ENGINE ASSEMBLY > INSTALLATION

for Preparation Click here


NOTICE:
  1. When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.
  2. After replacing the engine assembly, perform the both "injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester.



1. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR


A191854E01

  1. Temporarily tighten the bolt A.

  1. Temporarily tighten the bolt E.

  1. Tighten the bolt B and bolt C.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }

  1. Tighten the bolt A.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }

  1. Tighten the bolt D and bolt E and install the transverse engine engine mounting insulator.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }



2. INSTALL REAR BATTERY BRACKET REINFORCEMENT


A191853

  1. Install the rear battery bracket reinforcement with the 2 bolts.

    Torque:
    17 N*m{ 175 kgf*cm , 13 ft.*lbf }



3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)


    A203227E01

  1. Using SST, hold the crankshaft.

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

  1. Clean the 6 bolts and the 6 bolt holes.



    A192239E01

  1. Apply adhesive to 2 or 3 threads of the bolt end.

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.



    A203229E01

  1. Install the front drive plate spacer.
    Text in Illustration 
    *1
    		Front Drive Spacer
    *2
    		Drive Plate
    *3
    		Rear Drive Plate Spacer

    HINT:
    The front spacer is reversible.

  1. Install the drive plate and rear drive plate spacer onto the crankshaft.

  1. In several steps, uniformly install and tighten the 6 bolts in the sequence shown in the illustration.

    Torque:
    78 N*m{ 800 kgf*cm , 58 ft.*lbf }



4. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)


    C197455E01

  1. Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.
    Text in Illustration 
    *1
    		Knock Pin

  1. Apply clutch spline grease to the round of the crankshaft contact surface (*3) with the torque converter centerpiece.
    Text in Illustration 
    *2
    		Crankshaft

    Clutch spline grease:
    Toyota Genuine Clutch Spline Grease or equivalent

    Maximum spread:
    Approximately 1 g (0.353 oz)



    C195058E01

  1. Maintain the engine and CVT in a horizontal position, align the knock pins and holes*4, and tighten the 9 bolts shown the illustration.

    Torque:
    *1:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }
    *2:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }
    *3:
    39 N*m{ 398 kgf*cm , 29 ft.*lbf }

    NOTICE:
    1. Confirm that there are 2 knock pins on the fitting surface of the engine block before installing the CVT.
    2. Do not twist or apply excessive force to the CVT.
    3. Check that the torque converter rotates smoothly after installation of the CVT.

    HINT:
    Bolt length
    1. *1: 45 mm (1.77 in.)
    2. *2: 45 mm (1.77 in.)
    3. *3: 35 mm (1.38 in.)



5. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for CVT)


    P000601E07

  1. Clean and degrease the 6 drive plate and torque converter setting bolts.

  1. Apply adhesive to 2 or 3 threads on the ends of the 6 torque converter set bolts.
    Text in Illustration 
    *1
    		Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent



    A203227E01

  1. Use SST to hold the crankshaft pulley in place.

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



    C195071

  1. Install the 6 torque converter set bolts.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

    HINT:
    Tighten the black-colored bolt first, and then tighten the 5 silver-colored bolts.



6. INSTALL STARTER ASSEMBLY


    A198914

  1. Install the starter assembly with the 2 bolts.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

  1. Connect the connector.

  1. Connect the cable to terminal 30 with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

  1. Close the terminal cap.



7. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)


    A203227E01

  1. Using SST, hold the crankshaft.

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

  1. Clean the 6 bolts and the 6 bolt holes.



    A192239E01

  1. Apply adhesive to 2 or 3 threads of the bolt end.

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.



    A203280E01

  1. Install the flywheel sub-assembly with the 6 bolts in the order shown in the illustration.

    Torque:
    78 N*m{ 800 kgf*cm , 58 ft.*lbf }



8. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)


C195384E01
Text in Illustration 
*1
Clutch disc
*2
Flywheel

  1. Insert SST into the clutch disc assembly, and then insert them both into the flywheel sub-assembly.

    SST
    09301-00210  

    NOTICE:
    Insert the clutch disc assembly in the correct direction.



9. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)


C195383E01
Text in Illustration 
*1
Matchmark

  1. Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

  1. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

    SST
    09301-00210  

    Torque:
    19 N*m{ 195 kgf*cm , 14 ft.*lbf }

    HINT:
    1. Following the order in the illustration, tighten the bolts evenly one at a time.
    2. Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.



10. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)


    C195379

  1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

    Maximum non-alignment:
    0.5 mm (0.020 in.)



    C195380E01

  1. If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.

    SST
    09333-00013  



11. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

  1. Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.



    C195450

  1. Temporarily tighten the bleeder clutch release tube onto the clutch release with bearing cylinder assembly.



    C198620

  1. Install the new clutch release with the bearing cylinder with the 3 new bolts.

    NOTICE:
    1. The clutch release with bearing cylinder assembly and installation bolts cannot be reused and must be replaced with new ones.
    2. Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder assembly fits securely with the transaxle during installation. The first bolt should be tightened by hand the clutch release with bearing cylinder assembly.
    3. Ensure that none of the clutch disc spline grease adheres to the clutch release with bearing cylinder assembly.
    4. The clutch release with bearing cylinder assembly cannot be disassembled.

    Torque:
    23 N*m{ 229 kgf*cm , 17 ft.*lbf }

  1. Install the clutch tube boot onto the transaxle.

  1. Install the release cylinder bleeder plug onto the clutch release bleeder.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

  1. Install the release cylinder bleeder plug cap.



    C195353E01

  1. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.
    Text in Illustration 
    *1
    		Bleeder clutch release tube
    *2
    		Clutch release bleeder

  1. Temporarily tighten the 2 bolts and install the clutch release bleeder.



    C203689

  1. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

    Torque:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).



12. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)


C195353

  1. Separate the bleeder clutch release tube from the clutch release bleeder.

  1. Remove the 2 bolts and the clutch release bleeder.



13. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)


C195354E01

  1. Using SST, apply pressure of 0.1 MPa to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

    SST
    09992-00242  
    If the pressure drops, replace the bleeder clutch release tube.



14. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
Text in Illustration 
*1
Bleeder clutch release tube
*2
Clutch release bleeder


    C195353E01

  1. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

  1. Install the 2 bolts and clutch release bleeder.

    Torque:
    17 N*m{ 170 kgf*cm , 12 ft.*lbf }

  1. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

    Torque:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).



15. INSTALL BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)

  1. Install the bleeder clutch release tube with the bolt.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf }



    C198732

  1. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

    Torque:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).



16. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

  1. Make sure that the knock pins are not loose, bent, damaged or scratched and then install the transaxle onto the engine with the contact surfaces of the engine and transaxle flat against each other.

  1. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.



    C198742E01

  1. Install the 10 bolts.

    Torque:
    Bolt A:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }
    Bolt B :
    37 N*m{ 377 kgf*cm , 27 ft.*lbf } (for Flange Bolt)
    33 N*m{ 337 kgf*cm , 24 ft.*lbf } (for Bolt with Washer)
    Bolt C:
    39 N*m{ 398 kgf*cm , 29 ft.*lbf }

    NOTICE:
    Insert knock pins into the knock pin holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.



17. INSTALL EXHAUST MANIFOLD


    A199604E01

  1. Place the 2 new gaskets and install the exhaust manifold, tightening the nuts and bolts in the sequence shown in the illustration.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    A199602E01

  1. Install the No. 1 exhaust manifold heat insulator, tightening the nuts and bolts in the sequence shown in the illustration.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }



19. INSTALL AIR FUEL RATIO SENSOR


    A200973E01

  1. Using SST, install the air fuel ratio sensor to the exhaust manifold.

    SST
    09224-00010  

    Torque:
    without SST:
    44 N*m{ 449 kgf*cm , 32 ft.*lbf }
    with SST:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }

    NOTICE:
    1. The "with SST" torque value is effective when using SST with a fulcrum length of 30 mm (1.18 in.).
    2. The "with SST" torque value is effective when using a torque wrench with a fulcrum length of 300 mm (11.81 in.) (Click here).
    3. This torque value is effective when SST is parallel to the torque wrench.

  1. Install the wire harness clamp and connect the air fuel ratio sensor connector.



20. INSTALL MANIFOLD STAY


    A199603

  1. After temporarily tightening the manifold stay until the nut is firm against the exhaust manifold, fully tighten the manifold stay to the block with the 2 bolts and then fully tighten the nut on the exhaust manifold side.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }



21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


A203215

  1. Set the engine assembly with transaxle on the engine lifter.

  1. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator RH and transverse engine engine mounting insulator can be installed.

    CAUTION:
    Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

    NOTICE:
    1. Make sure that the engine is clear of all wiring and hoses.
    2. While raising the engine into the vehicle, do not allow it to contact the vehicle.



