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Partial Engine ASSY: Replacement

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM  ) 
  2. REMOVE ENGINE UNDER COVER RH 
  3. REMOVE ENGINE UNDER COVER LH 
  4. DRAIN ENGINE COOLANT (See  ENGINE COOLANT  ) 
  5. REMOVE FRONT WHEELS 
  6. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 4 nuts and the cylinder head cover No. 2.
      Fig 1: Removing Cylinder Head Cover Nuts And Bolts
      G00755906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE BATTERY 
  8. REMOVE AIR CLEANER ASSY (See  AIR CLEANER AND AIR DUCT  ) 
  9. DISCONNECT FUEL TUBE SUB-ASSY (See  FUEL SYSTEM  ) 

    SST 09268-21010

  10. DISCONNECT ACCELERATOR CONTROL CABLE ASSY 
  11. REMOVE RADIATOR ASSY (See  RADIATOR ASSY  ) 
  12. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See  TRANSMISSION CONTROL CABLE ASSY (MTM)  ) 
  13. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See  TRANSMISSION CONTROL CABLE ASSY (ATM)  ) 
  14. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) 
  15. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the union to check valve hose for the brake booster.
      Fig 2: Disconnecting Union To Check Valve Hose For Brake Booster
      G00755907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT HEATER WATER INLET HOSE A 
    1. Disconnect the heater water inlet hose from the air conditioner tube.
      Fig 3: Disconnecting Heater Water Inlet Hose From Air Conditioner Tube
      G00755908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Disconnect the heater water outlet hose from the air conditioner tube.
      Fig 4: Disconnecting Heater Water Outlet Hose From Air Conditioner Tube
      G00755909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT ENGINE WIRE 
    1. Remove the glove compartment door.
    2. Disconnect the engine wire harness from the ECM and junction block.
    3. Pull out the engine wire.
    4. Disconnect the engine wire from engine room junction block.
    5. Remove the body ground.
  19. REMOVE FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  20. REMOVE A/C COMPRESSOR (See  W/PULLEY COMPRESSOR ASSY  ) 

    HINT: 

    Secure the hoses off to the side instead of detaching.

  21. REMOVE FLOOR PANEL BRACE FRONT 
  22. REMOVE EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION, AND DISASSEMBLY & REASSEMBLY  ) 
  23. SEPARATE STEERING INTERMEDIATE SHAFT ASSY 
  24. REMOVE FRONT AXLE HUB LH NUT 
    1. Using SST and a hammer, unstake the lock nut.

      SST 09930-00010

      NOTE:
      • When removing the nut, unstake the lock nut completely.
      • Do not damage the threads of the drive shaft.
      • Do not use SST with the tip sharpened.
      • Set SST to the groove with the flat face facing upward.
      Fig 5: Unstaking Lock Nut
      G00755910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 30 mm socket wrench, remove the lock nut.

      HINT: 

      Perform the same procedure as above on the opposite side.

  25. DISCONNECT SPEED SENSOR FRONT LH (W/ ABS) 
    1. Remove the bolt, disconnect the speed sensor from the steering knuckle.

      HINT: 

      Perform the same procedure as above on the opposite side.

      Fig 6: Disconnecting Speed Sensor From Steering Knuckle
      G00755911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. SEPARATE TIE ROD END SUB-ASSY LH 
    1. Using SST, disconnect the tie rod end from the steering knuckle.

      SST 09628-62011

    NOTE: Do not damage the dust cover of the ball joint.

    HINT: 

    Perform the same procedure as above on the opposite side.

    Fig 7: Disconnecting Tie Rod End From Steering Knuckle
    G00755912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH 
    1. Using SST, disconnect the front suspension arm lower from the steering knuckle.

      SST 09628-00011

    HINT: 

    Perform the same procedure as above on the opposite side.

    Fig 8: Disconnecting Front Suspension Arm Lower From Steering Knuckle
    G00755913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. SEPARATE FRONT DRIVE SHAFT ASSY LH 
    1. Using a plastic hammer, detach the drive shaft from the axle hub by tapping.

    HINT: 

    Perform the same procedure as above on the opposite side.

