Engine Assembly: Installation: Installation

1. Using SST, hold the crankshaft.
   Fig 1: Holding Crankshaft With SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09213-58013 
     • 91651-60855
   • SST: 09330-00021 
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.

   Fig 2: Locating Bolts And Drive Plate

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

1. Hold the crankshaft with SST.
   Fig 3: Holding Crankshaft With SST

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   • SST: 09213-58013 
     • 91651-60855
   • SST: 09330-00021 
2. Clean the 8 bolts and their holes.
3. Apply adhesive to the 2 or 3 end threads of the bolts.
   Fig 4: Applying Bolt Adhesive

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *1

   Adhesive

   Adhesive

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

4. Install the flywheel with the 8 bolts in the order shown in the illustration.
   Fig 5: Locating Flywheel And Bolts

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

5. Mark paint marks on the upper edge of the bolt heads.
   Fig 6: Tightening Flywheel Bolts Additional 90 Degrees

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   TEXT IN ILLUSTRATION
   
   

   *a	Paint Mark

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.

1. Install the control cable bracket with 2 bolts.
   Fig 7: Locating Control Cable Bracket

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

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) 

1. Install the transverse engine mounting insulator with the 5 bolts.
   Fig 8: Locating Bolts And Transverse Engine Mounting Insulator

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

1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
   Fig 9: Identifying Engine Lifter

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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.
   Fig 10: Locating Through Bolt And Nut

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

4. Install the engine mounting insulator RH with the 6 bolts and nut.
   Fig 11: Identifying Engine Mounting Insulator Bolt Location

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   TEXT IN ILLUSTRATION
   
   

   *a

   Nut C

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

   for Bolt A

   Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

   for Bolt B

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

   for Nut C

5. Install the engine mounting stay RH with the 2 bolts.
   Fig 12: Locating Bolts And Engine Mounting Stay RH

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

6. w/o Painted Bolt:
   1. Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts.
      Fig 13: Identifying Front Suspension Crossmember And Bolts

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7. w/ Painted Bolt:
   1. Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with bolt A, bolt C and a new bolt B.
      NOTE:

      If bolt B has orange paint on the bolt head, it is a non-reusable bolt and must be replaced with a new bolts (Part No.: 90119-14151) if they are removed.

8. 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.
   Fig 14: Inserting SST Into Datum Holes

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   TEXT IN ILLUSTRATION
   
   

   *1	Bolt A	*2	Bolt B
   *3	Bolt C	-	-
   *a	Front	*b	Datum Hole
   *c	OK	*d	NG

   • SST: 09670-00010 

   Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

   for Bolt A

   Torque: 151 N*m (1540 kgf*cm, 111 ft.*lbf) 

   for Bolt B

   Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf) 

   for Bolt C

   WARNING:

   • Insert SST into the datum hole vertically.
   • If impossible to insert SST vertically, loosen all bolts and then insert SST again.

HINT: 

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

HINT: 

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

HINT: 

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

HINT: 

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

HINT: 

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

HINT: 

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

1. Using vernier calipers, measure the free length of the compression spring.
   Fig 15: Measuring Free Length Of Compression Spring

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   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.

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.
   Fig 16: Identifying Wooden Block And Gasket

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   TEXT IN ILLUSTRATION
   
   

   *1	Gasket
   *2	Wooden Block

   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.
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.
   Fig 17: Locating Heated Oxygen Sensor Connector

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1. Install the clutch release cylinder and clutch pipe with the 4 bolts.
   Fig 18: Locating Clutch Release Cylinder Assembly With Bolts

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

   for bolt A

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

   for bolt B

1. Connect the fuel tube connector and fuel pipe, and install the No. 1 fuel pipe clamp.
   Fig 19: Locating No. 1 Fuel Pipe Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   WARNING:

   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 the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

1. Connect heater water inlet hose A to the heater unit.
   Fig 20: Locating Heater Water Inlet Hose

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1. Connect heater water outlet hose A to the heater unit.
   Fig 21: Locating Heater Water Outlet Hose

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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

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2. Connect the engine wire harness connector to the ECM.
   Fig 23: Locating Wire Harness Clamps

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3. Connect the 2 wire harness clamps.
4. Connect the 2 connectors.
   Fig 24: Locating Connectors

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5. Install the transaxle earth wire with the bolt and 2 wire harness clamps (for Manual Transaxle).
   Fig 25: Locating Bolt And Wire Harness Clamp

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

6. Install the transaxle earth wire with the bolt and wire harness clamp (for Automatic Transaxle).
   Fig 26: Locating Bolt And Wire Harness Clamp

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

1. Install the No. 1 fuel vapor feed hose into the vacuum switching valve assembly.
   Fig 27: Locating No. 1 Fuel Vapor Feed Hose

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1. Install the union to check valve hose with the clip.
   Fig 28: Locating Clip And Check Valve Hose

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Fig 29: Identifying Transmission Control Cable Assembly Nut

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1. Install the transmission control cable assembly onto the control shaft lever with the nut.
   TEXT IN ILLUSTRATION
   
   

   *1	Control Cable Bracket
   *a	Marking

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

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.

Fig 30: Locating Control Cable Bracket

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1. Install the control cable assembly onto the control cable bracket with 2 new clips.
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.
   Fig 31: Removing/Installing Control Cable Assembly On Shift Lever Retainer

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   TEXT IN ILLUSTRATION
   
   

   *a	Projecting Part
   *b	Lock

   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.

1. Install the No. 2 radiator hose with the 2 clips.
   Fig 32: Locating Clips And No. 2 Radiator Hose

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Fig 33: Locating Bolts And Battery Carrier

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1. Install the battery carrier with the 5 bolts.

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

2. Install the clamp.

Fig 34: Locating Air Cleaner Bracket

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1. Install the air cleaner bracket with the 2 bolts.

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

2. Connect the wire harness clamp to the air cleaner bracket.

Fig 35: Locating Air Cleaner Hose Clamp

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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) 

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.
   Fig 36: Locating Clamps

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

5. Connect the ventilation hose to the air cleaner hose.
6. Connect the intake air flow meter connector and 2 wire harness clamps.

Fig 37: Locating Bolts And Outer Cowl Top Panel

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1. Install the outer cowl top panel with the 9 bolts.

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

2. Connect the wire harness clamp.
   Fig 38: Locating Wire Harness Clamp

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Fig 39: Identifying Claws Locations

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1. Engage the 2 claws to install the front air shutter seal RH.

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) 

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

Refer to ADJUSTMENT

Refer to TEST MODE PROCEDURE