    A191852E01

  1. Temporarily install the transverse engine engine mounting insulator with the through bolt.
    Text in Illustration 
    *1
    		Through Bolt

  1. Tighten the through bolt and bolt in the order shown in the illustration.

    Torque:
    Through bolt:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }

    Torque:
    Bolt:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }



    A191851E01

  1. Temporarily tighten the bolt A.

  1. Tighten the 2 bolts on the vehicle side in the sequence shown in the illustration.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }

  1. Fully tighten the bolt A.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }

  1. Tighten the bolt and the 2 nuts on the engine side and install the engine mounting insulator RH.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }



    C196452E01

  1. Secure the hole (A) shown in the illustration and the body with a piece of rope.
    Text in Illustration 
    *1
    		Rope

    NOTICE:
    When installing the engine assembly with the transaxle, make sure that the engine assembly does not move to the vehicle front, to prevent it from contacting other parts.



    A191850

  1. Connect the vacuum hose to the vacuum switching valve.



    A191934

  1. Remove the 2 bolts and the 2 engine hangers.



22. INSTALL ENGINE MOVING CONTROL ROD


C196136

  1. Install the engine moving control rod with the bolt.

    Torque:
    100 N*m{ 1020 kgf*cm , 74 ft.*lbf }



23. INSTALL ENGINE MOVING CONTROL ROD COVER (for Cold Area)


C197997

  1. Install the engine moving control rod cover with the 2 clips.



24. INSTALL COOLER COMPRESSOR ASSEMBLY


I104979

  1. Using a "TORX" socket wrench (E8), install the compressor with the 2 stud bolts.

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }



    I104981E01

  1. Install the compressor with the 2 bolts and the 2 nuts.

    Torque:
    25 N*m{ 250 kgf*cm , 18 ft.*lbf }

    HINT:
    Tighten the bolts and the nuts in the order shown in the illustration.

  1. Connect the connector.



25. INSTALL DISCHARGE HOSE SUB-ASSEMBLY


I104975

  1. Remove the attached vinyl tape from the discharge hose.

  1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

    Compressor oil:
    ND-OIL 8 or equivalent

  1. Install the O-ring onto the discharge hose.

  1. Connect the discharge hose to the cooler compressor with the bolt.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

  1. Install the discharge hose bracket installing bolt.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }



26. INSTALL SUCTION HOSE SUB-ASSEMBLY


I104976

  1. Remove the attached vinyl tape from the suction hose.

  1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

    Compressor oil:
    ND-OIL 8 or equivalent

  1. Install the O-ring onto the suction hose.

  1. Connect the suction hose to the cooler compressor with the bolt.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }



27. INSTALL FRONT FRAME ASSEMBLY

  1. Support the front frame assembly with 4 wooden blocks and the jack.



  1. Provisionally install the front frame assembly onto the body with the 6 bolts.


    C196131E01

    Text in Illustration 
    *1
    		Datum Hole
    *2
    		OK
    *3
    		NG
    Bolt
    		Underhead Length (mm)
    A
    		38
    B
    		69

  1. By inserting SST into the datum holes in the front frame assembly RH and LH alternately, tighten bolts A and B on both sides to the specified torque, in several steps.

    SST
    09670-00011  

    Torque:
    108 N*m{ 1101 kgf*cm , 80 ft.*lbf } for bolt A
    140 N*m{ 1428 kgf*cm , 103 ft.*lbf } for bolt B

    NOTICE:
    1. Insert SST into the datum hole in a vertical orientation.
    2. If SST can not be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.



    C196102

  1. Install the engine moving control rod to engine mounting control bracket with the bolt.

    Torque:
    120 N*m{ 1224 kgf*cm , 89 ft.*lbf }

  1. Remove the strong rope from engine mounting control bracket and body.



28. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

  1. Coat the spline of the inboard joint with gear oil.



    C196518

  1. Align the inboard joint splines and install the drive shaft with a screwdriver and hammer.

    NOTICE:
    1. Face the cut area of the front drive inboard joint hole snap ring downward.
    2. Do not damage the oil seal.
    3. Do not damage the inboard joint boot.

    HINT:
    Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.



29. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

  1. Coat the spline of the inboard joint shaft assembly with gear oil.

  1. Install the drive shaft assembly.



    C196113

  1. Using water pump pliers, install a new bearing bracket hole snap ring.

    NOTICE:
    Do not damage the boot and oil seal.

