Engine Assembly - Installation

1. Install drive shaft heat insulator sub-assembly

2. Install exhaust manifold

3. Install manifold support bracket

4. Install exhaust manifold heat insulator no. 1

5. Install wire harness clamp bracket

6. Install engine wire

7. Install booster vacuum tube

8. Install water by-pass pipe no. 1

9. Install intake manifold

10. Install oil level gauge sub-assembly

11. Install generator assembly

12. Install ignition coil no. 1

13. Install drive plate and ring gear sub-assembly (for automatic transaxle)

14. Install automatic transaxle assembly (for automatic transaxle)

15. Install flywheel sub-assembly (for manual transaxle)

16. Install clutch disc assembly (for manual transaxle)

17. Install clutch cover assembly (for manual transaxle)

18. Inspect and adjust clutch cover assembly (for manual transaxle)

19. Install manual transaxle assembly (for manual transaxle)

20. Install control cable bracket (for manual transaxle)

21. Install starter assembly

22. Install flywheel housing side cover

23. Connect heater water hose inlet a

24. Install water filler sub-assembly

25. Install fuel tube sub-assembly

26. Install ventilation hose no. 2

27. Install ventilation hose

28. Install front suspension crossmember sub-assembly

29. Install engine assembly with transaxle (for hatchback)

30. Install engine assembly with transaxle (for sedan)

31. Install drive plate and torque converter clutch setting bolt (for automatic transaxle)

32. Install flywheel housing under cover (for automatic transaxle)

33. Install front drive shaft assembly lh

34. Install front drive shaft assembly rh

35. Install automatic transmission case protector (w/o abs)

36. Install front axle assembly lh

37. Install front axle assembly rh

38. Install front stabilizer link assembly lh

39. Install front stabilizer link assembly rh

40. Install front suspension arm sub-assembly lower no. 1 lh

41. Install front suspension arm sub-assembly lower no. 1 rh

42. Install tie rod end sub-assembly lh

43. Install tie rod end sub-assembly rh

44. Install speed sensor front lh (w/ abs)

45. Install speed sensor front rh (w/ abs)

46. Install front flexible hose lh (w/o abs)

47. Install front flexible hose rh (w/o abs)

48. Install front axle shaft lh nut

49. Install front axle shaft rh nut

50. Install exhaust pipe assembly front

51. Install oxygen no. 2 sensor

52. Install console box assembly rear (for hatchback)

53. Install console box cover rear (for hatchback)

54. Install shifting hole cover sub-assembly (for hatchback)

55. Install rear console box assembly (for sedan)

56. Install console box carpet (for sedan)

57. Install console upper rear panel sub-assembly (for sedan)

58. Install upper console panel sub-assembly (for sedan)

59. Install instrument pad lower lh (for sedan)

60. Install instrument panel finish panel end lh (for sedan)

61. Install instrument panel finish panel lower center (for sedan)

62. Install shift lever knob sub-assembly (for manual transaxle)

63. Install steering column hole cover sub-assembly no. 1

64. Install steering sliding yoke sub-assembly

65. Install column hole cover silencer sheet

66. Connect engine wire

67. Install clutch release cylinder assembly (for manual transaxle)

68. Install with pulley compressor assembly (w/ air conditioning system)

69. Install fan & generator v belt

70. Adjust fan & generator v belt

71. Connect fuel tube sub-assembly

72. Connect heater water hose inlet a

73. Connect heater water outlet hose a (form heater unit)

74. Connect union to check valve hose

75. Install transmission control cable assembly (for automatic transaxle)

76. Install transmission control cable assembly (for manual transaxle)

77. Install cylinder head cover no. 2

78. Connect oil cooler outlet hose (for automatic transaxle)

79. Connect oil cooler inlet hose (for automatic transaxle)

80. Connect radiator hose no. 2

81. Connect radiator reservoir tank hose

82. Connect radiator hose no. 3

83. Install battery carrier

84. Install air cleaner bracket

85. Install air cleaner assembly

86. Install cowl top panel outer (for hatchback)

87. Install cowl top panel outer (for sedan)

88. Install front air shutter seal (for sedan)

89. Install cowl to register duct sub-assembly no. 2 (for hatchback)

90. Install front wiper motor and link (for hatchback)

91. Install front wiper motor and link (for sedan)

