Installation

INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

3. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. INSTALL KNOCK SENSOR
5. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY
6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
7. INSTALL IGNITION COIL ASSEMBLY
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
9. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
10. INSTALL INTAKE MANIFOLD ASSEMBLY

11. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install a new gasket and the water by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
12. INSTALL THERMOSTAT
13. INSTALL WATER INLET
14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
16. INSTALL NO. 2 MANIFOLD STAY
17. INSTALL MANIFOLD STAY
18. INSTALL OIL DIPSTICK GUIDE
19. INSTALL OIL DIPSTICK

20. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
21. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
(a) Clean the 8 bolts and 8 bolt holes.
(b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 130 N*m (1,326 kgf*cm, 96 ft.*lbf)
22. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
23. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
24. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
25. INSTALL DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle)
(a) Clean the 8 bolts and 8 bolt holes.
(b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
(d) Install the front spacer, drive plate and rear spacer onto the crankshaft.

(e) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf)
26. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle)
27. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
28. INSTALL STARTER ASSEMBLY
29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.

(b) Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)

(c) Install the bolt which is used to secure the front engine mounting bracket.
Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
32. INSTALL VANE PUMP ASSEMBLY
33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the engine lifter.

(b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.

(d) Install the engine mounting insulator RH with the 2 bolts and 2 nuts.
Torque:
52 N*m (530 kgf*cm, 38 ft.*lbf)
113 N*m (1,152 kgf*cm, 83 ft.*lbf) for bolt A

(e) Tighten the 2 bolts and 2 nuts.
Torque:
45 N*m (459 kgf*cm, 33 ft.*lbf) for bolt
133 N*m (1,356 kgf*cm, 98 ft.*lbf) for nut

(f) Install the front suspension member brace rear RH and LH with the 8 bolts.
Torque:
133 N*m (1,356 kgf*cm, 98 ft.*lbf) for bolt A
80 N*m (816 kgf*cm, 59 ft.*lbf) for bolt B

NOTICE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.

(g) Connect the return tube.

(h) Connect the oil reservoir to No. 1 pump hose.

(i) Remove the No. 1 and No. 2 engine hangers.
34. INSTALL FRONT AXLE HUB SUB-ASSEMBLY
35. INSTALL FRONT AXLE HUB HOLE SNAP RING
36. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH
37. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY RH
38. INSTALL TIE ROD END SUB-ASSEMBLY LH
39. INSTALL TIE ROD END SUB-ASSEMBLY RH
40. INSTALL FRONT SPEED SENSOR LH
41. INSTALL FRONT SPEED SENSOR RH
42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
44. INSTALL FRONT AXLE HUB NUT LH
45. INSTALL FRONT AXLE HUB NUT RH
46. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
47. INSTALL COLUMN HOLE COVER SILENCER SHEET
48. INSTALL FRONT EXHAUST PIPE ASSEMBLY

49. CONNECT ENGINE WIRE
(a) Install the ground cable with the bolt.

(b) Install the engine wire to the battery positive terminal with the nut.

(d) Install the engine wire harness with the 2 claws.
(e) Connect the 2 connectors.
50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
51. INSTALL COOLER COMPRESSOR ASSEMBLY
52. INSTALL GENERATOR ASSEMBLY
53. INSTALL FAN AND GENERATOR V BELT
54. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
55. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

57. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater outlet hose to the air conditioner tube.

58. CONNECT HEATER WATER INLET HOSE
(a) Connect the heater inlet hose to the air conditioner tube.

59. CONNECT UNION TO CONNECTOR TUBE HOSE
(a) Connect the union to connector tube to the booster vacuum tube.
60. CONNECT FUEL MAIN TUBE

61. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 4 bolts.
Torque: 12.8 N*m (131 kgf*cm, 9 ft.*lbf)
(b) Connect the clamp of the engine wire.

62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Connect the air cleaner case to the No. 1 air cleaner inlet.
(b) Install the air cleaner case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(c) Connect the clamp of the engine wire.
63. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
65. INSTALL RADIATOR ASSEMBLY
66. CONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)
67. CONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)
68. CONNECT RADIATOR HOSE OUTLET
69. CONNECT RADIATOR HOSE INLET
70. INSTALL BATTERY TRAY
71. INSTALL BATTERY
72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
73. ADD MANUAL TRANSAXLE OIL
74. ADD AUTOMATIC TRANSAXLE FLUID
75. ADD ENGINE COOLANT
76. CHECK FOR FUEL LEAKAGE
77. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for the engine coolant leaks.
78. CHECK FOR MANUAL TRANSAXLE OIL LEAKS
79. CHECK FOR AUTOMATIC TRANSAXLE FLUID LEAKS
80. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
81. INSTALL FRONT FENDER APRON SEAL RH
82. INSTALL ENGINE UNDER COVER LH
83. INSTALL ENGINE UNDER COVER RH
84. INSTALL FRONT WHEEL
85. PERFORM INITIALIZATION Testing and Inspection
(a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.