  1. Install a new bolt.

    Torque:
    32 N*m{ 330 kgf*cm , 24 ft.*lbf }

    NOTICE:
    Before installing a new bolt, check that there is rubber on the tip of a new bolt. If there is no rubber on the bolt, use a new one.



30. INSTALL FRONT AXLE ASSEMBLY LH

  1. Push the front axle out of the vehicle to align the splines of the drive shaft with the front axle and insert the front axle.

    NOTICE:
    1. Do not push the front axle further out of the vehicle than is necessary.
    2. Do not damage the outboard joint boot.
    3. Check for any foreign matter on the speed sensor rotor and insertion area.
    4. Do not damage the speed sensor rotor.



31. INSTALL FRONT AXLE ASSEMBLY RH

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



32. INSTALL FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH


C196519

  1. Install the lower arm onto the steering knuckle with a new castle nut.

    Torque:
    98 N*m{ 999 kgf*cm , 72 ft.*lbf }

    NOTICE:
    If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

  1. Install a new clip.



33. INSTALL FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER RH

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



34. INSTALL FRONT STABILIZER LINK ASSEMBLY LH


C193209

  1. Install the stabilizer link with the nut.

    Torque:
    74 N*m{ 755 kgf*cm , 55 ft.*lbf }

    HINT:
    If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold the stud.



35. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

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



36. INSTALL FRONT SPEED SENSOR LH


C196145

  1. Install the speed sensor onto the steering knuckle with the bolt.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

    NOTICE:
    1. Check that the speed sensor tip and installation area are free of foreign matter.
    2. Install the speed sensor without turning it from its original installation angle.



    C196521E01

  1. Install the flexible hose and speed sensor with the bolt.

    Torque:
    Bolt A:
    29 N*m{ 296 kgf*cm , 21 ft.*lbf }
    Bolt B:
    29 N*m{ 300 kgf*cm , 22 ft.*lbf }

    NOTICE:
    Install the flexible hose and speed sensor without twisting them.



37. INSTALL FRONT SPEED SENSOR RH

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



38. INSTALL FRONT AXLE SHAFT LH NUT

  1. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.

    NOTICE:
    1. Be sure to perform this work for a new drive shaft.
    2. Keep the threaded part free of oil and foreign objects.

  1. Using a 30 mm deep socket wrench, install a new axle hub nut.

    Torque:
    216 N*m{ 2203 kgf*cm , 159 ft.*lbf }



    C057566

  1. Using a chisel and hammer, stake the axle hub nut.



39. INSTALL FRONT AXLE SHAFT RH NUT

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



40. INSTALL UNION TO CHECK VALVE HOSE


A191849E01

  1. Install the union to check valve hose with the clip.

    HINT:
    Install the clip as shown in the illustration.



41. INSTALL NO. 1 FUEL VAPOR FEED HOSE


A191847

  1. Install the No. 1 fuel vapor feed hose with the clip.

  1. Install the No. 1 fuel vapor feed hose to the hose clamp.



42. INSTALL NO. 1 CLUTCH HOSE (for Manual Transaxle)


A204116

  1. Install the a new clip.

  1. Using a union nut wrench 10 mm, connect the No. 1 clutch hose to the clutch release cylinder to flexible hose tube.

    Torque:
    15 N*m{ 155 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench (Click here).



43. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


C195142

  1. Install the transmission control cable to the No. 1 transmission control cable bracket, using a new clip.



    C195097

  1. Using the nut, connect the transmission control cable to the transmission control shaft lever.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf }



44. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


C198735E01

  1. Install the 2 new clips <B> onto the transmission control cable.

  1. Connect the transmission control cable with the 2 clips <A> onto the transaxle.



45. INSTALL HEATER WATER HOSE OUTLET


I104911E01

  1. Install the heater water outlet hose onto the heater unit.

    HINT:
    Perform the installation with the hose clip and mark at the correct angle.



46. INSTALL HEATER WATER HOSE INLET


I104912E01

  1. Install the heater water inlet hose onto the heater unit.

    HINT:
    Perform the installation with the hose clip and mark at the correct angle.



47. INSTALL FUEL TUBE SUB-ASSEMBLY


A199570E01

  1. Push the tube connector into the pipe until the tube connector makes a "click" sound.

    NOTICE:
    1. Check whether there is any damage or foreign matter on the connected part of the fuel pipe.
    2. Check that the fuel tube connector and the pipe are securely connected by pulling on them after connecting.



