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Replacement (Manual Transmission)

WARNING: This page is about a different variant/trim than selected.
  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  2. REMOVE FRONT WHEELS 
  3. REMOVE ENGINE UNDER COVER LH 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE EXHAUST PIPE ASSY 
  6. DRAIN TRANSAXLE OIL 
    1. Remove the filler plug and gasket.
    2. Remove the drain plug and gasket, and drain the oil.
    3. Install the drain plug with a new gasket.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

  7. REMOVE HOOD SUB-ASSY 
  8. REMOVE CYLINDER HEAD COVER NO.2 
  9. REMOVE AIR CLEANER ASSY 
  10. REMOVE BATTERY CLAMP SUB-ASSY 
  11. REMOVE BATTERY 
  12. REMOVE BATTERY TRAY 
  13. REMOVE BATTERY CARRIER 
    1. Remove the 4 bolts and battery carrier.
    Fig 1: Removing Bolts Battery Carrier
    G02614524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) (see  CRUISE CONTROL ACTUATOR ASSY (2ZZ-GE)  ) 
  15. DISCONNECT WIRE HARNESS 
    1. Disconnect the wire harness clamp.
    2. Remove the 2 bolts and disconnect the 2 wire harness brackets.
    3. Remove the bolt and disconnect the ground cable.
      Fig 2: Removing Bolt Ground Cable
      G02614525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the ground cable.
    Fig 3: Removing Bolt Ground Cable
    G02614526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT CONNECTOR 
    1. Disconnect the back-up lamp switch connector.
      Fig 4: Disconnecting Back-Up Lamp Switch Connector
      G02614527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o ABS:

      Disconnect the speed sensor connector.

    Fig 5: Disconnecting Speed Sensor Connector
    G02614528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. SEPARATE CLUTCH RELEASE CYLINDER ASSY 
    1. Remove the 5 bolts and separate the release cylinder assy with the clutch piping from the transaxle.
    Fig 6: Removing Bolts
    G02614529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT 
    1. Remove the clip and washer and disconnect the shift cable from the transaxle.
    2. Remove the clip and disconnect the shift cable from the bracket.
    Fig 7: Removing Clip And Washer
    G02614530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT 
    1. Remove the clip and washer and disconnect the select cable from the transaxle.
    2. Remove the clip and disconnect the select cable from the bracket.
    Fig 8: Removing Clip And Washer
    G02614531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE STARTER ASSY 
    1. Remove the nut and disconnect the starter wire.
    2. Disconnect the starter connector.
    3. Remove the 2 bolts and starter assy.
    Fig 9: Removing Bolts Starter Assy
    G02614532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. SEPARATE STEERING INTERMEDIATE SHAFT (see  OVERHAUL  ) 
  22. REMOVE FRONT DRIVE SHAFT ASSY LH 
    • 1ZZ-FE engine type: (see OVERHAUL )
    • 2ZZ-GE engine type: (see OVERHAUL )

      SST 09520-01010, 09520-24010 (09520-32040)

  23. REMOVE FRONT DRIVE SHAFT ASSY RH 

    SST 09520-01010, 09520-24010 (09520-32040)

    HINT:

    Remove the RH side by following the same procedures as for the LH side.

  24. SEPARATE RETURN TUBE SUB-ASSY (see  OVERHAUL  ) 

    SST 09023-12701

  25. SEPARATE PRESSURE FEED TUBE ASSY (see  OVERHAUL  ) 
    Fig 10: Attaching Engine Chain Hoist To Hangers
    G02614533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. SUSPEND ENGINE ASSY 
    1. Install the 2 hangers in the correct direction.

      Parts No.: 

      Engine hanger: 12281-22021 

      No.1 engine hanger: 12281-15040 

      Bolt: 91512-B1016 

      Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 

    2. Attach the engine chain hoist to the hangers.
    CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
  27. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY (see  FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH  ) 
  28. SUPPORT MANUAL TRANSAXLE ASSY 
    1. Support the transaxle with a transmission jack.
  29. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 5 bolts, nut and engine mounting insulator LH from the body.
    Fig 11: Removing Bolts
    G02614534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Remove the 3 bolts and engine mounting bracket LH from the transaxle.
    Fig 12: Removing Bolts Engine Mounting Bracket LH
    G02614535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE MANUAL TRANSAXLE ASSY 
    1. Remove the 6 bolts and transaxle from the engine. 
    Fig 13: Removing Bolts Transaxle
    G02614536Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE ENGINE MOUNTING BRACKET FR 
    1. Remove the bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
    2. Remove the 2 bolts and engine mounting bracket FR from the transaxle.
    Fig 14: Removing Bolts Engine Mounting Bracket FR
    G02614537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE ENGINE MOUNTING BRACKET RR 
    1. Remove the bolt and engine mounting insulator RR from the engine mounting bracket RR.
    2. Remove the 3 bolts and engine mounting bracket RR from the transaxle.
    Fig 15: Removing Bolts Engine Mounting Bracket RR
    G02614538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL ENGINE MOUNTING BRACKET RR 
    1. Install the engine mounting bracket RR and 3 bolts to the transaxle.

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

    2. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR.

      Torque: 65 N.m (663 kgf.cm, 48 ft.lbf) 

    Fig 16: Installing Bolts
    G02614539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL ENGINE MOUNTING BRACKET FR 
    1. Install the engine mounting bracket FR and 2 bolts to the transaxle.

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

    2. Install the engine mounting insulator FR, bolt and nut to the engine mounting bracket FR.

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

    Fig 17: Installing Bolts
    G02614540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL MANUAL TRANSAXLE ASSY 
    1. Align the input shaft with the clutch disc and install the transaxle to the engine.
    2. Install the 6 bolts.

