CYLINDER HEAD GASKET > INSTALLATION

for Preparation Click here



1. INSTALL CYLINDER HEAD GASKET


A191972

  1. Place a new cylinder head gasket on the cylinder block sub-assembly.



2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE:
Place the cylinder head gently in order not to damage the gasket.

  1. Place the cylinder head on the cylinder block subassembly.

  1. Install the 8 plate washers to the cylinder head subassembly.

    NOTICE:
    Do not drop the washers into the cylinder head.



    A104982E01

  1. Apply engine oil to each bolt thread and seating surface.
    Text in Illustration 
    *1
    		Apply Engine Oil.



    A191971E01

  1. Using several passes, uniformly install and tighten the 8 cylinder head bolts with a 8 mm bi-hexagon wrench in the order shown in the illustration.

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf }



    A118683E02

  1. Mark the front of each cylinder head bolt with paint.

  1. Retighten the cylinder head bolts by additional 180° as shown in the illustration.
    Text in Illustration 
    *1
    		paint Mark

  1. Check that the paint mark are now 180° from the front.



3. INSTALL NO. 2 CAMSHAFT


    A191977E01

  1. Apply engine oil to the contact areas of the cam and journal of the camshaft and No. 2 camshaft.
    Text in Illustration 
    *1
    		Apply Engine Oil.

  1. Install the No. 2 camshaft.



4. INSTALL CAMSHAFT

  1. Apply engine oil to the cam of each No. 2 camshaft.



    A118677E02

  1. Install the camshafts as shown in the illustration.
    Text in Illustration 
    *1
    		No. 1 Camshaft.
    *2
    		No. 2 Camshaft
    *3
    		No. 3 Cylinder
    *4
    		No. 1 Cylinder
    *5
    		No. 2 Cylinder

    HINT:
    Make sure that the timing marks of the camshaft timing sprocket and camshaft timing sprocket face upward.



    A203186E01

  1. Place No. 1 camshaft bearing cap and No. 2 camshaft bearing caps and tighten the bolts to the specified torque in the order shown in the illustration.

    Torque:
    No. 1 camshaft bearing cap:
    15 N*m{ 153 kgf*cm , 1 ft.*lbf }
    No. 2 camshaft bearing cap:
    13 N*m{ 127 kgf*cm , 9 ft.*lbf }

    NOTICE:
    Install No. 1 camshaft bearing cap and No. 2 camshaft bearing caps with the front marks facing engine front.



5. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY


A117037E02

  1. While holding the hexagonal portion of the camshaft, tighten the bolts to install the camshaft timing sprocket.

    Torque:
    47 N*m{ 479 kgf*cm , 35 ft.*lbf }



6. INSTALL TIMING CHAIN GUIDE


    A191964

  1. Install the timing chain guide with the 2 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



7. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


A191965

  1. Align the groove of the crankshaft timing sprocket with the key of the crankshaft and install the crankshaft timing sprocket.



8. INSTALL CHAIN SUB-ASSEMBLY


A203187E01

  1. Align the yellow mark plate with the timing mark of the crankshaft timing sprocket and install the timing chain, as shown in the illustration.
    Text in Illustration 
    *1
    		Yellow Mark Plate
    *2
    		Timing Mark



    A105062E05

  1. Align the 2 orange mark plates with the timing marks of the camshaft timing sprockets and install the timing chain, as shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark
    *2
    		Orange Mark Plate



9. INSTALL TIMING CHAIN TENSION ARM


A191963

  1. Install the timing chain tension arm with the bolt.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



10. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


A104196

  1. Slightly turn the hexagonal portion of the camshaft (intake side) counterclockwise to leave some slack on the chain of the timing chain tensioner side.