48. INSTALL EFI FUEL PIPE CLAMP


    A199568

  1. Install the No. 1 fuel pipe clamp.



49. CONNECT NO. 2 RADIATOR HOSE


A203224E01

  1. Connect the No. 2 radiator hose with the clip.

    HINT:
    Install the clip as shown in the illustration.



50. INSTALL NO. 3 RADIATOR HOSE


A191842E01

  1. Install the No. 3 radiator hose with the 2 clips.

    HINT:
    Install the clip as shown in the illustration.



51. CONNECT RADIATOR RESERVOIR TANK HOSE


A191841E01

  1. Connect the radiator reservoir tank hose with the clip.

    HINT:
    Install the clip as shown in the illustration.



52. INSTALL FRONT BUMPER COVER


B213648

  1. Engage the 6 claws and install the front bumper cover.



    B213647

  1. Tighten the 4 screws.



    B213645

  1. Install the 5 clips.



    B222614E01

  1. Install the pin hold clip.

    NOTICE:
    Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertically.

    HINT:
    Use the same procedure for the RH and LH sides.



53. INSTALL ENGINE WIRE


A191838

  1. Connect the earth wire with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }

  1. Connect the 4 engine wire connectors and 2 clamps to the engine room junction block.



    A191836

  1. Connect the engine wire connector to the ECM.

  1. Turn the lever and connect the ECM connector.



54. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


55. INSTALL AIR CLEANER AND HOSE


A191834E01

  1. Align the 2 hinges with the case guide, to insert the case into the groove, and engage the 2 clamps to install the air cleaner cap.
    Text in Illustration 
    *1
    		Clamp
    *2
    		Guide

  1. Connect the air cleaner hose with the hose clamp.

    Torque:
    3.0 N*m{ 31 kgf*cm , 27 in.*lbf }

    HINT:
    Install the clip as shown in the illustration.

  1. Connect the ventilation hose with the clip

    HINT:
    Install the clip as shown in the illustration.



56. INSTALL NO. 2 BATTERY CARRIER


A191831

  1. Install the No. 2 battery carrier with the 3 bolts.

    Torque:
    17 N*m{ 75 kgf*cm , 13 ft.*lbf }

  1. Install the harness clamp.



57. INSTALL BATTERY TRAY


A191830

  1. Install the battery tray.



58. INSTALL BATTERY

  1. Install the battery onto the vehicle.

  1. Install the battery clamp with the 2 nuts.

    Torque:
    3.5 N*m{ 36 kgf*cm , 35 in.*lbf }

  1. Connect the cable to the battery terminal.

    Torque:
    5.0 N*m{ 55 kgf*cm , 43 in.*lbf }



59. INSTALL FAN AND GENERATOR V BELT


A191887E01

  1. Temporarily install the V-ribbed belt onto each pulley.
    Text in Illustration 
    *1
    		Crankshaft Pulley
    *2
    		Water Pump Assembly
    *3
    		Generator Assembly

    NOTICE:
    1. Before installing the V-ribbed belt, check each pulley for any kind of liquid and chips.
    2. Check that the ribs of the V-ribbed belt are correctly fitted into the grooves of the pulleys.



60. ADJUST FAN AND GENERATOR V BELT


A191886E02

  1. Turn the bolt B to adjust the tension of the V-ribbed belt.
    Text in Illustration 
    *1
    		Bolt B
    *2
    		Bolt A
    *3
    		Bolt C

  1. Tighten fixing bolts A and C.

    Torque:
    Bolt A:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }
    Bolt C:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



61. INSPECT FAN AND GENERATOR V BELT


    A191887E03

  1. Check the fan and generator V-ribbed belt deflection (when inspecting a vehicle w/o No. 1 engine cover, or without the No. 1 engine cover installed).
    Text in Illustration 
    *1
    		Crankshaft Pulley
    *2
    		Water Pump Pulley
    *3
    		Generator Pulley
    V100135
    		Specified Point

    Deflection:
    Pressing Force
    N (kg, Ib)
    		New Belt
    mm (in.)
    		Used Belt
    mm (in.)
    10
    (10, 22)
    		8.0 to 10.5
    (0.315 to 0.413)
    		11.0 to 14.0
    (0.433 to 0.551)

    NOTICE:
    1. Check the belt deflection between the pulleys at the indicated measurement point (directly between the pulleys).
    2. When installing a new belt, set its deflection value as specified.
    3. When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.
    4. When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.