92. Install cowl top ventilator louver lh (for hatchback lhd)

93. Install cowl top ventilator louver sub-assembly (for hatchback lhd)

94. Install cowl top ventilator louver lh (for hatchback rhd)

95. Install cowl top ventilator louver sub-assembly (for hatchback rhd)

96. Install cowl top ventilator louver sub-assembly (for sedan rhd)

97. Install cowl top ventilator louver sub-assembly (for sedan lhd)

98. Install cowl side ventilator sub-assembly lh (for sedan)

99. Install cowl side ventilator sub-assembly rh (for sedan)

100. Install hood to cowl top seal (for hatchback)

101. Install front wiper arm and blade assembly lh (for hatchback)

102. Install front wiper arm and blade assembly lh (for sedan)

103. Install front wiper arm and blade assembly rh (for hatchback)

104. Install front wiper arm and blade assembly rh (for sedan)

105. Install front wiper arm head cap (for hatchback)

106. Install front wiper arm head cap (for sedan)

107. Install battery tray

108. Install battery

109. Add engine coolant

110. Add automatic transaxle fluid (for automatic transaxle)

111. Inspect automatic transaxle fluid (for automatic transaxle)

112. Add manual transaxle oil (for manual transaxle)

113. Inspect manual transaxle oil (for manual transaxle)

114. Inspect fan & generator v belt

115. Check for fuel leakage

116. Check for engine oil leakage

117. Check for exhaust gas leakage

118. Check for engine coolant leakage

119. Install engine under cover rh

120. Install engine under cover lh

121. Install engine under cover sub-assembly (for rough road area specification vehicles)

122. Install front wheels

123. Inspect ignition timing

124. Inspect engine idling speed

125. Inspect co/hc

126. Inspect and adjust front wheel alignment

127. Inspect abs sensor signal (w/ abs)

​

1. Install the drive shaft heat insulator sub-assembly with the bolt and nut.

   Torque:

   18 N*m{183 kgf*cm, 13 ft.*lbf}

1. Tighten the bolts and nuts of the exhaust manifold, in the order shown in the illustration, through a new gasket.

   Torque:

   27 N*m{275 kgf*cm, 20 ft.*lbf}

1. Install the manifold bracket with the 3 bolts.

   Torque:

   44 N*m{449 kgf*cm, 33 ft.*lbf}

1. Install the exhaust manifold insulator with the 4 bolts.

   Torque:

   8.0 N*m{82 kgf*cm, 71 in.*lbf}

1. Install the 2 wire harness clamp brackets with the 2 bolts.

   Torque:

   10 N*m{102 kgf*cm, 89 in.*lbf}

1. Connect all sensor connectors and wire harness clamps to the engine assembly and install the engine wire harness.

1. Install the booster vacuum tube with the 2 bolts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Install water by-pass pipe No. 1 through a new gasket with the 2 bolts and 2 nuts.

   Torque:

   9.0 N*m{92 kgf*cm, 80 in.*lbf}

1. Install a new gasket onto the intake manifold.

2. Provisionally tighten the intake manifold nuts and bolts in the order shown in the illustration, and then tighten them to the specified torque.

   Torque:

   30 N*m{306 kgf*cm, 22 ft.*lbf}

3. Connect the engine wire to the intake manifold.

4. Connect the water by-pass hose to water by-pass pipe No. 1.

5. Connect the water by-pass hose to the cylinder head.

6. Connect the union to connector tube hose to the booster vacuum tube.

7. Connect the throttle with motor body assembly connector.

1. Provisionally install the generator with fixing bolt B.

2. Provisionally install the fan belt adjusting slider with fan belt adjusting slider fixing bolts A and B, then move the generator toward the cylinder block and tighten bolt B.

   Torque:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

3. Install the connector and wire harness clamp.

4. Install terminal B with the nut.

   Torque:

   9.8 N*m{100 kgf*cm, 7.2 ft.*lbf}

5. Install the terminal cap.

1. Hold the crankshaft with SST.

   SST

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

2. Clean the 6 bolts and their holes.

3. Apply adhesive to the 2 or 3 end threads of the bolts.

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
   

4. Install the drive plate spacer RR, drive plate and ring gear sub-assembly and drive plate spacer FR.

5. Install and uniformly tighten the 6 bolts in several steps, in the sequence shown in the illustration.

   Torque:

   88 N*m{900 kgf*cm, 65 ft.*lbf}

   NOTICE:

   Do not start the engine for at least 1 hour after performing the installation.

