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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 RADIATOR GRILLE 
  7. REMOVE FRONT BUMPER COVER 
  8. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 4 nuts and cylinder head cover No. 2.
      Fig 1: Removing 4 Nuts And Cylinder Head Cover
      G00758906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BATTERY 
  10. REMOVE AIR CLEANER ASSY 
  11. DISCONNECT FUEL TUBE SUB-ASSY (See  FUEL SYSTEM  ) 

    SST 09268-21010

  12. DISCONNECT ACCELERATOR CONTROL CABLE ASSY 
  13. REMOVE RADIATOR ASSY (See  RADIATOR ASSY  ) 
  14. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See  TRANSMISSION CONTROL CABLE ASSY (MTM)  ) 
  15. DISCONNECT TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See  TRANSMISSION CONTROL CABLE ASSY (ATM)  ) 
  16. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) 
  17. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the union to check valve hose from the brake booster.
      Fig 2: Disconnecting Union To Check Valve Hose
      G00758907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. 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
      G00758908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. 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
      G00758909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. 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 the engine room junction block.
    5. Remove the body ground.
  21. REMOVE FAN AND GENERATOR V BELT (See  DRIVE BELT  ) 
  22. REMOVE A/C COMPRESSOR (See  W/PULLEY COMPRESSOR ASSY  ) 

    HINT: 

    Secure the hoses off to the side instead of detaching.

  23. REMOVE FLOOR PANEL BRACE FRONT (See  EXHAUST  ) 
  24. REMOVE EXHAUST PIPE ASSY FRONT (See  EXHAUST  ) 
  25. SEPARATE SHAFT ASSY, STEERING INTERMEDIATE (See  OVERHAUL  ) 
  26. REMOVE FRONT AXLE HUB LH NUT 
    1. Using SST and a hammer, unstake the lock nut.

      SST 09930-00010

      Fig 5: Removing Unstake Lock Nut
      G00758910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    2. Using a 30 mm socket wrench, remove the lock nut.

    HINT: 

    Perform the same procedure as above on the opposite side.

  27. DISCONNECT SPEED SENSOR FRONT LH (W/ ABS) 
    1. Remove the bolt, disconnect the speed sensor from the steering knuckle.
      Fig 6: Removing Speed Sensor Bolt
      G00758911Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    Perform the same procedure as above on the opposite side.

  28. SEPARATE TIE ROD END SUB-ASSY LH 
    1. Using SST, disconnect the tie rod end from the steering knuckle.

      SST 09628-62011

      Fig 7: Disconnecting Tie Rod End From Steering Knuckle
      G00758912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Do not damage the dust cover of the ball joint.

    HINT: 

    Perform the same procedure as above on the opposite side.

  29. 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

      Fig 8: Disconnecting Front Suspension Arm Lower From Steering Knuckle
      G00758913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    Perform the same procedure as above on the opposite side.

  30. SEPARATE FRONT DRIVE SHAFT ASSY LH 
    1. Using a plastic hammer, detach the drive shaft from the axle hub by tapping.
      Fig 9: Detaching Drive Shaft From Axle Hub By Tapping
      G00758914Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    Perform the same procedure as above on the opposite side.

  31. 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 and nut, and then remove the engine mounting insulator RH.
      Fig 10: Removing Engine Mounting Insulator RH Nuts And Bolts
      G00758915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and detach the engine mounting bracket from the engine mounting insulator LH.
      Fig 11: Removing Engine Mounting Bracket 2 Bolts
      G00758916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the engine together with the transaxle.
      1. Remove the 8 bolts shown in the illustration.
      2. Carefully remove the engine assembly from the vehicle.
      Fig 12: Removing Suspension Crossmember 8 Bolts
      G00758917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and condenser.
    7. Install the 2 engine hangers as shown in the Fig 13.

      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: Installing 2 Engine Hangers
      G00758918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE VANE PUMP V BELT (See  DRIVE BELT  ) 
  33. REMOVE VANE PUMP ASSY 
    1. Disconnect the power steering oil pressure sensor harness.
    2. Remove the 2 bolts and vane pump assembly.
      Fig 14: Removing Vane Pump Assembly 2 Bolts
      G00758919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY 
    1. Remove the through bolt.
    2. Separate the engine and transaxle assembly from the suspension crossmember.
      Fig 15: Removing Front Suspension Crossmember Through Bolt
      G00758920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE STARTER ASSY (See  STARTER  ) 
  36. REMOVE GENERATOR ASSY (See  GENERATOR  ) 
  37. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE  ) 
  38. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) 
  39. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) 
  40. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) 
  41. REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL (See  ENGINE REAR OIL SEAL  ) 

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

  42. REMOVE VENTILATION HOSE 
  43. REMOVE VENTILATION HOSE NO. 2 
  44. 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: Removing Intake Manifold
      G00758921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE BOOSTER VACUUM TUBE 
    1. Remove the 2 bolts and booster vacuum tube.
      Fig 17: Removing Booster Vacuum Tube 2 Bolts
      G00758922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE MANIFOLD SUPPORT BRACKET 
    1. Remove the 3 bolts and manifold support bracket.
  47. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Remove the 4 bolts and exhaust manifold heat insulator.
      Fig 18: Removing Manifold Support Bracket 3 Bolts
      G00758923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE EXHAUST MANIFOLD 
    1. Remove the 3 bolts and 2 nuts, and then remove the exhaust manifold.
      Fig 19: Removing Exhaust Manifold 3 Bolts And 2 Nuts
      G00758924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE IGNITION COIL NO. 1 
    1. Remove the 4 bolts and pull out the 4 ignition coils.
  50. REMOVE WATER BY-PASS PIPE NO. 1 
    1. Remove the 2 nuts and 2 bolts and then remove the water by-pass pipe.
      Fig 20: Removing Ignition Coils 4 Bolts
      G00758925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the engine coolant temperature sensor.