    A240170E01

  1. Check the fan and generator V-ribbed belt deflection (when inspecting a vehicle while the No. 1 engine cover is installed).
    Text in Illustration 
    *1
    		Crankshaft Pulley
    *2
    		Water Pump Pulley
    *3
    		Generator Pulley
    V100135
    		Specified Point

    Deflection:
    Pressing Force
    N (kg, Ib)
    		New Belt
    mm (in.)
    		Used Belt
    mm (in.)
    10
    (10, 22)
    		4.5 to 6.0
    (0.177 to 0.236)
    		6.5 to 7.5
    (0.256 to 0.295)

    NOTICE:
    1. Check the belt deflection between the pulleys at the indicated measurement point (on the left side of the generator pulley, 55 mm (2.165 in.) from the center of the pulley).
    2. When installing a new belt, set its deflection value as specified.
    3. When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.
    4. When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.



62. INSTALL NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT


A191881E01

  1. Temporarily install the V-ribbed belt onto each pulley.
    Text in Illustration 
    *1
    		Crankshaft Pulley
    *2
    		Idler Pulley
    *3
    		Cooler Compressor Assembly

    NOTICE:
    1. Before installing the V-ribbed belt, check each pulley for any kind of liquid and chips.
    2. Check that the ribs of the V-ribbed belt are correctly fitted into the grooves of the pulleys.



63. ADJUST NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT


A191885E02

  1. Turn the bolt B to adjust the tension of the V-ribbed belt.
    Text in Illustration 
    *1
    		Bolt B
    *2
    		Bolt A

  1. Tighten bolt A.



64. INSPECT NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT


    A191881E03

  1. Check the No. 1 (cooler compressor to crankshaft pulley) belt.
    Text in Illustration 
    *1
    		Crankshaft Pulley
    *2
    		Idler Pulley
    *3
    		Cooler Compressor Assembly
    V100135
    		Specified Point

    Deflection:
    Pressing Force
    N (kg, Ib)
    		New Belt
    mm (in.)
    		Used Belt
    mm (in.)
    10
    (10, 22)
    		8.0 to 10.0
    (0.315 to 0.394)
    		11.0 to 14.0
    (0.433 to 0.551)

    NOTICE:
    1. Check the No. 1 (cooler compressor to crankshaft pulley) belt deflection at the specified point.
    2. When installing a new belt, set its deflection value as specified.
    3. When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.
    4. When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.



65. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    A104634

  1. Using a vernier caliper, measure the free length of the compression springs.

    Minimum Length:
    Item
    		Length
    Front
    		41.5 mm (1.634 in.)

    HINT:
    If the length is not as specified, replace the compression spring.



    A104635E01

  1. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

    NOTICE:
    1. Install the gasket in the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket by dropping it, etc.
    4. Do not damage the outer surface of the gasket.
    5. Do not push in the gasket with the exhaust pipe when connecting it.
    6. After the installation, check that the gaps between the flanges of the exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.



    A202951

  1. Install the front exhaust pipe assembly to the exhaust manifold with the 2 bolts and the 2 compression springs.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }



    A104634

  1. Using a vernier caliper, measure the free length of the compression springs.

    Minimum Length:
    Item
    		Length
    Rear
    		38.5 mm (1.594 in.)

    HINT:
    If the length is not as specified, replace the compression spring.



    A104635E01

  1. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

    NOTICE:
    1. Install the gasket in the correct direction.
    2. Do not reuse the gasket.
    3. Do not damage the gasket by dropping it, etc.
    4. Do not damage the outer surface of the gasket.
    5. Do not push in the gasket with the exhaust pipe when connecting it.
    6. After the installation, check that the gaps between the flanges of the front exhaust pipe assembly and tail exhaust pipe assembly are consistent front-to-rear and left-to-right.



    A199499

  1. Install the front exhaust pipe assembly to the tail exhaust pipe assembly with the 2 bolts and the 2 compression springs.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }



    A199496

  1. Connect the oxygen sensor connector and engage the clamp.



66. INSTALL FRONT WHEELS


67. ADD ENGINE COOLANT (w/ Water Inlet Drain Cock Plug)

  1. Tighten the water inlet drain cock plug.



    A201667

  1. Plunge the engine drain cock plug.



    A201665E01

  1. Install the water inlet clip.
    Text in Illustration 
    *1
    		Water Inlet Clip
    *2
    		Hose

  1. Disconnect the hose from the water inlet drain cock plug.

  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    for Manual Transaxle
    		4.3 liters (4.5 US qts, 3.8 Imp. qts)
    for CVT
    		4.5 liters (4.8 US qts, 4.0 Imp. qts)

    NOTICE:
    Never use water as a substitute for engine coolant.