    A203226E01

  1. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

  1. Remove the hexagon wrench, turn the crankshaft 2 complete revolutions and operate the chain tension assembly.
    Text in Illustration 
    *1
    		Hexagon Wrench



    A104722E04

  1. Make sure that the timing mark of the sprocket camshaft timing is at the top with the timing chain tensed (set No. 1 piston to the TDC/ compression).
    Text in Illustration 
    *1
    		Timing Mark



11. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL


A104994E01

  1. Apply engine oil to the lip of a new oil seal.
    Text in Illustration 
    *1
    		Apply Engine Oil.



    A203234E01

  1. Using SST, tap the oil seal straight in.

    SST
    09950-60010   (09951-00500, 09952-06010)
    09950-70010   (09951-07200)

    Correct oil seal position:
    Protrusion from chain cover edge:
    0.5 mm (0.020 in.) or less
    Installation depth from chain cover edge:
    1.0 mm (0.039 in.) or less



12. INSTALL VENTILATION CASE SUB-ASSEMBLY


A203253

  1. Install the ventilation case sub-assembly with the 3 bolts.

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



13. INSTALL STUD BOLT


    A191958

  1. Install the 2 stud bolts.



14. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

  1. Remove any oil packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head, and cylinder block.



  1. Apply seal packing as shown in the illustration.


    A203325E01

    Seal packing:
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.

    NOTICE:
    1. Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    2. Do not add engine oil for at least 2 hours after installation.
    3. Do not start the engine for at least 2 hours after installation.



    A191956E01

  1. Temporarily install the timing chain cover sub-assembly with the 12 bolts.
    Bolt Length 
    Item
    		Length
    Bolt A
    		80 mm (3.15 in.)
    Bolt B
    		40 mm (1.57 in.)
    Bolt C
    		45 mm (1.77 in.)
    Bolt D
    		70 mm (2.78 in.)
    Bolt E
    		45 mm (1.77 in.)



    A191954

  1. Install the new gasket to the timing chain cover sub-assembly.



    A191952E01

  1. Temporarily install the oil filter bracket with the 2 bolts.
    Bolt Length 
    Item
    		Length
    Bolt A
    		20 mm (0.79 in.)
    Bolt B
    		119 mm (4.69 in.)



    A191951

  1. Install the new gasket to the timing chain cover sub-assembly.



    A191950E01

  1. Temporarily install the water pump assembly with 5 bolts.
    Bolt Length 
    Item
    		Length
    Bolt A
    		55 mm (2.17 in.)
    Bolt B
    		20 mm (0.79 in.)



  1. Fully tighten the timing chain cover sub-assembly with the 19 bolts as shown in the illustration.


    A203189E01

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf } (Bolt A, C, E, F, G)
    40 N*m{ 408 kgf*cm , 30 ft.*lbf } (Bolt B, D)
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } (Bolt H)

    NOTICE:
    1. Install the chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    2. Do not add engine oil for at least 2 hours after installation.
    3. Do not start the engine for at least 2 hours after installation.

    Bolt Length 
    Item
    		Length
    Bolt A
    		80 mm (3.15 in.)
    Bolt B
    		40 mm (1.57 in.)
    Bolt C
    		45 mm (1.77 in.)
    Bolt D
    		70 mm (2.78 in.)
    Bolt E
    		55 mm (2.17 in.)
    Bolt F
    		20 mm (0.79 in.)
    Bolt G
    		119 mm (4.69 in.)
    Bolt H
    		45 mm (1.77 in.)

  1. Remove excess seal packing.



    A191958

  1. Using an E8 "TORX" socket, install the 2 stud bolts.



15. INSTALL TIMING GEAR COVER TIGHT PLUG

  1. Remove the hexagon wrench from the timing chain tensioner sub-assembly.

    HINT:
    Before removing, slightly turn the hexagonal portion of the camshaft assembly counterclockwise to leave some slack on the chain of the timing chain tensioner sub-assembly side.