    Fig 9: Detaching Drive Shaft From Axle Hub By Tapping
    G00755914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the bolt which is used to fix the liquid tube to the engine mounting insulator RH.
    3. Remove the 5 bolts, the nut and engine mounting insulator RH.
      Fig 10: Removing Nuts And Bolts Of Engine Mounting Insulator RH
      G00755915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and detach the engine mounting bracket from the engine mounting insulator LH.
      Fig 11: Detaching Engine Mounting Bracket From Engine Mounting Insulator LH
      G00755916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the engine together with transaxle.
      1. Remove the 8 bolts shown in the illustration.
      2. Carefully remove the engine assembly from the vehicle.
        Fig 12: Identifying Engine Assembly Bolts
        G00755917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and the condenser.
    7. Install the 2 engine hangers as shown in the illustration.

      Parts No.: 

      No. 1 engine hanger 12281-21010 

      Bolt 91642-81025 

      Torque: 40 N.m (408 kgf.cm, 30 ft.lbf) 

    8. Attach the engine sling and hang the engine with the chain block.
      Fig 13: Identifying Engine Hangers
      G00755918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE VANE PUMP V BELT (See  DRIVE BELT  ) 
  31. REMOVE VANE PUMP ASSY 
    1. Disconnect the power steering oil pressure sensor harness.
    2. Remove the 2 bolts and vane pump assembly.
      Fig 14: Locating Vane Pump Assembly Bolts
      G00755919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY 
    1. Remove the through bolt.
    2. Separate the engine and the transaxle assembly from the suspension crossmember.
      Fig 15: Identifying Front Suspension Crossmember Sub-Assembly Through Bolt
      G00755920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE STARTER ASSY (See  STARTER  ) 
  34. REMOVE GENERATOR ASSY (See  GENERATOR  ) 
  35. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE ASSY (MTM)  or  MANUAL TRANSAXLE ASSY (C50)  ) 
  36. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See  AUTOMATIC TRANSAXLE ASSY (ATM)  ) 
  37. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE  ) 
  38. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE  ) 
  39. REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See  MANUAL TRANSAXLE  or  AUTOMATIC TRANSAXLE ASSY (ATM)  ) 

    SST 09330-00021, 09213-58012 (91111-50845)

  40. REMOVE VENTILATION HOSE 
  41. REMOVE VENTILATION HOSE NO. 2 
  42. REMOVE INTAKE MANIFOLD 
    1. Using several steps, remove the 3 bolts and 2 nuts in the sequence shown in the illustration, then remove the intake manifold.
    2. Remove the gasket from the intake manifold.
      Fig 16: Identifying Removing Sequence Of Intake Manifold Nuts And Bolts
      G00755921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE BOOSTER VACUUM TUBE 
    1. Remove the 2 bolts and the booster vacuum tube.
      Fig 17: Installing Booster Vacuum Bolts
      G00755922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE MANIFOLD SUPPORT BRACKET 
    1. Remove the 3 bolts and the manifold support bracket.
      Fig 18: Removing Manifold Support Bracket Bolts
      G00755923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Remove the 4 bolts and the exhaust manifold heat insulator.
  46. REMOVE EXHAUST MANIFOLD 
    1. Remove the 3 bolts, the 2 nuts and the exhaust manifold.
      Fig 19: Removing Exhaust Manifold Nuts And Bolts
      G00755924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE IGNITION COIL NO. 1 
    1. Remove the 4 bolts and pull out the 4 ignition coils.
  48. REMOVE WATER BY-PASS PIPE NO. 1 
    1. Remove the 2 nuts, the 2 bolts and the water by-pass pipe.
      Fig 20: Removing Ignition Coil No. 1 Bolts
      G00755925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the water temperature sensor. SST 09817-33190
      Fig 21: Removing Water Temperature Sensor Using SST
      G00755926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE KNOCK SENSOR 
    1. Using SST, remove the knock sensor.

