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Partial Engine Assembly: Replacement

  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See  FUEL SYSTEM PRESSURE RELEASE  ). 
  2. REMOVE FRONT WHEELS 
  3. REMOVE ENGINE UNDER COVER RH 
  4. REMOVE ENGINE UNDER COVER LH 
  5. DRAIN COOLANT (See  COOLING - SPECIFICATIONS  ) 
  6. REMOVE CYLINDER HEAD COVER NO. 2 
    1. Remove the 2 nuts, 2 clips and cylinder head cover.
    Fig 1: Removing Cylinder Head Cover
    G02824380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT RADIATOR HOSE INLET 
    1. Disconnect the radiator hose inlet from the radiator.
  8. DISCONNECT RADIATOR HOSE OUTLET 
    1. Disconnect the radiator hose outlet from the radiator.
  9. DISCONNECT OIL COOLER INLET TUBE NO. 1 (A/T TRANSAXLE) 
    1. Disconnect the oil cooler inlet tube from the radiator.
  10. DISCONNECT OIL COOLER OUTLET TUBE NO. 1 (A/T TRANSAXLE) 
    1. Disconnect the oil cooler outlet tube from the radiator.
  11. REMOVE RADIATOR SUPPORT UPPER (W/ AIR CONDITIONER) 
    1. Remove the 2 bolts and 2 radiator support upper.
  12. REMOVE RADIATOR ASSY (W/ AIR CONDITIONER) 
    1. Disconnect the connector and harness clamp, and remove the radiator.
  13. REMOVE BATTERY 
  14. REMOVE BATTERY CARRIER 
    1. Remove the 4 bolts and battery carrier.
    Fig 2: Removing Battery Carrier
    G02824381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE AIR CLEANER ASSEMBLY WITH HOSE 
    1. Separate an intake air flow meter connector.
    2. Separate the VSV connector.
    3. Disconnect 3 vacuum hoses, as shown in the illustration.
    4. Loosen an air cleaner hose clump and separate an air cleaner hose.
    5. Remove the air cleaner cap.
    6. Remove the air filter.
      Fig 3: Disconnecting 3 Vacuum Hoses
      G02824382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the wire harness clamp, connector and hose.
    8. Remove the 3 bolts and the air cleaner case.
    Fig 4: Disconnecting Wire Harness Clamp
    G02824383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE EFI FUEL PIPE CLAMP (See  FUEL RAILS & FUEL INJECTORS  ) 
  17. DISCONNECT FUEL TUBE SUB-ASSY (See  FUEL RAILS & FUEL INJECTORS  ) 
  18. SEPARATE ACCELERATOR CONTROL CABLE ASSY 
    1. Loosen the nut, and remove the accelerator control cable.
  19. REMOVE CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) 
    1. Disconnect the actuator connector.
    2. Remove the 2 bolts, and disconnect the actuator from the body.
    Fig 5: Disconnect Actuator Connector
    G02824384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose from the brake booster.
  21. DISCONNECT HEATER INLET WATER HOSE 
    1. Disconnect the heater inlet water hose from the air conditioner tube.
    Fig 6: Disconnecting Heater Inlet Water Hose
    G02824385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Disconnect the heater outlet water hose from the air conditioner tube.
    Fig 7: Disconnecting Heater Outlet Water Hose
    G02824386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE) (See  REPLACEMENT  ) 
  24. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE) (See  REPLACEMENT  ) 
  25. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE) (See  FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT  ) 
  26. SEPARATE CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See  REPLACEMENT  ) 
  27. REMOVE GLOVE COMPARTMENT DOOR ASSY 
  28. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the engine ECM and junction block.
    2. Pull out the engine wire.
    3. Remove the engine room relay block cover.
    4. Disconnect the engine wire from the engine room relay block.
    Fig 8: Disconnecting Engine Wire From Engine ECM And Junction Block
    G02824387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE FAN AND GENERATOR V BELT 
    1. Turn the drive belt tensioner clockwise to relieve tension on the belt, and then remove the belt.
    2. Carefully return the tensioner to the unloaded position.
    Fig 9: View Of Serpentine Belt
    G02824388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER) (See  REPLACEMENT  ) 

    HINT:

    Hung up the hoses instead of detaching.

