C 

      Fig 13: Locating Front Suspension Crossmember And Bolts
      G05399132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION:
      • Insert SST into the datum hole vertically.
      • If impossible to insert SST vertically, loosen all bolts and then insert SST again.
        Fig 14: Inserting SST Into Datum Hole Vertically
        G04828790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)  (See INSTALLATION )
  23. INSTALL FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)  (See INSTALLATION )
  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  26. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  27. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    The installation procedure for the RH side is the same as that for the LH side.

  28. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
  29. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    The installation procedure for the RH side is the same as that for the LH side.

  30. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  31. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    The installation procedure for the RH side is the same as that for the LH side.

  32. INSTALL TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  33. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    The installation procedure for the RH side is the same as that for the LH side.

  34. INSTALL SPEED SENSOR FRONT LH  (See INSTALLATION )
  35. INSTALL SPEED SENSOR FRONT RH 

    HINT:

    The installation procedure for the RH side is the same as that for the LH side.

  36. INSTALL FRONT AXLE SHAFT LH NUT  (See INSTALLATION )
  37. INSTALL FRONT AXLE SHAFT RH NUT 

    HINT:

    The installation procedure for the RH side is the same as that for the LH side.

  38. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Using vernier calipers, measure the free length of the compression spring.

      Minimum length (Front side): 40.5 mm (1.594 in.) 

      Minimum length (Rear side): 38.5 (1.516 in.) 

      If the length is not as specified, replace the compression spring.

      Fig 15: Measuring Free Length Of Compression Spring
      G04828691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.
      NOTE:
      • Install the exhaust pipe gasket in the correct direction.
      • Do not damage the outer surface of the exhaust pipe gasket.
      • Do not reuse the exhaust pipe gasket.
      • Do not push in the gasket with the exhaust pipe when connecting it.
        Fig 16: Identifying Wooden Block And Gasket
        G04828692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 exhaust pipe supports.
    4. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4 compression springs and 4 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

    5. Pass the sensor connector through the floor panel and install the grommet.
    6. Connect the heated oxygen sensor connector.
      7. Fig 17: Locating Heated Oxygen Sensor Connector
      G05398807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT FLOOR BRACE CENTER  (See INSTALLATION )
  40. INSTALL FRONT CONSOLE BOX  (See INSTALLATION )
  41. INSTALL REAR CONSOLE BOX ASSEMBLY  (See INSTALLATION )
  42. INSTALL CONSOLE BOX REAR COVER  (See INSTALLATION )
  43. INSTALL CONSOLE BOX CARPET  (See INSTALLATION )
  44. INSTALL CONSOLE PANEL UPPER  (See INSTALLATION )
  45. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  46. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See INSTALLATION )
  47. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY  (See INSTALLATION )
  48. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  49. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch release cylinder and clutch pipe with the 4 bolts.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) for bolt A 

      12 N*m (122 kgf*cm, 9 ft.*lbf) for bolt B 

      Fig 18: Locating Bolts
      G04831674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube connector and fuel pipe, and install the No. 1 fuel pipe clamp.
      CAUTION: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.
      Fig 19: Locating No. 1 Fuel Pipe Clamp
      G05399102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT HEATER WATER INLET HOSE A 
    1. Connect heater water inlet hose A to the heater unit.
      Fig 20: Locating Heater Water Inlet Hose
      G05399101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Connect heater water outlet hose A to the heater unit.
      Fig 21: Locating Heater Water Outlet Hose
      G05399100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. CONNECT ENGINE WIRE 
    1. Connect the 2 engine wire harness connectors and 2 wire harness clamps to the engine room junction block.
      Fig 22: Locating Connectors And Clamp
      G05399099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the engine wire harness connector to the ECM.
    3. Connect the 2 wire harness clamps.
      Fig 23: Locating Wire Harness Clamps
      G05399098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the 2 connectors.
      Fig 24: Locating Connectors
      G05399097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the transaxle earth wire with the bolt and 2 wire harness clamps (for Manual Transaxle).

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 25: Locating Bolt And Wire Harness Clamp
      G05399096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the transaxle earth wire with the bolt and wire harness clamp (for Automatic Transaxle).

      Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

      Fig 26: Locating Bolt And Wire Harness Clamp
      G05399095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL NO. 1 FUEL VAPOR FEED HOSE 
    1. Install the No. 1 fuel vapor feed hose into the vacuum switching valve assembly.
      Fig 27: Locating No. 1 Fuel Vapor Feed Hose
      G05399094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL UNION TO CHECK VALVE HOSE 
    1. Install the union to check valve hose with the clip.
      Fig 28: Locating Clip And Check Valve Hose
      G05399093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Install the transmission control cable assembly onto the control shaft lever with the nut.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 29: Locating Transmission Control Cable Assembly And Nut
      G05399148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Fix the transmission control cable assembly onto the control cable bracket with a new clip.
      NOTE: Make sure that the marking on the cable is aligned with the slit in the transmission control cable bracket before installing the cable.
  57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Install the control cable assembly onto the control cable bracket with 2 new clips.
      2. Fig 30: Locating Clips And Cables
      G04831643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the control cable assembly and install the 2 washers and 2 clips.
    3. Install the control cable assembly onto the shift lever retainer.
      NOTE:
      • Install the cable with the protruding portion of the cable outer facing upward.
      • After installing, check that the lock of the cable outer is protruding beyond portion A. as shown in the illustration.
        • Fig 31: Identifying Protruding Portion Of Cable
        G05399150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL WITH PULLEY COMPRESSOR ASSEMBLY  (See INSTALLATION )
  59. INSTALL RADIATOR ASSEMBLY  (See INSTALLATION )
  60. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY  (See INSTALLATION )
  61. INSTALL UPPER RADIATOR SUPPORT ABSORBER  (See REASSEMBLY )
  62. INSTALL NO. 1 COOLER COVER  (See INSTALLATION )
  63. INSTALL HOOD LOCK ASSEMBLY  (See INSTALLATION )
  64. CONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle)  (See INSTALLATION )
  65. CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle)  (See INSTALLATION )
  66. CONNECT NO. 1 RADIATOR HOSE  (See INSTALLATION )
  67. INSTALL NO. 2 RADIATOR HOSE 
    1. Install the No. 2 radiator hose with the 2 clips.
      2. Fig 32: Locating Clips And No. 2 Radiator Hose
      G05399090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL FRONT BUMPER COVER  (See INSTALLATION )
  69. INSTALL FAN AND GENERATOR V BELT  (See INSTALLATION  )
  70. ADJUST FAN AND GENERATOR V BELT  (See INSTALLATION  )
  71. INSPECT FAN AND GENERATOR V BELT  (See INSTALLATION  )
  72. INSTALL NO. 2 CYLINDER HEAD COVER  (See INSTALLATION )
  73. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 5 bolts.

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      Fig 33: Locating Bolts And Battery Carrier
      G05399089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clamp.
  74. INSTALL AIR CLEANER BRACKET 
    1. Install the air cleaner bracket with the 2 bolts.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      Fig 34: Locating Bolts And Air Cleaner Bracket
      G04828736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the wire harness clamp to the air cleaner bracket.
  75. INSTALL AIR CLEANER ASSEMBLY 
    1. Install the air cleaner case with air cleaner inlet with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      Fig 35: Identifying Bolts And Air Cleaner Case With Air Cleaner Inlet
      G04828735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the wire harness to the air cleaner case.
    3. Install the air cleaner element.
    4. Install and lock the air cleaner cap with air cleaner hose and then tighten the air cleaner hose clamp.

      Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) 

      Fig 36: Locating Clamps
      G05399086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the ventilation hose to the air cleaner hose.
    6. Connect the intake air flow meter connector and 2 wire harness clamps.
  76. INSTALL OUTER COWL TOP PANEL 
    1. Install the outer cowl top panel with the 9 bolts.

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

      Fig 37: Locating Bolts And Outer Cowl Top Panel
      G05399085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the wire harness clamp.
      Fig 38: Locating Wire Harness Clamp
      G05399084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. INSTALL FRONT AIR SHUTTER SEAL RH 
    1. Engage the 2 claws to install the front air shutter seal RH.
      2. Fig 39: Identifying Claws Locations
      G05399083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL FRONT WIPER MOTOR AND LINK  (See INSTALLATION )
  79. INSTALL COWL TOP VENTILATOR LOUVER LH  (See INSTALLATION )
  80. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  81. INSTALL HOOD TO COWL TOP SEAL  (See INSTALLATION )
  82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  84. INSTALL FRONT WIPER ARM HEAD CAP  (See INSTALLATION )
  85. INSTALL BATTERY TRAY 
  86. INSTALL BATTERY 
    1. Install the battery onto the vehicle with the battery clamp.

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

    2. Connect the cable to the battery terminal.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  87. ADD ENGINE COOLANT  (See REPLACEMENT )
  88. ADD AUTOMATIC TRANSAXLE OIL (for Automatic Transaxle) 
  89. INSPECT AUTOMATIC TRANSAXLE OIL (for Automatic Transaxle)  (See ON-VEHICLE INSPECTION )
  90. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) 
  91. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle)  (See ON-VEHICLE INSPECTION )
  92. INSPECT FOR FUEL LEAK 
  93. INSPECT FOR ENGINE OIL LEAK 
  94. INSPECT FOR EXHAUST GAS LEAK 
  95. INSPECT FOR ENGINE COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  96. INSTALL ENGINE UNDER COVER RH 
  97. INSTALL ENGINE UNDER COVER LH 
  98. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  99. INSPECT IGNITION TIMING  (See ON-VEHICLE INSPECTION  )
  100. INSPECT ENGINE IDLING SPEED  (See ON-VEHICLE INSPECTION  )
  101. INSPECT CO/HC  (See ON-VEHICLE INSPECTION  )
  102. INSPECT FRONT WHEEL ALIGNMENT 

    (See ADJUSTMENT )

  103. INSPECT ABS SENSOR SIGNAL 

    (See TEST MODE PROCEDURE )

  104. INSPECT VSC SENSOR SIGNAL 

    (See TEST MODE PROCEDURE )

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