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Engine Assembly: Installation

  1. INSTALL HEATER INLET WATER HOSE 
  2. INSTALL RADIATOR HOSE INLET 
  3. INSTALL WATER BY-PASS HOSE NO. 2 
  4. INSTALL RADIO SETTING CONDENSER 
    1. Install the condenser with the bolt.

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

  5. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
    1. Install a new gasket onto the engine coolant temperature sensor.
      Fig 1: Installing Condenser With Bolt
      G04461159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, install the engine coolant temperature sensor.

      SST 09817-33190 

      Torque: 19.6 N*m (200 kgf*cm, 14 ft.*lbf) 

      Fig 2: Installing Engine Coolant Temperature Sensor Using SST
      G04461160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL EXHAUST MANIFOLD (for 2WD) 
    1. Install a new gasket and the exhaust manifold with the 5 nuts.

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

      Fig 3: Installing Gasket And Exhaust Manifold With Nuts
      G04461161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (for 2WD) 
    1. Install the exhaust manifold heat insulator with the 4 bolts [A].

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

    2. Connect the air fuel ratio sensor connector [B].
      Fig 4: Installing Exhaust Manifold Heat Insulator With Bolts [A]
      G04461162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL MANIFOLD STAY (for 2WD) 
    1. Install the manifold stay with 3 bolts.

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

  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Install the V-ribbed belt tensioner assembly (See INSTALLATION  ).
      Fig 5: Installing Manifold Stay With Bolts
      G04461163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL KNOCK SENSOR 
    1. Install the knock sensor with the nut.

      Torque: 20 N*m (205 kgf*cm, 15 ft.*lbf) 

      Fig 6: Installing Knock Sensor With Nut
      G04461164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL CRANKSHAFT POSITION SENSOR 
    1. Install the crankshaft position sensor with the 2 bolts.

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

      Fig 7: Installing Crankshaft Position Sensor With Bolts
      G04461165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL CAMSHAFT POSITION SENSOR 
    1. Install the camshaft position sensor with the bolt.

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

  13. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Install the engine oil pressure switch assembly (See ON-VEHICLE INSPECTION ).
  14. INSTALL THERMOSTAT 
    1. Install the thermostat (See REMOVAL ).
  15. INSTALL WATER INLET 
    1. Install the water inlet (See REMOVAL ).
      Fig 8: Installing Camshaft Position Sensor With Bolt
      G04461166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL WATER BY-PASS PIPE NO. 1 (for 2WD) 
    1. Install a new gasket and the water by-pass pipe No. 1 with the 2 nuts and 2 bolts.

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

    2. Connect the knock sensor clamp.
      Fig 9: Installing Water By-Pass Pipe No. 1 (2WD)
      G04461167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL WATER BY-PASS PIPE NO. 1 (for 4WD) 
    1. Install a new gasket and the water by-pass pipe No. 1 with the 2 nuts and 2 bolts.

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

    2. Connect the knock sensor clamp.
  18. INSTALL OIL LEVEL GAGE GUIDE 
    1. Apply a light coat of engine oil to a new O-ring and install it onto the oil level gage guide.
      Fig 10: Installing Water By-Pass Pipe No. 1 (4WD)
      G04461168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the oil level gage guide with the bolt.

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

    3. Connect the crankshaft position sensor clamp.
  19. INSTALL INTAKE MANIFOLD (for 2WD) 
    1. Install the intake manifold (See INSTALLATION  ).
  20. INSTALL INTAKE MANIFOLD (for 4WD) 
    1. Install the intake manifold (See INSTALLATION  ).
  21. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY 
  22. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Install the fuel delivery pipe sub-assembly (See INSTALLATION ).
      Fig 11: Installing Oil Level Gage Guide With Bolt
      G04461169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the ignition coil assembly (See INSTALLATION  ).
  24. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Install the flywheel sub-assembly (See INSTALLATION  ).

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

  25. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Install the drive plate & ring gear sub-assembly (See INSTALLATION  ).

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

  26. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch disc assembly (See INSTALLATION ).

      SST 09301-00210 

  27. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch cover assembly (See INSTALLATION ).
  28. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Install the automatic transaxle assembly.

      HINT:

  29. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 
    1. Install the manual transaxle assembly (See INSTALLATION ).
  30. INSTALL STARTER ASSEMBLY 
    1. Install the starter assembly (See INSTALLATION ).
  31. INSTALL TRANSFER ASSEMBLY (for 4WD) 
    1. Install the transfer assembly (See INSTALLATION ).
  32. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD) 
    1. Install the transfer stiffener plate RH (See INSTALLATION ).
  33. INSTALL TRANSFER STIFFENER PLATE CENTER (for 4WD) 
    1. Install the transfer stiffener plate center (See INSTALLATION ).
  34. INSTALL ENGINE MOUNTING BRACKET RR (for 4WD) 
    1. Install the engine mounting bracket RR (See INSTALLATION ).
  35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) 
    1. Install the front drive shaft assembly RH (See INSTALLATION ).
  36. INSTALL EXHAUST MANIFOLD (for 4WD) 
    1. Install a new gasket and the exhaust manifold with the 5 nuts.