  31. SEPARATE RETURN TUBE SUB-ASSY 
    1. Disconnect the vane pump oil reservoir from the oil reservoir bracket.
    2. Remove the 2 bolts installing the return tube.
    Fig 10: Removing 2 Bolts Of Return Tube
    G02824389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT DOOR SCUFF PLATE RH 
  33. REMOVE COWL SIDE TRIM BOARD RH 
  34. REMOVE COLUMN HOLE COVER SILENCER SHEET 
    1. Remove the 2 clips and column hole cover silencer sheet.
  35. SEPARATE STEERING INTERMEDIATE SHAFT (See  OVERHAUL  ) 
  36. REMOVE FLOOR PANEL BRACE FRONT 
    1. Remove the 2 nuts and floor panel brace front.
  37. REMOVE EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  38. REMOVE FRONT AXLE HUB LH NUT (See  FRONT AXLE LH HUB  ) 

    SST 09930-00010

  39. REMOVE FRONT AXLE HUB RH NUT 

    SST 09930-00010

    HINT:

    Perform the same procedure as above on the opposite side.

  40. SEPARATE TIE ROD END SUB-ASSY LH) 

    SST 09628-62011

  41. SEPARATE TIE ROD END SUB-ASSY RH 

    SST 09628-62011

    HINT:

    Perform the same procedure as above on the opposite side.

  42. SEPARATE FRONT STABILIZER LINK ASSY LH (See  OVERHAUL  ) 
  43. SEPARATE FRONT STABILIZER LINK ASSY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  44. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH (See  REMOVAL & INSTALLATION  ) 
  45. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  46. SEPARATE FRONT AXLE ASSY LH (See  FRONT  . 
  47. SEPARATE FRONT AXLE ASSY RH  See FRONT .

    HINT:

    Perform the same procedure as above on the opposite side.

  48. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 4 bolts, 2 nuts and engine mounting insulator.
      Fig 11: Removing Engine Mounting
      G02824390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and nut, detach the engine mounting insulator from the vehicle.
      Fig 12: Removing Through Bolt And Nut
      G02824391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 6 bolts, as shown in the illustration.
    5. Carefully, remove the engine with transaxle from the vehicle.
      Fig 13: Removing 6 Bolts
      G02824392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 2 engine hangers with the 2 bolts.

      Part No.: 

      No. 1 engine hanger 12281-15040 

      No. 2 engine hanger 12281-22021 

      Bolt 91512-B1016 

      Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 

      HINT:

      Be sure to install engine hanger (12281-22021) to the front side of the engine and engine hanger (12281-15040) to the rear side.

    7. Using the chain block and engine sling device, hang the engine assembly.
    Fig 14: Installing Engine Hanger
    G02824393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. SEPARATE POWER STEERING VANE PUMP ASSY. 
    NOTE: Do not disconnect the hose.
  50. REMOVE FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER 
    1. Remove the through bolt and a nut, detach the engine mounting insulator FR from the engine mounting bracket.
      Fig 15: Removing Through Bolt And A Nut
      G02824394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the through bolt, detach the engine mounting insulator RR from the suspension crossmember.
    3. Separate the engine and transaxle assembly from the suspension crossmember and engine mounting member.
    Fig 16: Removing Through Bolt
    G02824395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE STARTER ASSY (See  STARTERS  ) 
  52. REMOVE MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See  REPLACEMENT  ) 
  53. REMOVE AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE) (See  COROLLA (A245E) & MATRIX (A246E)  ) 
  54. REMOVE CLUTCH COVER ASSY (M/T TRANSAXLE) (See  CLUTCH  ) 
  55. REMOVE CLUTCH DISC ASSY (M/T TRANSAXLE) (See  CLUTCH  ) 
  56. REMOVE FLYWHEEL SUB-ASSY (M/T TRANSAXLE) 
    1. Fix the crankshaft with SST, then remove the 8 bolts and flywheel.

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

    Fig 17: Removing Flywheel Assy
    G02824396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE) 
    1. Fix the crankshaft with SST, then remove the 8 bolts and drive plate & ring gear.

