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Engine Assembly: Installation

  1. INSTALL HEATER INLET WATER HOSE 
  2. INSTALL RADIATOR HOSE INLET 
  3. INSTALL WATER bypass HOSE NO.2 
  4. INSTALL RADIO SETTING CONDENSER 
    1. Install the condenser with the bolt.

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

  5. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Install a new gasket onto the engine coolant temperature sensor.
      Fig 1: Locating Condenser Bolt
      G05192964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the engine coolant temperature sensor.

      SST 09817-33190 

      Torque: 19.6 N*m (200 kgf*cm, 14 ft.*lbf) 

    Fig 2: Locating Engine Coolant Temperature Sensor
    G05192962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL EXHAUST MANIFOLD 
    1. Install a new gasket and the exhaust manifold with the 5 nuts.

      Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) 

    Fig 3: Locating Gasket And Exhaust Manifold Nuts
    G05192961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Install the exhaust manifold heat insulator with the 4 bolts [A].

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Connect the air fuel ratio sensor connector [B].
    Fig 4: Locating Exhaust Manifold Heat Insulator Bolts [A]
    G05192967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL MANIFOLD STAY 
    1. Install the manifold stay with 3 bolts.

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the V-ribbed belt tensioner assembly (See )INSTALLATION .
    Fig 5: Locating Manifold Stay Bolts
    G05192959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL KNOCK SENSOR 
    1. Install the knock sensor with the nut.

      Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) 

    Fig 6: Locating Knock Sensor Nut
    G05192958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the crankshaft position sensor with the 2 bolts.

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

    Fig 7: Locating Crankshaft Position Sensor Bolts
    G05192957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CAMSHAFT POSITION SENSOR 
    1. Install the camshaft position sensor with the bolt.

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

  13. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Install the engine oil pressure switch assembly (See ON-VEHICLE INSPECTION ).
  14. INSTALL THERMOSTAT 
    1. Install the thermostat (See INSTALLATION ).
    Fig 8: Locating Camshaft Position Sensor Bolt
    G05192956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL WATER INLET 
    1. Install the water inlet (See INSTALLATION ).
  16. INSTALL WATER bypass PIPE N0.1 
    1. Install a new gasket and the water bypass pipe No. 1 with the 2 nuts and 2 bolts.

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

    2. Connect the knock sensor clamp.
  17. INSTALL OIL LEVEL GAUGE GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it onto the oil level gauge guide.
      Fig 9: Locating Water bypass Pipe No.1 - 2WD Nuts And Bolts
      G05192955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil level gauge guide with the bolt.

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

    3. Connect the crankshaft position sensor clamp.
  18. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold (See INSTALLATION ).
  19. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY 
  20. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Install the fuel delivery pipe sub-assembly (See INSTALLATION ).
    Fig 10: Locating Oil Level Gage Guide Bolt
    G05192954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the ignition coil assembly (See )INSTALLATION .
  22. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Install the flywheel sub-assembly (See INSTALLATION ).

      SST 09960-10010 (09962-01000, 09963-01000) 

  23. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Install the drive plate & ring gear sub-assembly (See INSTALLATION ).

      SST 09960-10010 (09962-01000, 09963-01000) 

  24. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch disc assembly (See INSTALLATION ).

      SST 09301-00210 

  25. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch cover assembly (See INSTALLATION ).
  26. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 
    1. Install the automatic transaxle assembly (See INSTALLATION ).
  27. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 
    1. Install the manual transaxle assembly (See INSTALLATION ).
  28. INSTALL STARTER ASSEMBLY 
    1. Install the starter assembly (See INSTALLATION ).
  29. INSTALL FRONT SUSPENSION CROSSMEMBER W/ 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 engine mounting insulator RR, into the engine mounting bracket RR.

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

      Fig 11: Locating Engine Mounting Insulator RR Bolt
      G05192953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt, which is used to secure the engine mounting insulator FR, into the engine mounting bracket FR.

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

  30. INSTALL VANE PUMP ASSEMBLY 
    1. Install the vane pump assembly (See INSTALLATION ).
  31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Install the engine with transaxle onto the vehicle.
    3. Temporarily install the suspension crossmember with the 6 bolts.
      Fig 12: Locating Engine Mounting Insulator FR Bolt
      G05192975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 13: Locating Suspension Crossmember Bolts
      G05192950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting insulator LH with the through bolt and nut.

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

      Fig 14: Locating Engine Mounting Insulator LH Bolt And Nut
      G05192949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.

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

      Fig 15: Locating Engine Mounting Insulator RH Bolts And Nuts
      G05192770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert SST into the positioning holes on the right handle crossmember and on the right-handle of the vehicle.

      SST 09670-00010 

    7. Temporarily tighten the bolt A first, then bolt B.
      Fig 16: Inserting SST Into Positioning Holes On Right Handle Crossmember
      G05192979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Insert SST into the positioning holes on the left handle crossmember and on the left-handle of the vehicle.

      SST 09670-00010 

    9. Temporarily tighten the bolt A first, then bolt B.
    10. Insert SST into the positioning holes on the right-handle crossmember and right-handle of the vehicle, then tighten the bolts to the specified torque.
    11. Insert SST into the positioning holes on the right-handle crossmember and left-handle of the vehicle, then tighten the bolts to the specified torque.

      SST 09670-00010 

      Torque: Bolt A 

      157 N*m (1,601 kgf*cm, 116 ft.*lbf) 

      Bolt B 

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

      Fig 17: Inserting SST Into Positioning Holes On Right Handle Crossmember
      G05192980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Tighten the 2 bolts as shown in the illustration.