    A107399E01

  1. Clean the plug and the bolt holes of the timing chain cover and apply adhesive to the threads of the plug.
    Text in Illustration 
    *1
    		Adhesive

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



    A191890

  1. Using an 8 mm socket hexagon wrench, install the timing gear tight plug.

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



16. INSTALL CRANKSHAFT PULLEY

  1. Align the pulley set key with the key groove of the pulley.



    A191911E01

  1. Using SST, hold the pulley in place and tighten the bolt.

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

    Torque:
    180 N*m{ 1835 kgf*cm , 133 ft.*lbf }



17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


A191937

  1. Apply a light coat of engine oil to the O-ring.

  1. Install the camshaft timing oil control valve assembly with the bolt.

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

  1. Connect the camshaft timing oil control valve assembly connector.



18. INSTALL CRANKSHAFT POSITION SENSOR


A191938

  1. Apply a light coat of engine oil to the O-ring.

  1. Install the crankshaft position sensor with the bolt.

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

  1. Connect the crankshaft position sensor connector.



19. INSTALL OIL STRAINER SUB-ASSEMBLY


    A191947

  1. Install a new gasket to the oil strainer sub-assembly.



    A191946

  1. Install the oil strainer sub-assembly with the 2 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 76 in.*lbf }



20. INSTALL OIL PAN SUB-ASSEMBLY


A203191E01

  1. Remove any grease from the installation surfaces of the cylinder block sub-assembly and oil pan sub-assembly.

  1. Apply seal packing to the oil pan sub-assembly and install it onto the cylinder block assembly.
    Text in Illustration 
    *1
    		Seal Packing
    *2
    		Contact surface between timing chain cover and cylinder block
    *3
    		Contact surface between oil seal retainer and cylinder block

    Seal packing:
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.

    NOTICE:
    1. Start and finish applying the seal packing on the seal surface with the cylinder block sub-assembly.
    2. Apply seal packing to the contact surfaces between the timing chain cover and cylinder block, and between the oil seal retainer and cylinder block.
    3. Install the oil pan sub-assembly within 3 minutes and tighten the bolts within 15 minutes of applying the seal packing.



    A203240E01

  1. Tighten the specified 6 bolts in the order shown in the illustration.

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



    A203241E01

  1. Tighten the 6 bolts and 3 nuts.
    Text in Illustration 
    *1
    		Nut
    *2
    		Bolt A
    *3
    		Bolt B

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } (Nut and Bolt B)
    24 N*m{ 245 kgf*cm , 18 ft.*lbf } (Bolt A)



21. INSTALL OIL FILTER BRACKET STAY


A191953

  1. Install the oil filter bracket stay with the 2 bolts.

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



22. INSTALL NO. 1 WATER BY-PASS PIPE


    A203251

  1. Install a new gasket to the cylinder head.



    A203252

  1. Install a new gasket to the No. 1 water by-pass pipe.



    A203250

  1. Temporarily tighten the bolt and install the 2 nuts.

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

  1. Fully tighten the bolt.

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



23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


A191906

  1. Clean the cylinder head cover, cylinder head assembly and timing chain cover assembly.

  1. Fit the cylinder head cover gasket into the gasket groove on the cover and onto the center bosses.



    A203331E01

  1. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.118 to 0.157 in.)) to the contact surface between the cylinder head assembly and timing chain cover assembly, as shown in the illustration.

    Seal packing:
    Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent



    A191896E01

  1. Tighten the bolts A, and then the bolts B.
    Text in Illustration 
    *1
    		Bolt A
    *2
    		Bolt B

    NOTICE:
    After tightening all of the bolts, check that the bolts A meet the specified torque.

