Engine Assembly: Installation
- INSTALL ENGINE COOLANT TEMPERATURE SENSOR
- Using SST, install a new gasket and the ECT sensor.
SST 09817-33190
Torque: 20 N*m (208 kgf*cm, 15 ft.*lbf)
- Using SST, install a new gasket and the ECT sensor.
- INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
- Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil.
Adhesive:
Part No. 08833-00080 THREE BOND 1344 or equivalent
- Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
- Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil.
- INSTALL RADIO SETTING CONDENSER
- Install the condenser with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
- Install the condenser with the bolt.
- INSTALL KNOCK SENSOR
- Install the sensor with the nut as shown in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
- Install the sensor with the nut as shown in the illustration.
- INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See INSTALLATION )
- INSTALL IGNITION COIL ASSEMBLY
- Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Install the 4 ignition coils with the 4 bolts.
- INSTALL ENGINE MOUNTING BRACKET RH
- Remove the engine mounting bracket RH with the 3 bolts.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
- Remove the engine mounting bracket RH with the 3 bolts.
- INSTALL OIL COOLER PIPE (w/ Oil Cooler)
- Install a new gasket and the pipe with the bolt and 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Install a new gasket and the pipe with the bolt and 2 nuts.
- INSTALL NO. 1 WATER BY-PASS PIPE
- Install a new gasket and the pipe with the bolt and 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Install a new gasket and the pipe with the bolt and 2 nuts.
- INSTALL THERMOSTAT (See INSTALLATION )
- INSTALL WATER INLET (See INSTALLATION )
- INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
- Except for PZEV:
- Install a new gasket onto the cylinder head.
- Temporarily tighten the exhaust manifold converter with the 5 nuts.
- Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 N*m (378 kgf*cm, 27 ft.*lbf)
- Connect the air-fuel ratio sensor connector.
- Install the exhaust manifold heat insulator with the 4 bolts.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
- For PZEV:
- Install a new gasket onto the cylinder head.
- Temporarily tighten the exhaust manifold converter with the 5 nuts.
- Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 N*m (378 kgf*cm, 27 ft.*lbf)
- Connect the air-fuel ratio sensor connector.
- Except for PZEV:
- INSTALL NO. 2 MANIFOLD STAY
- Install the stay with the bolt and nut.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
- Install the stay with the bolt and nut.
- INSTALL MANIFOLD STAY
- Install the stay with the bolt and nut.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
- Install the stay with the bolt and nut.
- INSTALL OIL LEVEL GAUGE GUIDE
- Apply a light coat of engine oil to a new O-ring and install it to the guide.
- Install the oil level gauge guide with the bolt.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
- INSTALL DRIVE SHAFT BEARING BRACKET
- Install the bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
- Install the bracket with the 3 bolts.
- INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
- Install the intake manifold insulator onto the cylinder block.
- INSTALL NO. 2 VENTILATION HOSE
- INSTALL INTAKE AIR CONTROL VALVE (for PZEV) (See INSTALLATION )
- INSTALL INTAKE MANIFOLD
- Install a new gasket into the intake manifold.
- Install the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 N*m (305 kgf*cm, 22 ft.*lbf)
- INSTALL FUEL DELIVERY PIPE WITH INJECTOR (See INSTALLATION )
- REMOVE ENGINE STAND
- INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) (See INSTALLATION )
- INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See REASSEMBLY )
- INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See REASSEMBLY )
- INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) (See INSTALLATION )
- INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
HINT:
See INSTALLATION .
- INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
HINT:
See INSTALLATION .
- INSTALL STARTER ASSEMBLY (for Manual Transaxle) (See INSTALLATION )
- INSTALL STARTER ASSEMBLY (for Automatic Transaxle) (See INSTALLATION )
- INSTALL ENGINE WIRE
- INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See INSTALLATION )
- INSTALL FRONT FRAME ASSEMBLY
- A/T:
Install the engine mounting insulator LH with the nut.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
- M/T:
Install the engine mounting insulator LH with the bolt.
Torque: 143 N*m (1,459 kgf*cm, 105 ft.*lbf)
- Install the engine mounting insulator RH with the nut.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
- Install the engine mounting insulator FR with the bolt.
Torque: 87 N*m (888 kgf*cm, 64 ft.*lbf)
- M/T:
Install the engine lateral control rod with the bolt.
Torque: 89 N*m (910 kgf*cm, 66 ft.*lbf)
- A/T:
- INSTALL VANE PUMP ASSEMBLY
- Install the vane pump to the engine with the 2 bolts.
Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf)
- Connect the oil pressure switch connector.
- Install the vane pump to the engine with the 2 bolts.
- INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
- Set the engine assembly with transaxle on the engine lifter.
- Install the engine assembly to the vehicle.
- Install the frame side plate LH and RH with the 4 bolts and 2 nuts.
Torque:
Bolt A
85 N*m (867 kgf*cm, 63 ft.*lbf)
Bolt B and nut
32 N*m (326 kgf*cm, 24 ft.*lbf)
- Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
Bolt C
85 N*m (867 kgf*cm, 63 ft.*lbf)
Bolt D and nut
32 N*m (326 kgf*cm, 24 ft.*lbf)
- INSTALL STEERING SLIDING YOKE (See INSTALLATION )
- INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
- Install the exhaust pipe support bracket with the 2 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
- Install the exhaust pipe support bracket with the 2 bolts.
- INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) (See INSTALLATION )
- INSTALL FRONT AXLE ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT AXLE ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See INSTALLATION )
- INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT:
Use the same procedures described for the LH side.
- INSTALL TIE ROD ASSEMBLY LH (See INSTALLATION )
- INSTALL TIE ROD ASSEMBLY RH
HINT;
Use the same procedures described for the LH side.