    HINT:
    TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

  1. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.



    A198874E04

  1. Fill the radiator reserve tank with coolant to the FULL level.
    Text in Illustration 
    *a
    		FULL Line

  1. Install the water filler cap sub-assembly.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:
      When squeezing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

  1. Stop the engine, and wait until the engine coolant cools down.

  1. Remove the water filler cap sub-assembly and check the coolant level.
    If the coolant level is below the LOW line, repeat all of the procedures above.



    A198874E05

  1. When the coolant level stops going down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *a
    		FULL Line
    *b
    		LOW Line



68. ADD ENGINE COOLANT (w/o Water Inlet Drain Cock Plug)

  1. Tighten the radiator drain cock plug.

  1. Remove the water filler cap sub-assembly.

  1. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    for Manual Transaxle
    		4.3 liters (4.5 US qts, 3.8 Imp. qts)
    for CVT
    		4.5 liters (4.8 US qts, 4.0 Imp. qts)

    NOTICE:
    Never use water as a substitute for engine coolant.

    HINT:
    TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

  1. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.



    A198874E04

  1. Fill the radiator reserve tank with coolant to the FULL level.
    Text in Illustration 
    *a
    		FULL Line

  1. Install the water filler cap sub-assembly.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:
      When squeezing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

  1. Stop the engine, and wait until the engine coolant cools down.

  1. Remove the water filler cap sub-assembly and check the coolant level.
    If the coolant level is below the LOW line, repeat all of the procedures above.



    A198874E05

  1. When the coolant level stops going down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *a
    		FULL Line
    *b
    		LOW Line



69. ADD ENGINE OIL


70. INSPECT FOR ENGINE COOLANT LEAK

CAUTION:
To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.



    A198898E01

  1. Fill the radiator assembly with engine coolant, and attach a radiator cap tester.
    Text in Illustration 
    *1
    		Radiator Cap Tester

  1. Pump the tester to 118 kPa (1.2 kgf/cm2, 17.1 psi), and then check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.



71. INSPECT FOR MANUAL TRANSAXLE OIL LEAK


    D025304E40

  1. Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the manual transmission filler plug opening.

    NOTICE:
    Excessively large or small amounts of oil may cause problems.

    Text in Illustration 
    *1
    		0 to 5 mm (0 to 0.20 in.)

  1. Check for oil leakage when the oil level is low.



    C203684E01

  1. Install the manual transmission filler plug and a new gasket.
    Text in Illustration 
    *1
    		Filler plug

    Torque:
    39 N*m{ 400 kgf*cm , 29 ft.*lbf }



72. INSPECT FOR ENGINE OIL LEAK


73. INSPECT FOR EXHAUST GAS LEAK


74. INSPECT FOR FUEL LEAK


75. INSPECT IGNITION TIMING

NOTICE:
  1. Turn all the electrical systems and the air conditioning off.
  2. Inspect the ignition timing with the cooling fan off.
  3. When checking the ignition timing, shift the transmission to the neutral position.

  1. When using the intelligent tester:

    1. Warm up and stop the engine.

    2. Connect the intelligent tester to the DLC3.

    3. Turn the ignition switch to ON.

    4. Enter the following menus: Powertrain / Engine and ECT / Active Test / TE1 (TC) / ON.

      HINT:
      Refer to the intelligent tester operator's manual for further information regarding the selection of Active Test.

    5. Inspect the ignition timing during idling.

      Ignition timing:
      8 to 12° BTDC

    6. Enter the following menus: Powertrain / Engine and ECT / Active Test / TE1 (TC) / OFF.

    7. Turn the ignition switch off.

    8. Disconnect the intelligent tester from the DLC3.



  1. When not using the intelligent tester:

    1. Remove the No. 3 engine under cover (w/ No. 1 Engine Cover) (Click here).

    2. Remove the No. 1 engine cover (w/ No. 1 Engine Cover) (Click here).

    3. Warm up and stop the engine.



      4. A191882

    4. Install the tester terminal of a timing light onto the position shown in the illustration.

      NOTICE:
      1. Use a timing light that detects the first signal.
      2. Wrap the wire harness with tape after checking.