      SST 09816-30010

  51. REMOVE ENGINE OIL PRESSURE SWITCH ASSY 
    1. Using SST, remove the oil pressure switch.

      SST 09268-46021

      Fig 22: Removing Knock Sensor Using SST
      G00755927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REPLACE PARTIAL ENGINE ASSY 
  53. INSTALL ENGINE OIL PRESSURE SWITCH ASSY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive: 

      Part No. 08833-00080, THREE BOND 1344, 

      LOCTITE 242 or equivalent 

    2. Using SST, install the oil pressure switch.

      SST 09268-46021

      Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 

    NOTE: Do not start the engine within 1 hour of installation.
  54. INSTALL KNOCK SENSOR 
    1. Using SST, install the knock sensor.

      SST 09816-30010

      Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) 

      Fig 23: Installing Knock Sensor Using SST
      G00755928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Install a new gasket to the water temperature sensor.
    2. Using SST, fix the water temperature sensor.

      SST 09817-33190

      Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) 

      Fig 24: Fixing Water Temperature Sensor Using SST
      G00755929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL WATER BY-PASS PIPE NO. 1 
    1. Install a new gasket and the water by-pass pipe with the 2 bolts and 2 nuts.

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

  57. INSTALL IGNITION COIL NO. 1 

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

  58. INSTALL EXHAUST MANIFOLD 
    1. Using several steps, install a new exhaust manifold gasket and exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.
      Fig 25: Identifying Installing Sequence Of Exhaust Manifold Nuts And Bolts
      G00755930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 27 N.m (275 kgf.cm, 20 ft.lbf) 

  59. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Install the exhaust manifold heat insulator No. 1 with the 4 bolts.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

  60. INSTALL MANIFOLD SUPPORT BRACKET 
    1. Install the manifold support bracket with the 3 bolts.

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

  61. INSTALL BOOSTER VACUUM TUBE 
    1. Install the booster vacuum tube with the 2 bolts.

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

  62. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket to the intake manifold.
    2. Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

      Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 

      Fig 26: Identifying Installing Sequence Of Intake Manifold Nuts And Bolts
      G00755931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See  ENGINE REAR OIL SEAL  ) 

    SST 09213-58012 (91111-50845), 09330-00021

  64. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE  ) 
  65. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE  ) 
  66. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE ASSY (MTM)  or  MANUAL TRANSAXLE ASSY (C50)  ) 
  67. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See  AUTOMATIC TRANSAXLE ASSY (ATM)  ) 
  68. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
  69. INSTALL STARTER ASSY (See  STARTER  ) 
  70. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY 
    1. Fasten the bolt to secure the engine and transaxle assembly to the suspension crossmember.

      Torque: 64 N.m (653 kgf.cm, 47 ft.lbf) 

      Fig 27: Fastening Bolt Securing Engine And Transaxle Assembly To Suspension Crossmember
      G00755932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL VANE PUMP ASSY 
    1. Install the vane pump assembly with the 2 bolts.

      Torque: 44 N.m (449 kgf.cm, 33 ft.lbf) 

    HINT: 

    After adjusting the V-ribbed belt, tighten bolt A.

  72. INSTALL VANE PUMP V BELT 
    1. Temporarily install the V-ribbed belt on each pulley.
  73. ADJUST VANE PUMP V BELT 
    Fig 28: Installing Vane Pump Assembly Bolts
    G00755933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine with the transaxle on the engine lifter.
    2. Install the engine with the transaxle to the engine compartment.
    3. Temporarily install the suspension crossmember with the 8 bolts.
      Fig 29: Installing Suspension Crossmember Bolts
      G00755934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting bracket LH to the engine mounting insulator LH with the 2 bolts.

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

      Fig 30: Installing Engine Mounting Bracket LH To Engine Mounting Insulator LH Bolts
      G00755935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine mounting insulator RH with the 5 bolts and nut.

      Torque: 

      Bolt A 45 N.m (459 kgf.cm, 33 ft.lbf) 

      Bolt B 52 N.m (530 kgf.cm, 38 ft.lbf) 

      Nut 52 N.m (530 kgf.cm, 38 ft.lbf) 

    6. Install the liquid tube with the bolt.

      Torque: 

      Bolt C 9.8 N.m (100 kgf.cm, 7.2 ft.lbf) 

      Fig 31: Installing Engine Mounting Insulator RH Bolts
      G00755936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Insert SST to the positioning holes on the right-hand crossmember and on the right-hand of the vehicle.