- INSTALL FRONT SPEED SENSOR LH (See INSTALLATION )
- INSTALL FRONT SPEED SENSOR RH
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
- INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT AXLE HUB NUT LH (See INSTALLATION )
- INSTALL FRONT AXLE HUB NUT RH
HINT:
Use the same procedures described for the LH side.
- INSTALL FRONT EXHAUST PIPE ASSEMBLY
HINT:
See INSTALLATION .
- INSTALL COMPRESSOR AND MAGNETIC CLUTCH
- Install the cooler compressor with the 4 bolts.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
NOTE: Tighten the bolts in the order shown in the illustration to install the cooler compressor.
- Install the cooler compressor with the 4 bolts.
- INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
- CONNECT FUEL TUBE SUB-ASSEMBLY
- Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.NOTE:
- Check for damage or contamination on the connected part of the pipe.
- Check if the pipe and the connector are securely connected by trying to pull them apart.
- Install the No. 1 fuel pipe clamp.
- Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
- INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
HINT:
See INSTALLATION .
- REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)
HINT:
See REMOVAL .
- CONNECT RETURN TUBE SUB-ASSEMBLY
- Connect the return tube sub-assembly.
- CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
- Connect the No. 1 oil reservoir to pump hose.
- INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
- Connect the ends of the 2 cables and install the 2 washers and 2 clips.
- Install 2 new clips to the control cable bracket.
- INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
- Install the control lever with a new clip and the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
- Connect the cable to the transaxle.
- Install the control lever with a new clip and the nut.
- CONNECT ENGINE WIRE
- Connect the clamp.
- Install the ground cables with the 2 bolts to the body.
Torque:
Bolt A
8.4 N*m (85 kgf*cm, 74 in.*lbf)
Bolt B
12 N*m (123 kgf*cm, 9 ft.*lbf)
- Connect the clamp to the bracket.
- Connect the 3 connectors to the engine room junction block. Then, install it with the nut.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
- INSTALL ECM
HINT:
See INSTALLATION .
- CONNECT HEATER INLET WATER HOSE
- Connect the heater inlet water hose.
- CONNECT HEATER OUTLET WATER HOSE
- Connect the heater outlet water hose.
- CONNECT OIL COOLER INLET HOSE (See INSTALLATION )
- CONNECT OIL COOLER OUTLET HOSE (See INSTALLATION )
- CONNECT RADIATOR HOSE INLET
- Install the clamp and connect the radiator hose inlet.
- CONNECT RADIATOR HOSE OUTLET
- Install the clamp and connect the radiator hose outlet.
- CONNECT NO. 1 VACUUM HOSE CONNECTOR
- Install the clamp and connect the vacuum hose connector.
- INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
- Install the 3 bolts and No. 2 mounting bracket RH.
Torque: 52 N*m (531 kgf*cm, 38 ft.*lbf)
- Install the 3 bolts and No. 2 mounting bracket RH.
- INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
- Install the engine moving control rod with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
- Install the ground cable with the bolt.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
- Install the engine moving control rod with the 3 bolts.
- INSTALL NO. 2 ENGINE MOUNTING STAY RH
- Install the No. 2 mounting stay RH with the 2 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
- Install the No. 2 mounting stay RH with the 2 bolts.
- INSTALL BATTERY
- Install the battery and battery tray.
- Install the battery clamp with the bolt and nut.
Torque:
Bolt
9.0 N*m (92 kgf*cm, 80 in.*lbf)
Nut
3.5 N*m (36 kgf*cm, 31 in.*lbf)
- INSTALL AIR CLEANER CASE SUB-ASSEMBLY
- Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Connect the hose clamp.
- Install the air cleaner case with the 3 bolts.
- INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See INSTALLATION )
- INSTALL AIR CLEANER INLET ASSEMBLY
- Install the air cleaner inlet with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the air cleaner inlet with the 2 bolts.
- INSTALL V-RIBBED BELT (See INSTALLATION )
- INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY (See INSTALLATION )
- INSTALL WINDSHIELD WIPER LINK ASSEMBLY
HINT:
See INSTALLATION .
- INSTALL FRONT WHEEL
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
- ADD ENGINE OIL
- CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
- BLEED CLUTCH LINE (for Manual Transaxle) (See INSTALLATION )
- ADD ENGINE COOLANT (See ON-VEHICLE INSPECTION )
- ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) (See INSTALLATION )
- ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) (See INSTALLATION )
- ADD POWER STEERING FLUID
- BLEED POWER STEERING FLUID (See BLEEDING )
- CHECK FOR FUEL LEAKS (See ON-VEHICLE INSPECTION )
- CHECK FOR ENGINE OIL LEAKS
- CHECK FOR ENGINE COOLANT LEAKS (See ON-VEHICLE INSPECTION )
- CHECK FOR EXHAUST GAS LEAKS
- CHECK SHIFT LEVER POSITION (See ON-VEHICLE INSPECTION )
- ADJUST FRONT WHEEL ALIGNMENT
HINT:
See ADJUSTMENT .
- CHECK IGNITION TIMING (See INSPECTION )
- CHECK ENGINE IDLE SPEED (See INSPECTION )
- INSPECT CO/HC (See INSPECTION )
- INSTALL FRONT FENDER APRON SEAL RH
- INSTALL ENGINE UNDER COVER LH
- INSTALL ENGINE UNDER COVER RH
- INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
- Install the engine cover with the 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Install the engine cover with the 2 nuts.
- CHECK ABS SPEED SENSOR SIGNAL
- ABS: See TEST MODE PROCEDURE
- VSC (for BOSCH): See TEST MODE PROCEDURE
- VSC (for ADVICS): See TEST MODE PROCEDURE