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

    Fig 18: Removing Drive Plate & Ring Gear
    G02824397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE GENERATOR ASSY (See  GENERATORS & REGULATORS  ). 
  59. REMOVE IGNITION COIL ASSY 
    1. Disconnect the 4 ignition coil connectors.
      Fig 19: Disconnecting Ignition Coil Connectors
      G02824398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and nut installing the engine wire.
      Fig 20: Removing Engine Wire Bolt And Nut
      G02824399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts and 4 ignition coils.
    Fig 21: Removing Ignition Coil Bolts
    G02824400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE FUEL DELIVERY PIPE SUB-ASSY (See  FUEL RAILS & FUEL INJECTORS  ) 
  61. REMOVE INTAKE MANIFOLD 
    1. Disconnect the 2 water hoses from the throttle body.
    2. Disconnect the 2 vacuum hoses from the intake manifold.
    3. Remove the 4 bolts, 2 nut, 2 wire brackets, the intake manifold and throttle body assembly.
    4. Remove the gasket from the intake manifold and throttle body assembly.
    Fig 22: Removing Intake Manifold And Throttle Body Assembly
    G02824401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE OIL LEVEL GAUGE SUB-ASSY 
    1. Remove the oil level gauge guide from the oil level gauge guide.
  63. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Remove the bolt and oil level gauge guide.
    Fig 23: Removing Oil Level Gauge Guide Bolt
    G02824402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE WATER BY-PASS PIPE NO.1 
    1. Remove the 2 bolts, 2 nuts, water by-pass pipe and gasket.
    Fig 24: Removing Water By-Pass Pipe And Gasket
    G02824403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE WATER INLET 
    1. Remove the 2 nuts and water inlet.
    Fig 25: Removing Water Inlet
    G02824404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE THERMOSTAT 
  67. REMOVE ENGINE OIL PRESSURE SWITCH ASSY 

    SST 09268-46021

  68. REMOVE CRANK POSITION SENSOR NO. 1 
    1. Remove the bolt and cam position sensor.
    Fig 26: Removing Cam Position Sensor
    G02824405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE CRANK POSITION SENSOR 
    1. Remove the 2 bolts and crank position sensor.
    Fig 27: Removing Crank Position Sensor
    G02824406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE KNOCK CONTROL SENSOR 
    1. Remove the nut and knock control sensor.
    Fig 28: Removing Knock Control Sensor
    G02824407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE V-RIBBED BELT TENSIONER ASSY 
    1. Remove the bolts, nut and V-ribbed belt tensioner.
    Fig 29: Removing V-Ribbed Belt Tensioner
    G02824408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and transverse engine mounting bracket.
    Fig 30: Removing Transverse Engine Mounting Bracket
    G02824409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE MANIFOLD STAY 
    1. Remove the 3 bolts and manifold stay.
    Fig 31: Removing Manifold Stay
    G02824410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Remove the 4 bolts and exhaust manifold heat insulator.
    Fig 32: Removing Exhaust Manifold Heat Insulator
    G02824411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE EXHAUST MANIFOLD 
    1. Remove the 5 nuts, exhaust manifold and gasket.
    Fig 33: Removing Exhaust Manifold
    G02824412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the E.F.I. engine coolant temperature sensor.

      SST 09817-33190

    Fig 34: Removing E.F.I. Engine Coolant Temperature Sensor
    G02824413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE RADIO SETTING CONDENSER 
    1. Remove the bolt and condenser.
    Fig 35: Removing Radio Setting Condenser
    G02824414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE WATER BY-PASS HOSE NO. 2 
  79. REMOVE RADIATOR HOSE INLET 
  80. REMOVE HEATER INLET WATER HOSE 
  81. REPLACE PARTIAL ENGINE ASSY 
  82. INSTALL RADIO SETTING CONDENSER 
    1. Install the condenser with the bolt.

      Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

    Fig 36: Installing Radio Setting Condenser
    G02824415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR 
    1. Install a new gasket to the E.F.I. engine coolant temperature sensor.
    2. Using SST, install the E.F.I. engine coolant temperature sensor.

      SST 09817-33190

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

    Fig 37: Installing E.F.I. Engine Coolant Temperature Sensor
    G02824416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL EXHAUST MANIFOLD 
    1. Install a new gasket and the exhaust manifold with the 5 nuts.

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

    Fig 38: Installing Exhaust Manifold
    G02824417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Install the exhaust manifold heat insulator with the 4 bolts.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

    Fig 39: Installing Exhaust Manifold Heat Insulator
    G02824418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL MANIFOLD STAY 
    1. Install the manifold stay with the 3 bolts.

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

    Fig 40: Installing Manifold Stay
    G02824419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Install the transverse engine mounting bracket with the 3 bolts.

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

    Fig 41: Installing Turnovers Engine Mounting Bracket
    G02824420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL V-RIBBED BELT TENSIONER ASSY 
    1. Install the V-ribbed belt tensioner with the bolt and nut.

      Torque: 

      Nut 29 N.m (296 kgf.cm, 21 ft.lbf) 

      Bolt 69 N.m (704 kgf.cm, 51 ft.lbf) 

    Fig 42: Installing V-Ribbed Belt Tensioner
    G02824421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. INSTALL KNOCK CONTROL SENSOR 
    1. Install the knock control sensor with the nut.