      Torque: 

      Bolt A: 64 N.m (650 kgf.cm, 47 ft.lbf) 

      Bolt B: 47 N.m (480 kgf.cm, 35 ft.lbf) 

      Bolt C: 23 N.m (230 kgf.cm, 17 ft.lbf) 

    Fig 18: Installing Bolts
    G02614541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the engine mounting bracket LH to the transaxle with the 3 bolts.

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

    Fig 19: Installing BOLTS Engine Mounting Bracket LH To Transaxle
    G02614542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH with the 5 bolts and nut.

      Torque: 

      Bolt A: 52 N.m (530 kgf.cm, 38 ft.lbf) 

      Bolt B: 80 N.m (816 kgf.cm, 59 ft.lbf) 

    Fig 20: Installing Bolts Engine Mounting Insulator LH
    G02614543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY (see  FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH  ) 

    SST 09670-00010

  40. CONNECT STEERING INTERMEDIATE SHAFT (see  OVERHAUL  ) 
  41. INSTALL COLUMN HOLE COVER SILENCER SHEET (see  OVERHAUL  ) 
  42. CONNECT RETURN TUBE SUB-ASSY (see  OVERHAUL  ) 

    SST 09023-12701

  43. CONNECT PRESSURE FEED TUBE ASSY (see  OVERHAUL  ) 

    SST 09023-12701

  44. INSTALL FRONT DRIVE SHAFT ASSY LH (see  OVERHAUL  ) 
  45. INSTALL FRONT DRIVE SHAFT ASSY RH 

    HINT:

    Install the RH side by following the same procedures as for the LH side.

    Fig 21: Installing Bolts Starter Assy
    G02614544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. INSTALL STARTER ASSY 
    1. Install the starter assy and 2 bolts to the transaxle.

      Torque: 37 N.m (378 kgf.cm, 27 ft.lbf) 

    2. Connect the starter connector.
    3. Install the wire and nut to the starter assy.

      Torque: 13 N.m (131 kgf.cm, 9 ft.lbf) 

    Fig 22: Installing Clip To Control Cable Bracket
    G02614545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT 
    1. Connect the shift cable end and install the washer and clip.
    2. Install a new clip to the control cable bracket.
    Fig 23: Installing Clip To Control Cable Bracket
    G02614546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT 
    1. Connect the select cable end and install the washer and clip.
    2. Install a new clip to the control cable bracket.
  49. CONNECT CLUTCH RELEASE CYLINDER ASSY 
    1. Install the release cylinder with the 5 bolts.

      Torque: 

      Bolt A: 25 N.m (250 kgf.cm, 19 ft.lbf) 

      Bolt B: 12 N.m (120 kgf.cm, 9 ft.lbf) 

      Bolt C: 5.0 N.m (51 kgf.cm, 44 in..lbf) 

    Fig 24: Installing Bolts Release Cylinder
    G02614547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. CONNECT CONNECTOR 
    1. Connect the back-up lamp switch connector.
      Fig 25: Connecting Back-Up Lamp Switch Connector
      G02614548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o ABS:

      Connect the speed sensor connector.

    Fig 26: Connecting Speed Sensor Connector
    G02614549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT WIRE HARNESS 
    1. Install the 2 wire harness brackets to the transaxle with the 2 bolts.

      Torque: 

      Bolt A: 26 N.m (260 kgf.cm, 19 ft.lbf) 

      Bolt B: 13 N.m (131 kgf.cm, 9 ft.lbf) 

    2. Connect the wire harness clamp.
    3. Install the ground cable with the bolt.

      Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

      Fig 27: Installing Ground Cable Bolts
      G02614550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the bolt and ground cable.

      Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

    Fig 28: Installing Ground Cable Bolts
    G02614551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) (see  CRUISE CONTROL ACTUATOR ASSY (2ZZ-GE)  ) 
  53. INSTALL BATTERY CARRIER 
    1. Install the battery carrier and 4 bolts.

      Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

    Fig 29: Installing Battery Carrier Bolts
    G02614552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. INSTALL BATTERY TRAY 
  55. INSTALL BATTERY 
  56. INSTALL BATTERY CLAMP SUB-ASSY 

    Torque: 

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

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

  57. INSTALL AIR CLEANER ASSY 

    Torque: 7.0 N.m (71 kgf.cm, 62 in..lbf) 

  58. INSTALL CYLINDER HEAD COVER NO.2 

    Torque: 7.0 N.m (71 kgf.cm, 62 in..lbf) 

  59. INSTALL HOOD SUB-ASSY 

    Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

  60. INSPECT HOOD SUB-ASSY 
  61. ADJUST HOOD SUB-ASSY (see  HOOD  ) 
  62. ADD TRANSAXLE OIL (see  FRONT DIFFERENTIAL OIL SEAL (MTM)   ) 
  63. INSPECT TRANSAXLE OIL (see  MANUAL TRANSAXLE OIL (MTM)   ) 
  64. BLEED POWER STEERING FLUID (see  ON-VEHICLE INSPECTION  ) 
  65. INSTALL FRONT WHEELS 

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

  66. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  67. INSTALL EXHAUST PIPE ASSY 
  68. INSTALL ENGINE UNDER COVER LH 
  69. INSTALL ENGINE UNDER COVER RH 
  70. INSPECT FRONT WHEEL ALIGNMENT (see  FRONT WHEEL ALIGNMENT  ) 
  71. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) (see  TEST MODE PROCEDURE  ) 
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