1. Make sure that the knock pin is installed on the engine side.

2. Install the automatic transaxle with torque converter with the 7 bolts.

   Torque:

   30 N*m{301 kgf*cm, 22 ft.*lbf}

   CAUTION:

   Make sure that the torque converter rotates.

1. Hold the crankshaft with SST.

   SST

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

2. Clean the 6 bolts and their holes.

3. Apply adhesive to the 2 or 3 end threads of the bolts.

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
   

4. Install the flywheel with the 6 bolts in the order shown in the illustration.

   Torque:

   49 N*m{500 kgf*cm, 38 ft.*lbf}

5. Mark paint marks on the bolt heads on the engine upper side.

6. Tighten the bolts 90° in the sequence order shown in the illustration.

   NOTICE:

   Do not start the engine for at least 1 hour after performing the installation.

1. Insert SST into the clutch disc assembly, then insert them both into the flywheel sub-assembly.

   SST

   09301-00210
   

   NOTICE:

   Insert clutch disc assembly in the correct direction.

1. Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

2. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

   HINT:

   1. Following the order in the illustration, tighten the bolts evenly one at a time.
      
   2. Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.
      

   SST

   09301-00210
   

1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

   Maximum non-alignment:

   0.5 mm (0.020 in.)
   

2. If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.

   SST

   09333-00013
   

1. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.

2. Install the 7 bolts.

   Torque:

   33 N*m{336 kgf*cm, 24 ft.*lbf}

1. Install the control cable bracket with the 2 bolts.

   Torque:

   25 N*m{250 kgf*cm, 18 ft.*lbf}

1. Install the starter assembly with the 2 bolts.

   Torque:

   37 N*m{377 kgf*cm, 27 ft.*lbf}

2. Connect the connector.

3. Connect terminal 30 with the nut.

   Torque:

   9.8 N*m{100 kgf*cm, 7.2 ft.*lbf}

4. Close the terminal cap.

1. Insert the protruding portion into the end of the cylinder block and while pushing it along the cylinder block, fit the claw into the cylinder block.

   NOTICE:

   1. Make sure that the claw makes a click sound, indicating that it fits tightly.
      
   2. Replace the claw with a new one if it does not fit tightly or is deformed.
      

1. Connect heater water inlet hose A to the cylinder head.

1. Connect radiator hose No. 1 to the cylinder head.

2. Install the water filler sub-assembly with 2 nuts.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

3. Connect radiator hose No. 1 to the water filler.

1. Connect the fuel tube connector and fuel pipe and install fuel pipe clamp No. 2.

   CAUTION:

   Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

1. Install ventilation hose No. 2 with the clip.

1. Install the ventilation hose with the clip.

1. Install the engine moving control rod with the through bolt.

   Torque:

   120 N*m{1,224 kgf*cm, 89 ft.*lbf}

2. Remove the 2 bolts and remove the 2 engine hangers.

3. Install the oxygen sensor wiring bracket with the bolt.

   Torque:

   60 N*m{612 kgf*cm, 44 ft.*lbf}

4. Install the radio setting condenser with the bolt.

   Torque:

   40 N*m{408 kgf*cm, 30 ft.*lbf}

1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.

2. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator RH and LH can be installed.

3. Install the engine mounting insulator LH with the through bolt and nut.

   Torque:

   52 N*m{530 kgf*cm, 38 ft.*lbf}

4. Install the engine mounting insulator RH with the 5 bolts and nut.

   Torque:

   45 N*m{459 kgf*cm, 33 ft.*lbf}for Bolt A

   52 N*m{530 kgf*cm, 38 ft.*lbf}for Bolt B

   52 N*m{530 kgf*cm, 38 ft.*lbf}for Nut C

5. Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts.

6. Insert SST into the datum holes in the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.
   

   
   
   
   

   SST

   09670-00010
   

   Torque:

   87 N*m{887 kgf*cm, 64 ft.*lbf} for Bolt A

   160 N*m{1631 kgf*cm, 118 ft.*lbf} for Bolt B with Bolt strength Class 11T

   151 N*m{1540 kgf*cm, 111 ft.*lbf} for Bolt B with Bolt strength Class 10T

   98 N*m{999 kgf*cm, 72 ft.*lbf} for Bolt C

   CAUTION:

   1. Insert SST into the datum hole vertically.
      
   2. If impossible to insert SST vertically, loosen all the bolts and then insert SST again.
      

1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.

2. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator RH and LH can be installed.