      SST 09817-33190

      Fig 21: Removing Engine Coolant Temperature Sensor
      G00758926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE KNOCK SENSOR 
    1. Using SST, remove the knock sensor.

      SST 09816-30010

      Fig 22: Removing Knock Sensor
      G00758927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE ENGINE OIL PRESSURE SWITCH ASSY 
    1. Using SST, remove the oil pressure switch.

      SST 09268-46021

  54. REPLACE PARTIAL ENGINE ASSY 
  55. 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.
  56. 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
      G00758928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Install a new gasket to the engine coolant temperature sensor.
    2. Using SST, fix the engine coolant temperature sensor.

      SST 09817-33190

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

      Fig 24: Installing Engine Coolant Temperature Sensor
      G00758929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. 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) 

  59. INSTALL IGNITION COIL NO. 1 
    1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 
  60. INSTALL EXHAUST MANIFOLD 
    1. Using several steps, install a new exhaust manifold gasket and the exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.

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

      Fig 25: Installing Exhaust Manifold 3 Bolts And 2 Nuts
      G00758930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. 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) 

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

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

  63. 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) 

  64. 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: Installing Intake Manifold
      G00758931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL (See  ENGINE REAR OIL SEAL  ) 

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

  66. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) 
  67. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) 
  68. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See  MANUAL TRANSAXLE  ) 
  69. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) 
  70. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
  71. INSTALL STARTER ASSY (See  STARTER  ) 
  72. 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: Installing Front Suspension Crossmember Bolts
      G00758932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. 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, first tighten bolt, A, then tighten bolt B.

  74. INSTALL VANE PUMP V BELT 
    1. Temporarily install the V-ribbed belt on each pulley.
      Fig 28: Installing Vane Pump Assembly 2 Bolts
      G00758933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. ADJUST VANE PUMP V BELT (See  DRIVE BELT  ) 
  76. 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 8 Bolts
      G00758934Courtesy 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 2 Bolts
      G00758935Courtesy 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 5 Bolts And Nut
      G00758936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Insert SST to the positioning holes of the right hand cross-member and vehicle.

      SST 09670-00010

    8. Temporarily tighten bolt A, then tighten bolt B.
      Fig 32: Inserting SST To Positioning Holes Of Right Hand Cross-Member And Vehicle
      G00758937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Insert SST to the positioning holes of the left-hand cross-member and vehicle.

      SST 09670-00010

    10. Temporarily tighten bolt A, then tighten bolt B.
    11. Insert SST to the positioning holes of the right-hand crossmember and vehicle again, 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) 

    12. Insert SST to the positioning holes of the left-handle crossmember and vehicle again, 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) 

      Fig 33: Inserting SST To Positioning Holes Of Left-Handle Crossmember And Vehicle
      G00758938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    13. Tighten the 4 bolts shown in the illustration.

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

      Fig 34: Tightening 4 Bolts
      G00758939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. 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.

  78. 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 tapered portions of the tie rod end not to make 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.

  79. 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.

  80. 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.

    HINT: 

    Perform the same procedure as above on the opposite side.

    Fig 35: Stakeing Hub Nut
    G00758940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL SHAFT ASSY, STEERING INTERMEDIATE (See  OVERHAUL  ) 
  82. INSTALL EXHAUST PIPE ASSY FRONT (See  EXHAUST  ) 
  83. INSTALL FLOOR PANEL BRACE FRONT (See  EXHAUST  ) 
  84. INSTALL A/C COMPRESSOR (See  W/PULLEY COMPRESSOR ASSY  ) 
  85. INSTALL FAN AND GENERATOR V BELT 
    1. Temporarily install the V-ribbed belt on each pulley.
  86. ADJUST FAN AND GENERATOR V BELT (See  ENGINE  ) 
  87. INSTALL RADIATOR ASSY (See  RADIATOR ASSY  ) 
  88. CONNECT FUEL TUBE SUB-ASSY (See  FUEL SYSTEM  ) 
  89. INSTALL AIR CLEANER ASSY 
  90. 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: Installing Cylinder Head Cover No. 2
      G00758941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSTALL FRONT BUMPER COVER 
  92. INSTALL ENGINE UNDER COVER LH 
    1. Torque: 
    2. 5.0 N.m (51 kgf.cm, 44 in.lbf) for Bolt 
    3. 5.0 N.m (51 kgf.cm, 44 in.lbf) for Nut 
  93. INSTALL ENGINE UNDER COVER RH 
    1. Torque: 
    2. 5.0 N.m (51 kgf.cm, 44 in.lbf) for Bolt 
    3. 5.0 N.m (51 kgf.cm, 44 in.lbf) for Nut 
  94. ADD ENGINE OIL 
  95. ADD ENGINE COOLANT (See  ENGINE COOLANT  ) 
  96. CHECK FOR ENGINE OIL LEAKS 
  97. CHECK FOR ENGINE COOLANT LEAKS (See  COOLING SYSTEM  ) 
  98. CHECK FOR FUEL LEAKS 
  99. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
  100. CHECK IDLE SPEED AND IGNITION TIMING (See  ENGINE  ) 
  101. INSPECT CO/HC (See  ENGINE  ) 
  102. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS) 
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