    Torque:
    7.7 N*m{ 79 kgf*cm , 68 in.*lbf }

  1. Install the wire harness to the cylinder head cover sub-assembly.



    A191889

  1. Connect the vacuum switching valve connector.



    A191850

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



24. INSTALL OIL FILLER CAP SUB-ASSEMBLY


A191940

  1. Install the oil filler cap sub-assembly.



25. INSTALL DRIVE SHAFT BEARING BRACKET


A191879

  1. Install the drive shaft bearing bracket with the 2 bolts.

    Torque:
    64 N*m{ 650 kgf*cm , 47 ft.*lbf }



26. INSTALL WIRE HARNESS CLAMP BRACKET


A191878

  1. Install the wiring harness clamp bracket with the bolt.

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



27. INSTALL WATER FILLER ASSEMBLY


A191877

  1. Install the water filler assembly with the bolt.

    Torque:
    13 N*m{ 127 kgf*cm , 10 ft.*lbf }



28. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


A191874

  1. Install the new O-ring to the oil level dipstick guide sub-assembly.



    A191873

  1. Install the oil level dipstick guide sub-assembly with the bolt.

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



29. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY


30. INSTALL IDLER PULLEY


A191872

  1. Install the idler pulley with the 3 bolts.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }



31. INSTALL NO. 2 RADIATOR HOSE


A191870E01

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

    HINT:
    Install the clip as shown in the illustration.



32. INSTALL NO. 1 IGNITION COIL


A191868

  1. Install the 3 No. 1 ignition coils with the 3 bolts.

    Torque:
    9.0 N*m{ 91 kgf*cm , 80 in.*lbf }

  1. Connect the 3 No. 1 ignition coil connectors.



33. INSTALL NO. 1 RADIATOR HOSE


A191869E01

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

    HINT:
    Install the clip as shown in the illustration.



34. INSTALL WATER BY-PASS HOSE ASSEMBLY


A191866E01

  1. Install the water by-pass hose assembly with the 2 clips.

    HINT:
    Install the clips as shown in the illustration.



35. INSTALL EGR VALVE ASSEMBLY


    A199580

  1. Install a new gasket to the cylinder head.

  1. Insert the EGR valve into the stud bolt, rotate the EGR valve to avoid contact with the delivery pipe, and temporarily install the EGR valve.



    A202847E01

  1. Connect the water by-pass hose.

  1. Connect the EGR valve connector.



36. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


A201012

  1. Temporarily install the intake manifold insulator with a new gasket, the 2 bolts and the nut.



37. INSTALL INTAKE MANIFOLD


    A200985

  1. Install the stud bolt on the intake manifold.



    A200986

  1. Install a new gasket on the intake manifold.



    A200984

  1. Temporarily install the intake manifold with the 2 bolts and 2 nuts.



    A201014E01

  1. Tighten the 4 bolts and 3 nuts in the sequence shown in the illustration.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }



    A200982

  1. Connect the union to check valve hose with the hose clamp.

  1. Connect the vacuum hose.

  1. Connect the ventilation hose with the hose clamp.



    A201013

  1. Tighten the 2 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Engage the 4 wire harness clamps and install the wire harness to the intake manifold.

  1. Connect the vacuum sensor connector.



    A201008

  1. Install the 2 water by-pass hoses on the intake manifold.

  1. Connect the fuel vapor feed hose with the hose clamp.

  1. Connect the vacuum switching valve connector



38. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


A191861

  1. Install the new gasket onto the intake manifold.



    A191860

  1. Install the throttle with motor body assembly with the 3 bolts and nut.

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

  1. Connect the throttle with motor body assembly connector.



    A191859

  1. Connect the 2 water by-pass hoses with the 2 clips.

    HINT:
    Install the clips as shown in the illustration.

  1. Install the 2 water by-pass hoses to the hose clamp.



39. INSTALL GENERATOR ASSEMBLY


    A198911

  1. Temporarily install the generator assembly with the bolt.



    A198910E01

  1. Temporarily install the fan belt adjusting bar with bolt A and bolt B.

  1. Tighten bolt B with the generator assembly near the cylinder block.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf }



    A201679

  1. Install the 2 brackets with the 2 bolts.

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



    A198909

  1. Connect the connector and wire harness clamps.

  1. Install the terminal B with the nut.

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

  1. Install the terminal cap.



40. 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 }



41. 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.)



42. 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.



43. 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.



44. 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 }



45. 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.



46. 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.



47. 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  



48. 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).



49. 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).



50. 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.



51. 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).



52. 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).



53. 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.



54. 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 }



55. 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 }



56. 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.



57. 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 }



58. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

  1. Install the engine assembly with transaxle (Click here).