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

    Fig 43: Installing Knock Control Sensor
    G02824422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL CRANK POSITION SENSOR 
    1. Install the crank position sensor with the 2 bolts.

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

    Fig 44: Installing Crank Position Sensor
    G02824423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSTALL CRANK POSITION SENSOR NO.1 
    1. Install the cam position sensor with the bolts.

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

    Fig 45: Installing Crank Position Sensor No.1
    G02824424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. INSTALL ENGINE OIL PRESSURE SWITCH ASSY (See  ON-VEHICLE INSPECTION  ) Adhesive: Part No.08833 - 00080, THREE BOND 1344. 

    SST 09268-46021

  93. INSTALL THERMOSTAT (See  REPLACEMENT  ) 
  94. INSTALL WATER INLET 
    1. Install the water inlet with the 2 nuts.

      Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) 

    Fig 46: Installing Water Inlet
    G02824425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. INSTALL WATER BY-PASS PIPE NO.1 
    1. Install a new gasket and water by-pass with the 2 nuts and 2 bolts.

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

    Fig 47: Installing Water By Pass Pipe
    G02824426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. INSTALL OIL LEVEL GAUGE GUIDE 
    1. Apply a light coat of a new O-ring and install it to the oil level gauge guide.
    2. Install the oil level gauge guide with the bolt.

      Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

    Fig 48: Installing Oil Level Gauge Guide
    G02824427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. INSTALL INTAKE MANIFOLD 
    1. Install a new gasket to the intake manifold.
    2. Install the intake manifold and throttle body assembly with the 2 brackets, 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

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

    3. Connect the 2 vacuum hoses to the intake manifold.
    4. Connect the 2 water hoses to the throttle body.
    Fig 49: Installing Intake Manifold
    G02824428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. INSTALL FUEL DELIVERY PIPE SUB-ASSY (See  FUEL RAILS & FUEL INJECTORS  ) 
  99. INSTALL IGNITION COIL ASSY 
    1. Install the 4 ignition coils with the 4 bolts.

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

      Fig 50: Installing Ignition Coil Assy
      G02824429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire with the bolt and nut.

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

    Fig 51: Installing Engine Wire
    G02824430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. INSTALL GENERATOR ASSY (See  GENERATOR  ) 
  101. INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE) 
    1. Fix the crankshaft with SST.

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

      Fig 52: Installing Crankshaft Pulley
      G02824431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the bolt and bolt hole.
    3. Apply adhesive to the bolts.

      Adhesive: 

      Part No. 09330-00070, THREE BOND or equivalent. 

    4. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.

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

      Fig 53: Tightening 8 Bolts In Sequence
      G02824432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Mark the bolts with paint.
    6. Retighten the bolts by an additional 90°.
    7. Check that the point marked bolts are moved at 90°C angle.
    Fig 54: Locating Mark Bolts With Paint
    G02824433Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE) 
    1. Fix the crankshaft with SST.

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

      Fig 55: Installing Crankshaft Pulley
      G02824434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Clean the bolt and bolt hole.
    3. Apply adhesive to the bolts.

      Adhesive: 

      Part No. 09330-00070, THREE BOND or equivalent. 

    4. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.

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

    Fig 56: Tightening 8 Bolts In Sequence
    G02824435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE) (See  CLUTCHES  ) 

    SST 09301-00210

  104. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE) (See  CLUTCHES  ) 

    SST 09301-00210

  105. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE) (See  REPLACEMENT  ) 
  106. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE). (See  COROLLA (A245E) & MATRIX (A246E)  ) 
  107. INSTALL STARTER ASSY (See  STARTERS  ) 
  108. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER 
    1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
    2. Install the bolt holding the rear engine mounting bracket to the mounting insulator.

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

      Fig 57: Installing Bolt Holding Rear Engine Mounting Bracket To Mounting Insulator
      G02824436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt holding the front engine mounting bracket to the mounting insulator.

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

    Fig 58: Installing Bolt Holding Front Engine Mounting Bracket To Mounting Insulator
    G02824437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  109. INSTALL POWER STEERING VANE PUMP ASSY. 
  110. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine with transaxle on the engine lifter.
    2. Install the engine with transaxle to the vehicle.
    3. Temporarily, install the suspension crossmember and 6 bolts.
    4. Install the engine mounting insulator LH.

      Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) 

    5. Install the engine mounting insulator RH.

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

      Fig 59: Installing Suspension Crossmember And 6 Bolts
      G02824438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert SST to the positioning holes on the right handle crossmember and on the right-handle of the vehicle.