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

      Fig 12: Installing Gasket And Exhaust Manifold With Nuts
      G04461170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (for 4WD) 
    1. Install the exhaust manifold heat insulator with the 4 bolts.

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

      Fig 13: Installing Exhaust Manifold Heat Insulator With Bolts
      G04461171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL HEATED OXYGEN SENSOR (for 4WD) 
    1. Using SST, install the heated oxygen sensor.

      SST 09224-00010 

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

      Fig 14: Installing Heated Oxygen Sensor Using SST
      G04461172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL MANIFOLD STAY (for 4WD) 
    1. Install the manifold stay with the 2 bolts.

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

  40. INSTALL FRONT SUSPENSION CROSSMEMBER W/ CENTER MEMBER 
    1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
      Fig 15: Installing Manifold Stay With Bolts
      G04461173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the through bolt, which is used to secure the engine mounting insulator RR, into the engine mounting bracket RR.

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

      Fig 16: Installing Bolt Securing Engine Mounting Insulator RR, Into Engine Mounting Bracket RR
      G04461174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt, which is used to secure the engine mounting insulator FR, into the engine mounting bracket FR.

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

      Fig 17: Installing Bolt Securing Engine Mounting Insulator FR, Into Engine Mounting Bracket FR
      G04461175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY (for 4WD) 
    1. Install the rack & pinion power steering gear assembly (See INSTALLATION ).

      SST 09023-38200 

  42. INSTALL VANE PUMP ASSEMBLY 
    1. Install the vane pump assembly (See INSTALLATION ).
  43. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Install the engine with transaxle onto the vehicle.
    3. Temporarily install the suspension crossmember with the 6 bolts.
      Fig 18: Installing Suspension Crossmember With Bolts
      G04461176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting insulator LH with the through bolt and nut.

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

      Fig 19: Installing Engine Mounting Insulator LH With Bolt And Nut
      G04461177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine mounting insulator RH with the 4 bolts and 2 nuts.

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

      Fig 20: Installing Engine Mounting Insulator RH With Bolts And Nuts
      G04461178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Insert SST into 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 21: Tightening Bolt A, First Then Bolt B (1 Of 2)
      G04461179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Insert SST into 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 into the positioning holes on the right-handle crossmember and right-handle of the vehicle, then tighten the bolts to the specified torque.
    11. Insert SST into the positioning holes on the right-handle crossmember and left-handle of the vehicle, then tighten the bolts to the specified torque.

      SST 09670-00010 

      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) 

      Fig 22: Tightening Bolt A, First Then Bolt B (2 Of 2)
      G04461180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Tighten the 2 bolts as shown in the illustration.

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      NOTE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
  44. INSTALL FRONT AXLE ASSEMBLY LH 
    1. Install the front axle assembly LH (See INSTALLATION ).
      Fig 23: Tightening Bolts As Shown
      G04461181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  46. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH 
    1. Install the front suspension arm sub-assembly lower No. 1 LH (See INSTALLATION ).
  47. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  48. INSTALL TIE ROD END SUB-ASSEMBLY LH 
    1. Install the tie rod end sub-assembly LH (See INSTALLATION ).
  49. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  50. INSTALL SPEED SENSOR FRONT LH (w/ ABS) 
    1. Install the speed sensor front LH (See INSTALLATION ).
  51. INSTALL SPEED SENSOR FRONT RH (w/ ABS) 

    HINT:

    Perform the same procedure as above on the opposite side.

  52. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 
    1. Install the front stabilizer link assembly LH (See INSTALLATION ).
  53. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  54. INSTALL FRONT AXLE HUB LH NUT 
    1. Install the front axle hub LH nut (See INSTALLATION ).
  55. INSTALL FRONT AXLE HUB RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  56. INSTALL STEERING INTERMEDIATE SHAFT 
    1. Install the steering intermediate shaft (See INSPECTION ).
  57. INSTALL COLUMN HOLE COVER SILENCER SHEET 
  58. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for 2WD) 
    1. Install the exhaust pipe assembly front (See INSTALLATION ).
  59. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for 4WD) 
    1. Install the exhaust pipe assembly front (See INSTALLATION ).
  60. INSTALL FLOOR PANEL BRACE FRONT (for 2WD) 
    1. Install the floor panel brace front (See INSTALLATION ).
  61. INSTALL EXHAUST PIPE ASSEMBLY CENTER (for 4WD) 
    1. Install the exhaust pipe assembly center (See INSTALLATION ).
  62. TEMPORARILY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSEMBLY (for 4WD) 
    1. Temporarily tighten the propeller with center bearing shaft assembly (See INSTALLATION ).
  63. CONNECT ENGINE WIRE 
  64. INSTALL FRONT SEAT ASSEMBLY RH (for 4WD) 
    1. Install the front seat assembly RH (See INSTALLATION ).
  65. INSTALL CENTER PILLAR GARNISH LOWER RH (for 4WD) 
  66. INSTALL REAR DOOR SCUFF PLATE RH (for 4WD) 
  67. INSTALL COWL SIDE TRIM BOARD RH 
  68. INSTALL FRONT DOOR SCUFF PLATE RH 
  69. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY 
  70. INSTALL RETURN TUBE SUB-ASSEMBLY (for 2WD) 
    1. Install the return tube with the 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) 