3. Install the engine mounting insulator LH with the through bolt and nut.

   Torque:

   52 N*m{530 kgf*cm, 38 ft.*lbf}

4. Install the engine mounting insulator RH with the 5 bolts and nut.

   Torque:

   52 N*m{530 kgf*cm, 38 ft.*lbf}

5. Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts.

6. Insert SST into the datum holes in the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.
   

   
   
   
   

   SST

   09670-00010
   

   Torque:

   87 N*m{887 kgf*cm, 64 ft.*lbf} for Bolt A

   160 N*m{1631 kgf*cm, 118 ft.*lbf} for Bolt B with Bolt strength Class 11T

   151 N*m{1540 kgf*cm, 111 ft.*lbf} for Bolt B with Bolt strength Class 10T

   98 N*m{999 kgf*cm, 72 ft.*lbf} for Bolt C

   CAUTION:

   1. Insert SST into the datum hole vertically.
      
   2. If impossible to insert SST vertically, loosen all the bolts and then insert SST again.
      

1. Tighten the 6 torque converter set bolts.

   Torque:

   27 N*m{275 kgf*cm, 20 ft.*lbf}

1. for Automatic Transaxle:
   

   1. Coat the spline of the inboard joint with ATF.

2. for Manual Transaxle:
   

   1. Coat the spline of the inboard joint with gear oil.

3. Align the inboard joint splines and install the drive shaft with a screwdriver and hammer.

   NOTICE:

   1. Face the cut area of the front drive inboard joint hole snap ring downward.
      
   2. Do not damage the oil seal.
      
   3. Do not damage the inboard joint boot.
      

   HINT:

   Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

HINT:

The installation procedure for the RH side is the same as that for the LH side.

1. Install the transmission case protector with the 2 bolts.

   Torque:

   23 N*m{235 kgf*cm, 17 ft.*lbf}

1. Push the front axle out of the vehicle to align the spline of the drive shaft with the front axle and insert the front axle.

   NOTICE:

   1. Do not push the front axle further out of the vehicle than is necessary.
      
   2. Do not damage the outboard joint boot.
      
   3. Check for any foreign matter on the speed sensor rotor and insertion part.
      
   4. Do not damage the speed sensor rotor.
      

HINT:

Use the same procedure as for the LH side.

1. Install the stabilizer link with the nut.

   Torque:

   74 N*m{755 kgf*cm, 55 ft.*lbf}

   HINT:

   If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold the stud.

HINT:

Use the same procedure as for the LH side.

1. Install the lower arm onto the steering knuckle with a new castle nut.

   Torque:

   98 N*m{1000 kgf*cm, 72 ft.*lbf}

   NOTICE:

   If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

2. Install a new clip.

HINT:

Use the same procedure as for the LH side.

1. Install the tie rod end onto the steering knuckle with a new castle nut.

   Torque:

   49 N*m{500 kgf*cm, 36 ft.*lbf}

   NOTICE:

   If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

2. Install a new cotter pin.

HINT:

Use the same procedure as for the LH side.

1. Install the speed sensor onto the steering knuckle with the bolt.

   Torque:

   8.5 N*m{87 kgf*cm, 75 in.*lbf}

   NOTICE:

   1. Check that the speed sensor tip and installation portion are free of foreign matter.
      
   2. Install the speed sensor without turning it from its original installation angle.
      

2. Install the flexible hose and speed sensor with the bolt.

   Torque:

   29 N*m{300 kgf*cm, 22 ft.*lbf}

   NOTICE:

   Install the flexible hose and speed sensor without twisting them.

HINT:

Use the same procedure as for the LH side.

1. Install the flexible hose with the bolt.

   Torque:

   29 N*m{300 kgf*cm, 22 ft.*lbf}

   NOTICE:

   Install the flexible hose and speed sensor without twisting them.

HINT:

Use the same procedure as for the LH side.

1. Using a 30 mm socket wrench, install a new axle hub nut.

   Torque:

   216 N*m{2203 kgf*cm, 160 ft.*lbf}

2. Using a chisel and hammer, stake the axle hub nut.

HINT:

Use the same procedure as for the LH side.

1. Using vernier calipers, measure the free length of the compression spring.

   Minimum length (Front side):

   40.5 mm (1.594 in.)
   

   Minimum length (Rear side):

   38.5 (1.516 in.)
   

   If the length is not as specified, replace the compression spring.
   