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

    NOTE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
  32. INSTALL FRONT AXLE ASSEMBLY LH 
    1. Install the front axle assembly LH (See INSTALLATION ).
    Fig 18: Locating Bolts
    G05192981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  34. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH 
    1. Install the front suspension arm sub-assembly lower No. 1 LH (See INSTALLATION ).
  35. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  36. INSTALL TIE ROD END SUB-ASSEMBLY LH 
    1. Install the tie rod end sub-assembly LH (See INSTALLATION ).
  37. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  38. INSTALL SPEED SENSOR FRONT LH (w/ ABS) 
    1. Install the speed sensor front LH (See INSTALLATION ).
  39. INSTALL SPEED SENSOR FRONT RH (w/ ABS) 

    HINT:

    Perform the same procedure as above on the opposite side.

  40. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 
    1. Install the front stabilizer link assembly LH (See INSTALLATION ).
  41. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  42. INSTALL FRONT AXLE HUB LH NUT 
    1. Install the front axle hub LH nut (See INSTALLATION ).
  43. INSTALL FRONT AXLE HUB RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  44. INSTALL STEERING INTERMEDIATE SHAFT 
    1. Install the steering intermediate shaft (See INSTALLATION ).
  45. INSTALL COLUMN HOLE COVER SILENCER SHEET 
  46. INSTALL EXHAUST PIPE ASSEMBLY FRONT 
    1. Install the exhaust pipe assembly front (See INSTALLATION ).
  47. INSTALL FLOOR PANEL BRACE FRONT 
    1. Install the floor panel brace front (See INSTALLATION ).
  48. CONNECT ENGINE WIRE 
  49. INSTALL COWL SIDE TRIM BOARD RH 
  50. INSTALL FRONT DOOR SCUFF PLATE RH 
  51. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY 
  52. INSTALL RETURN TUBE SUB-ASSEMBLY 
    1. Install the return tube with the 2 bolts.

      Torque: Bolt A 

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

      Bolt B 

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

    2. Install the vane pump oil reservoir onto the oil reservoir bracket.
    Fig 19: Locating Return Tube Bolts
    G05192982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) 
    1. Install the compressor and magnetic clutch (See INSTALLATION ).
  54. INSTALL GENERATOR ASSEMBLY 
    1. Install the generator assembly (See INSTALLATION ).
  55. INSTALL FAN AND GENERATOR V BELT 
  56. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch release cylinder assembly (See INSTALLATION ).
  57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Install the transmission control cable assembly (See INSTALLATION ).
  58. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Install the transmission control cable assembly (See INSTALLATION ).
  59. CONNECT HEATER OUTLET WATER HOSE 
  60. CONNECT HEATER INLET WATER HOSE 
  61. CONNECT UNION TO CHECK VALVE HOSE 
  62. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly (See INSTALLATION ).
  63. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Connect the air cleaner case to the air cleaner inlet No. 1 [A].
    2. Install the air cleaner case with the 3 bolts [B].

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

    3. Connect the clamp [C] of the engine wire.
  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 
    1. Install the air cleaner cap sub-assembly (See INSTALLATION ).
    Fig 20: Locating Air Cleaner Case Bolts [B]
    G05192983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL BATTERY CARRIER 
    1. Install the battery carrier and bracket with the 4 bolts.

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

  66. INSTALL BATTERY TRAY 
  67. INSTALL BATTERY 

    Torque: Bolt 

    5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    Nut 

    3.5 N*m (36 kgf*cm, 31 in.*lbf) 

    Terminal 

    5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    Fig 21: Locating Battery Carrier And Bracket Bolts
    G05194247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL RADIATOR ASSEMBLY (w/ Air Conditioning System) 
    1. Install the radiator assembly (See INSTALLATION ).
  69. CONNECT OIL COOLER OUTLET HOSE NO.1 (for Automatic Transaxle) 
  70. CONNECT OIL COOLER INLET HOSE NO.1 (for Automatic Transaxle) 
  71. CONNECT RADIATOR HOSE OUTLET 
  72. CONNECT RADIATOR HOSE INLET 
  73. INSTALL FRONT WHEELS 

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

  74. ADD ENGINE COOLANT 
    1. Add the engine coolant (See ON-VEHICLE INSPECTION ).
  75. CONNECT BATTERY NEGATIVE TERMINAL 

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

  76. INSPECT FOR ENGINE COOLANT LEAK 
    1. Check for the engine coolant leaks (See ON-VEHICLE INSPECTION ).
  77. INSPECT FOR ENGINE OIL LEAK 
  78. INSPECT FOR FUEL LEAK 
  79. INSPECT FOR EXHAUST GAS LEAK 
  80. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust the front wheel alignment (See ADJUSTMENT ).
  81. CHECK ABS SPEED SENSOR SIGNAL (w/ ABS) 
    1. Check the ABS speed sensor signal (See TEST MODE PROCEDURE ).
  82. INSPECT IGNITION TIMING 
    1. Inspect the ignition timing (See ENGINE ).

      SST 09843-18040 

  83. INSPECT ENGINE IDLING SPEED 
    1. Inspect the engine idling speed (See ENGINE ).
  84. INSPECT CO/HC 
    1. Inspect the CO/HC (See ENGINE ).
  85. INSTALL CYLINDER HEAD COVER NO.2 
    1. Install the cylinder head cover No. 2 (See INSTALLATION ).
  86. INSTALL ENGINE UNDER COVER LH 
  87. INSTALL ENGINE UNDER COVER RH 
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