      5. A118802E01

    5. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      SST
      09843-18040  

      NOTICE:
      Check the terminal numbers before connecting them. Connecting the wrong terminals could damage the engine.

    6. Turn the ignition switch to ON.

    7. Inspect the ignition timing during idling.

      Ignition timing:
      8 to 12° BTDC

      HINT:
      Run the engine speed at 1000 to 1300 rpm for 5 seconds and then check that the engine speed returns to the idling speed.

    8. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

    9. Turn the ignition switch off.

    10. Remove the timing light.

    11. Install the No. 1 engine cover (w/ No. 1 Engine Cover) (Click here).

    12. Install the No. 3 engine under cover (w/ No. 1 Engine Cover) (Click here).



76. INSPECT ENGINE IDLING SPEED

NOTICE:
  1. Turn all the electrical systems and the air conditioning off.
  2. Inspect the engine idling speed with the cooling fan off.
  3. When checking the idling speed, shift the transmission to the neutral position.

  1. Warm up and stop the engine.

  1. When using the intelligent tester:

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to ON.

    3. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine SPD.

      HINT:
      Refer to the intelligent tester operator's manual for further information regarding the selection of Data List.

    4. Inspect the engine idling speed.

      Idling speed:
      650 to 800 rpm

    5. Turn the ignition switch off.

    6. Disconnect the intelligent tester from the DLC3.



    A118802E02

  1. When not using an intelligent tester:

    1. Install SST to terminal 9 (TAC) of the DLC3, and then connect a tachometer.

      SST
      09843-18040  

      NOTICE:
      Check the terminal numbers before connecting them. Connecting the wrong terminals could damage the engine.

    2. Turn the ignition switch to ON.

    3. Inspect the engine idling speed.

      Idling speed:
      650 to 800 rpm

    4. Turn the ignition switch off.

    5. Disconnect the tachometer.

    6. Remove SST from terminal 9 (TAC).



77. INSPECT CO/HC

HINT:
The ECM controls the concentration of CO/HC in the emission gas.

  1. Start the engine.

  1. Run the engine at 2500 rpm for approximately 180 seconds.

  1. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.

  1. Check the CO/HC concentration during idling and when running at 2500 rpm.

    Standard:
    CO concentration:
    0.2 % or less
    HC concentration:
    70 ppm or less

    If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
    1. Check the heated oxygen sensor operation (Click here).
    2. See the table below for possible causes, and then inspect the applicable parts and repair them if necessary.

    CO
    		HC
    		Problem
    		Cause
    Normal
    		High
    		Rough idling
    1. Faulty ignition:
      1. Fouled, shorted or improperly gapped plugs
    2. Incorrect valve clearance
    3. Leakage from intake and exhaust valves
    4. Leakage from cylinders
    Low
    		High
    		Rough idling
    (Fluctuating HC reading)
    1. Lean mixture causing misfire
    2. Faulty SFI systems:
      1. Faulty pressure regulator
      2. Faulty engine coolant temperature sensor
      3. Faulty mass air flow meter
      4. Faulty ECM
      5. Faulty injectors
      6. Faulty throttle body
    High
    		High
    		Rough idling
    (Black smoke from exhaust)
    1. Faulty SFI systems:
      1. Faulty pressure regulator
      2. Faulty engine coolant temperature sensor
      3. Faulty mass air flow meter
      4. Faulty ECM
      5. Faulty injectors
      6. Faulty throttle body



78. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

  1. Inspect and adjust front wheel alignment (Click here).



79. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)


A240172E01

  1. Temporarily install the No. 1 engine cover with the 2 bolts and nut.

  1. Fully tighten the 2 bolts and nut in the order shown in the illustration.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



80. INSTALL NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)


A240173E01

  1. Temporarily install the No. 1 cooler cover with the 2 nuts.

  1. Fully tighten the 2 nuts in the order shown in the illustration.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }



81. INSTALL NO. 3 ENGINE UNDER COVER


A191832

  1. Install the No. 3 engine under cover with the 3 clips.



82. INSTALL NO. 1 ENGINE UNDER COVER


83. INSTALL NO. 2 ENGINE UNDER COVER


84. INSTALL FRONT FLOOR COVER RH


85. INSTALL FRONT FLOOR COVER LH


86. INSTALL WINDSHIELD WIPER MOTOR AND LINK

  1. Install the windshield wiper motor and link (Click here).