      SST 09670-00010

    7. Temporarily tighten the bolt A first, then Bolt B.
      Fig 60: Inserting SST To Positioning Holes
      G02824439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Insert SST to the positioning holes on the left handle crossmember and on the left-handle of the vehicle.

      SST 09670-00010

    9. Temporarily tighten the bolt A first, then Bolt B.
    10. Insert SST to the positioning holes on the right-handle crossmember and right-handle of the vehicle, then tighten the bolts with a specified torque.
    11. Insert SST to the positioning holes on the right-handle crossmember and left-handle of the vehicle, then tighten the bolts with a specified torque.

      SST 09670-00010

      Fig 61: Inserting SST To Positioning Holes On Right-Handle Crossmember
      G02824440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      Bolt A 157 N.m (1,601 kgf.cm, 116 ft.lbf) 

      Bolt B 113 N.m (1,152 kgf.cm, 83 ft.lbf) 

    12. Tighten the 2 bolts, as shown in the illustration.
      Fig 62: Tightening 2 Bolts
      G02824441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 39 N.m (398 kgf.cm, 29 ft.lbf) 

    NOTE: After installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
  111. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See  REMOVAL & INSTALLATION  ) 
  112. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  113. INSTALL FRONT STABILIZER LINK ASSY LH (See  OVERHAUL  ) 
  114. INSTALL FRONT STABILIZER LINK ASSY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  115. INSTALL TIE ROD END SUB-ASSY LH 
  116. INSTALL TIE ROD END SUB-ASSY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  117. INSTALL FRONT AXLE HUB LH NUT (See  FRONT AXLE LH HUB  ) 
  118. INSTALL FRONT AXLE HUB RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  119. INSTALL EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  120. INSTALL FLOOR PANEL BRACE FRONT 
    1. Install front floor panel brace with the 2 nuts.

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

  121. INSTALL STEERING INTERMEDIATE SHAFT (See  OVERHAUL  ) 
  122. INSTALL RETURN TUBE SUB-ASSY 
    1. Install the return tube with 2 bolts.

      Torque: 

      Bolt A 5.0 N.m (51 kgf.cm, 44 in. lbf) 

      Bolt B 7.8 N.m (80 kgf.cm, 69 in. lbf) 

    Fig 63: Installing Return Tube
    G02824442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  123. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER) (See  REPLACEMENT  ) 
  124. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE) (See  REPLACEMENT  ) 
  125. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL) 
    1. Install the actuator with the 2 bolts.
    2. Connect the actuator connector.

      Torque: 6.0 N.m (61 kgf.cm, 53 in. lbf) 

    Fig 64: Installing Actuator
    G02824443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  126. INSTALL AIR CLEANER ASSEMBLY WITH HOSE 
    1. Install the air cleaner case with the 3 bolts.

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

    2. Connect the wire harness clamp, connector and hose.
    3. Install the air filter.
    4. Install the air cleaner cap.
    5. Connect the air cleaner hose.
      Fig 65: Connecting Wire Harness Clamp
      G02824444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect 3 vacuum hoses, as shown in the illustration.
    7. Connect the VSV connector.
    8. Connect the intake air flow meter connector.
    Fig 66: Connecting 3 Vacuum Hoses
    G02824445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  127. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 4 bolts.

      Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

    Fig 67: Installing Battery Carrier
    G02824446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  128. INSTALL BATTERY 

    Torque: 

    Bolt 5.0 N.m (51 kgf.cm, 44 in. lbf) 

    Nut 3.0 - 4.0 N.m (31 - 41 kgf.cm, 27 - 35 in. lbf) 

  129. INSTALL RADIATOR SUPPORT UPPER (W/ AIR CONDITIONER) 
    1. Install the 2 radiator support uppers with the 2 bolts.

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

  130. INSTALL CYLINDER HEAD COVER NO.2 
    1. Install the cylinder head cover with the 2 nuts and 2 clips.

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

    Fig 68: Locating Cylinder Head Cover
    G02824447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  131. INSTALL FRONT WHEELS 

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

  132. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE) 
  133. ADD ENGINE OIL 
  134. ADD COOLANT (See  REPLACEMENT  ) 
  135. CHECK ENGINE OIL LEAK 
  136. CHECK ENGINE COOLANT LEAK (See  REPLACEMENT  ) 
  137. CHECK FUEL LEAK 
  138. CHECK EXHAUST GAS LEAK 
  139. INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See  INSPECTION  ) 

    SST 09843-18040

  140. INSPECT CO/HC (See  INSPECTION  ) 
  141. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See  ADJUSTMENT  ) 
  142. CHECK ABS SPEED SENSOR SIGNAL 
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