      SST 09670-00010

    8. Temporarily tighten bolt A, then tighten bolt B.
      Fig 32: Inserting SST To Positioning Holes On Right-Hand Crossmember
      G00755937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Insert SST to the positioning holes on the left-hand cross-member and on the left-hand of the vehicle.

      SST 09670-00010

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

      SST 09670-00010

      Fig 33: Inserting SST To Positioning Holes On Left-Hand Cross-Member
      G00755938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      Bolt A 116 N.m (1,183 kgf.cm, 86 ft.lbf) 

      Bolt B 70 N.m (714 kgf.cm, 52 ft.lbf) 

    12. Insert SST to the positioning holes on the left-hand cross-member and the left-hand of the vehicle, then tighten the bolts to the specified torque.

      SST 09670-00010

      Torque: 

      Bolt A 116 N.m (1,183 kgf.cm, 86 ft.lbf) 

      Bolt B 70 N.m (714 kgf.cm, 52 ft.lbf) 

    13. Tighten the 4 bolts, shown in the illustration.

      Torque: 47 N.m (479 kgf.cm, 35 ft.lbf) 

      Fig 34: Tightening Bolts Of RH And LH Crossmembers
      G00755939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH 
    1. Install the front suspension arm lower to the steering knuckle with the nut.

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

    2. Install a new clip.

    HINT: 

    Perform the same procedure as above on the opposite side.

  76. INSTALL TIE ROD END SUB-ASSY LH 
    1. Connect the tie rod end to the steering knuckle with the nut.

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

    2. Install a new cotter pin.
    NOTE:
    • Be careful of the threads and taper portions of the tie rod end to prevent contact with oils.
    • After tightening the castle nut, turn it clockwise within 60° to align the pin holes for the cotter pin.

    HINT: 

    Perform the same procedure as above on the opposite side.

  77. CONNECT SPEED SENSOR FRONT LH (W/ ABS) 
    1. Install the speed sensor with the bolt.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

    HINT: 

    Perform the same procedure as above on the opposite side.

  78. INSTALL FRONT AXLE HUB LH NUT 
    1. Using a 30 mm socket wrench, install the new hub nut.

      Torque: 216 N.m (2,203 kgf.cm, 160 ft.lbf) 

    2. Using a chisel, stake the hub nut.
      Fig 35: Installing Front Axle Hub LH Nut
      G00755940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    Perform the same procedure as above on the opposite side.

  79. INSTALL STEERING INTERMEDIATE SHAFT ASSY (See  OVERHAUL  ) 
  80. INSTALL EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION, AND DISASSEMBLY & REASSEMBLY  ) 
  81. INSTALL FLOOR PANEL BRACE FRONT 
  82. INSTALL A/C COMPRESSOR (See  W/PULLEY COMPRESSOR ASSY  ) 
  83. INSTALL FAN AND GENERATOR V BELT 
    1. Temporarily install the V-ribbed belt on each pulley.
  84. ADJUST FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  85. INSTALL RADIATOR ASSY (See  RADIATOR ASSY  ) 
  86. CONNECT FUEL TUBE SUB-ASSY (See  FUEL SYSTEM  ) 
  87. INSTALL AIR CLEANER ASSY (See  AIR CLEANER AND AIR DUCT  ) 
  88. INSTALL CYLINDER HEAD COVER NO. 2 
    1. First tighten nut A, then tighten bolt B.

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

      Fig 36: Locating Cylinder Head Cover No. 2 Bolts
      G00755941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. ADD ENGINE OIL 
  90. ADD ENGINE COOLANT (See  ENGINE COOLANT  ) 
  91. CHECK FOR ENGINE OIL LEAKS 
  92. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
  93. CHECK FOR FUEL LEAKS (See  ON-VEHICLE INSPECTION  ) 
  94. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See  FRONT WHEEL ALIGNMENT  ) 
  95. CHECK IDLE SPEED AND IGNITION TIMING (See  INSPECTION  ) 
  96. INSPECT CO/HC (See  INSPECTION  ) 
  97. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) 
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