2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

   NOTICE:

   1. Install the exhaust pipe gasket in the correct direction.
      
   2. Do not damage the outer surface of the exhaust pipe gasket.
      
   3. Do not reuse the exhaust pipe gasket.
      
   4. Do not push in the gasket with the exhaust pipe when connecting it.
      

3. Install the 3 No. 4 exhaust pipe supports.

4. Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4 compression springs and 4 bolts.

   Torque:

   43 N*m{439 kgf*cm, 32 ft.*lbf}

   
   
   
   
   
   

1. Using SST, install the sensor onto the front exhaust pipe.

   SST

   09224-00010
   

   Torque:

   44 N*m{449 kgf*cm, 32 ft.*lbf}

2. Pass the sensor connector through the floor panel and install the grommet.

3. Connect the sensor connector.

1. Engage the 2 clips and install the console box with the bolt.

1. Engage the 8 claws to install the console box rear cover.

1. Install clip B onto the body portion and install No. 1 steering column hole cover onto the body portion with clip A.

   Text in Illustration

   *1	Clip A
   *2	Clip B

   NOTICE:

   Make sure that the lip portion of No. 1 steering column hole cover is not damaged.

1. Align the matchmarks and install the sliding yoke onto the intermediate shaft with bolt B.

   Text in Illustration

   *1	Bolt A
   *2	Bolt B
   *a	Matchmark

   Torque:

   35 N*m{360 kgf*cm, 26 ft.*lbf}

2. Tighten bolt A.

   Torque:

   35 N*m{360 kgf*cm, 26 ft.*lbf}

1. Install the column hole cover silencer sheet with the 2 clips.

2. Install the floor carpet.

1. Install the transaxle earth wire of the engine room wire harness with the bolts.

2. Connect the 2 engine wire harness connectors and wire harness clamp to the engine room junction block.

3. Connect the engine wire harness connector to the ECM.

1. Install the clutch release cylinder and clutch pipe with the 4 bolts.

   Torque:

   12 N*m{120 kgf*cm, 8.7 ft.*lbf} for bolt A

   12 N*m{122 kgf*cm, 8.9 ft.*lbf} for bolt B

1. Provisionally tighten the compressor with the bolt.

2. Tighten the compressor with the 4 bolts.

   Torque:

   25 N*m{255 kgf*cm, 18 ft.*lbf}

   NOTICE:

   Tighten the bolts in the sequence order shown in the illustration to install the compressor.

3. Connect the connector and the clamp.

1. Provisionally install the fan and generator V belt onto each pulley.

   NOTICE:

   1. Make sure that there is no foreign matter or liquid, such as oil, on the belt and pulleys.
      
   2. Make sure that the V belt is securely fitted into the rib grooves of the pulley.
      

1. Insert an adjusting bar between the engine mounting bracket and generator assembly. Pull the adjusting bar towards the vehicle front to adjust the generator V belt tension.

   NOTICE:

   Do not insert the adjusting bar between the camshaft timing oil control valve assembly and generator assembly. It could damage the camshaft timing oil control valve assembly.

2. First tighten bolt A, then tighten bolt B.

   Torque:

   19 N*m{189 kgf*cm, 14 ft.*lbf} for bolt A

   54 N*m{551 kgf*cm, 40 ft.*lbf} for bolt B

1. Connect the fuel tube connector and fuel pipe, and install fuel pipe clamp No. 1.

   CAUTION:

   Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

1. Connect heater water inlet hose A to the heater unit.

1. Connect heater water outlet hose A to the heater unit.

1. Connect the union to check valve hose to the booster vacuum tube.

1. Install the transmission control cable onto the control shaft lever with the nut.

   Torque:

   12 N*m{122 kgf*cm, 9 ft.*lbf}

2. Install the transmission control cable into the bracket with the new clip.

1. Connect the 2 cable ends and install the 2 washers and the 2 clips.

2. Install 2 new clips onto the control cable bracket.

1. Tighten 2 A nuts, then 2 B nuts .

   Torque:

   7.0 N*m{71 kgf*cm, 62 in.*lbf}

1. Connect the oil cooler outlet hose with the clip.

1. Connect the oil cooler inlet hose with the clip.

1. Connect radiator hose No. 2 to the water inlet.

1. Connect the radiator reservoir tank hose to the water filler.

1. Connect radiator hose No. 3 to the water filler.

1. Install the battery carrier with the 5 bolts.

   Torque:

   17 N*m{173 kgf*cm, 13 ft.*lbf}

2. Install the clamp.

1. Install the air cleaner bracket with the 2 bolts.

   Torque:

   19 N*m{194 kgf*cm, 14 ft.*lbf}

2. Connect the wire harness clamp to the air cleaner bracket.

1. Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts.

