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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) 

      2. Fig 1: Locating Bolt And Condenser
      G04865562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL KNOCK SENSOR (See  INSPECTION  ) 
  5. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY (See  INSTALLATION  ) 
  6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (See  INSTALLATION  ) 
  7. INSTALL IGNITION COIL ASSEMBLY (See  REMOVAL  ) 
  8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See  INSTALLATION  )
  9. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (See  INSPECTION  ) 
  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) 

      2. Fig 2: Locating Water By-Pass Pipe, Nuts And Bolts
      G04865561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL THERMOSTAT (See  REMOVAL  ) 
  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) 

      2. Fig 3: Locating Drive Shaft Bearing Bracket And Bolts
      G04865560Courtesy 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: Holding Crankshaft With SST
      G04865556Courtesy 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) 

      5. Fig 5: Locating Flywheel Bolts
      G04865567Courtesy 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 

    4. Install the front spacer, drive plate and rear spacer onto the crankshaft.
      Fig 6: Holding Crankshaft With SST
      G04865556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

      6. Fig 7: Locating Flywheel Bolts
      G04865569Courtesy 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: Locating Transaxle Bolts And Nuts
      G04865570Courtesy 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) 

      4. Fig 9: Locating Through Bolt
      G04865554Courtesy 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: Locating Through Bolt And Engine Mounting
      G04865572Courtesy 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: Locating Engine Mounting Insulator LH
      G04865550Courtesy 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: Locating Engine Mounting Insulator RH With Bolts And 2 Nuts
      G04865574Courtesy 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: Locating Transaxle Bolts And Nuts
      G04865552Courtesy 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: Locating Front Suspension Member Brace Rear RH And LH With Bolts
      G04865576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the return tube.
      Fig 15: Locating Return Tube
      G04865548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the oil reservoir to No. 1 pump hose.
      Fig 16: Locating Oil Reservoir To Pump Hose
      G04865547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the No. 1 and No. 2 engine hangers.
      10. Fig 17: Identifying Engine Hanger
      G04865368Courtesy 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  DISPOSAL  ) 
  41. INSTALL FRONT SPEED SENSOR RH (See  DISPOSAL  ) 
  42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See  DISPOSAL  ) 
  43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (See  DISPOSAL  ) 
  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  DISASSEMBLY  ) 
  49. CONNECT ENGINE WIRE 
    1. Install the ground cable with the bolt.
      Fig 18: Locating Ground Cable And Nut
      G04865546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire to the battery positive terminal with the nut.
      Fig 19: Locating Nut From Battery Positive Terminal
      G04865545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 clamps of the engine wire.
      Fig 20: Locating Engine Wire And Clamps
      G04865544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire harness with the 2 claws.
    5. Connect the 2 connectors.
      6. Fig 21: Installing Engine Wire Harness With 2 Claws
      G04865543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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  REMOVAL  )
  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: Locating Heater Water Outlet Hose From Air Conditioner Tube
      G04865542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT HEATER WATER INLET HOSE 
    1. Connect the heater inlet hose to the air conditioner tube.
      Fig 23: Locating Heater Water Inlet Hose From Booster Vacuum Tube
      G04865541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the union to connector tube to the booster vacuum tube.
      2. Fig 24: Locating Connector Tube Hose From Booster Vacuum Tube
      G04865540Courtesy 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) 

    2. Connect the clamp of the engine wire.
      Fig 25: Locating Battery Carrier And Bolts
      G04865539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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) 

    3. Connect the clamp of the engine wire.
    Fig 26: Locating Air Cleaner Case And Bolt
    G04865538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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  COOLANT  ) 
  76. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  77. CHECK FOR ENGINE COOLANT LEAKS 
    1. Check for the engine coolant leaks (see COOLANT ).
  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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