    2. Install the vane pump oil reservoir onto the oil reservoir bracket.
      Fig 24: Installing Return Tube With Bolts (1 Of 2)
      G04461182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL RETURN TUBE SUB-ASSEMBLY (for 4WD) 
    1. Install the return tube with 3 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) 

    2. Install the vane pump oil reservoir onto the oil reservoir bracket.
  72. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) 
    1. Install the compressor and magnetic clutch (See INSTALLATION ).
      Fig 25: Installing Return Tube With Bolts (2 Of 2)
      G04461183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSTALL GENERATOR ASSEMBLY 
    1. Install the generator assembly (See INSTALLATION ).
  74. INSTALL FAN AND GENERATOR V BELT 
  75. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch release cylinder assembly (See INSTALLATION ).
  76. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Install the transmission control cable assembly (See INSTALLATION , INSTALLATION ).
  77. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Install the transmission control cable assembly (See INSTALLATION ).
  78. CONNECT HEATER OUTLET WATER HOSE 
  79. CONNECT HEATER INLET WATER HOSE 
  80. CONNECT UNION TO CHECK VALVE HOSE 
  81. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly (See INSTALLATION ).
  82. INSTALL CRUISE CONTROL ACTUATOR ASSEMBLY (w/ Cruise Control) 
    1. Install the actuator with the 2 bolts [A].

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

    2. Connect the actuator connector [B].
  83. INSTALL ACCELERATOR CONTROL CABLE ASSEMBLY (for 4WD) 
    Fig 26: Installing Actuator With Bolts [A]
    G04461184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Connect the air cleaner case to the air cleaner inlet No. 1 [A].
    2. Install the air cleaner case with the 3 bolts [B].

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

    3. Connect the clamp [C] of the engine wire.
  85. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2WD) 
    1. Install the air cleaner cap sub-assembly (See INSTALLATION ).
      Fig 27: Installing Air Cleaner Case With Bolts [B]
      G04461185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 4WD) 
    1. Install the air cleaner cap sub-assembly (See INSTALLATION ).
  87. INSTALL BATTERY CARRIER 
    1. Install the battery carrier and bracket with the 4 bolts.

      Torque: 12.8 N*m (131 kgf*cm, 9 ft.*lbf) 

  88. INSTALL BATTERY TRAY 
  89. INSTALL BATTERY 

    Torque: Bolt 

    5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    Nut 

    3.5 N*m (36 kgf*cm, 31 in.*lbf) 

    Terminal 

    5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    Fig 28: View Of Battery Carrier Mounting Bolts
    G04461616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL RADIATOR ASSEMBLY (w/ Air Conditioning System) 
    1. Install the radiator assembly (See REMOVAL ).
  91. CONNECT OIL COOLER OUTLET HOSE NO. 1 (for Automatic Transaxle) 
  92. CONNECT OIL COOLER INLET HOSE NO. 1 (for Automatic Transaxle) 
  93. CONNECT RADIATOR HOSE OUTLET 
  94. CONNECT RADIATOR HOSE INLET 
  95. INSTALL FRONT WHEELS 

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

  96. ADD TRANSFER OIL (for 4WD) 
    1. Add the transfer oil (See ON-VEHICLE INSPECTION ).
  97. ADD AUTOMATIC TRANSAXLE FLUID (for 4WD) 
  98. ADD ENGINE COOLANT 
    1. Add the engine COOLANT .
  99. CONNECT BATTERY NEGATIVE TERMINAL 

    Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  100. CHECK ENGINE COOLANT LEAKAGE 
    1. Check for the engine coolant leakage (See ON-VEHICLE INSPECTION ).
  101. CHECK ENGINE OIL LEAKAGE 
  102. CHECK FUEL LEAKAGE 
  103. CHECK EXHAUST GAS LEAKAGE 
  104. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust the front wheel alignment (See ADJUSTMENT ).
  105. CHECK ABS SPEED SENSOR SIGNAL (w/ ABS) 
    1. Check the ABS speed sensor signal (See ANTI-LOCK BRAKE SYSTEM ).
  106. INSPECT IGNITION TIMING 
    1. Inspect the ignition timing (See ON-VEHICLE INSPECTION  ).

      SST 09843-18040 

  107. INSPECT ENGINE IDLING SPEED 
    1. Inspect the engine idling speed (See ON-VEHICLE INSPECTION  ).
  108. INSPECT CO/HC 
    1. Inspect the CO/HC (See ON-VEHICLE INSPECTION  ).
  109. INSTALL CYLINDER HEAD COVER NO. 2 
    1. Install the cylinder head cover No. 2 (See INSTALLATION  ).
  110. INSTALL ENGINE UNDER COVER LH 
  111. INSTALL ENGINE UNDER COVER RH 
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