   Torque:

   7.8 N*m{80 kgf*cm, 69 in.*lbf}

2. Connect the wire harness to the air cleaner case.

3. Install the air cleaner element.

4. Install and lock the air cleaner cap and air cleaner hose and then tighten the air cleaner hose clamp.

   Torque:

   4.0 N*m{41 kgf*cm, 35 in.*lbf}

5. Connect the ventilation hose to the air cleaner hose.

6. Connect the vacuum switching valve connector and wire harness clamp.

7. Connect the fuel vapor feed hose and fuel vapor feed hose No. 1 to the vacuum switching valve assembly.

8. Connect the intake air flow meter connector and wire harness clamp.

1. Install the cowl top panel with the 9 bolts.

   Torque:

   6.5 N*m{66 kgf*cm, 57 in.*lbf}

2. Connect the wire harness clamp.

1. Install the cowl top panel outer with the 8 bolts.

   Torque:

   6.5 N*m{66 kgf*cm, 57 in.*lbf}

2. Install the cowl top to cowl inner brace with the 2 bolts.

   Torque:

   6.5 N*m{66 kgf*cm, 57 in.*lbf}

3. Connect the wire harness clamp.

1. Engage the 3 claws to install the front air shutter seal.

1. Engage the claw to install cowl to register duct No. 2.

1. Connect the connector.

2. Slide the wiper link as shown in the illustration and engage the rubber pin with the body.

3. Install the front wiper motor and link with the 2 bolts.

   Torque:

   5.5 N*m{56 kgf*cm, 49 in.*lbf}

1. Connect the connector.

2. Slide the wiper link as shown in the illustration and engage the rubber pin with the body.

3. Install the front wiper motor and link with the 2 bolts.

   Torque:

   5.5 N*m{56 kgf*cm, 49 in.*lbf}

1. Engage the 4 claws and install the cowl top ventilator louver LH.

2. Install the 2 clips.

1. Connect the washer hose.

2. Engage the 11 claws and install the cowl top ventilator louver sub-assembly.

3. Install the clip.

4. Connect the washer hose.

5. Engage the 2 hooks and install cowl top ventilator louver center No. 1.

1. Engage the 4 claws and install the cowl top ventilator louver LH.

2. Install the clip.

1. Engage the 10 claws and install the cowl top ventilator louver sub-assembly.

2. Install the clip.

3. Connect the washer hose.

1. Connect the washer hoses.

2. Engage the 5 hooks.

3. Engage the 10 hooks and the 6 claws.

4. Install the cowl top ventilator louver sub-assembly with the 2 clips.

1. Connect the washer hoses.

2. Engage the 5 hooks.

3. Engage the 8 hooks and the 4 claws.

4. Install the cowl top ventilator louver sub-assembly with the 3 clips.

1. Engage the 3 claws and install the cowl side ventilator sub-assembly LH.

HINT:

Use the same procedure as for the LH side.

1. Engage the 7 clips and install the hood to cowl top seal.

1. Scrape any metal powder off the serrated part of the wiper arm with a round file or the equivalent (when reinstalling).

2. Clean the wiper pivot serrations with a wire brush.

3. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

4. Align the blade tip with the mark on the windshield glass, as shown in the illustration.

5. Tighten the nut of the front wiper arm.

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

1. Scrape any metal powder off the serrated part of the wiper arm with a round file or the equivalent (when reinstalling).

2. Clean the wiper pivot serrations with a wire brush.

3. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

4. Align the blade tip with the mark on the windshield glass, as shown in the illustration.

5. Tighten the nut of the front wiper arm.

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

1. Scrape any metal powder off the serrated part of the wiper arm with a round file or the equivalent (when reinstalling).

2. Clean the wiper pivot serrations with a wire brush.

3. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

4. Align the blade tip with the mark on the windshield glass, as shown in the illustration.

5. Tighten the nut of the front wiper arm.

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

1. Scrape any metal powder off the serrated part of the wiper arm with a round file or the equivalent (when reinstalling).

2. Clean the wiper pivot serrations with a wire brush.

3. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

4. Align the blade tip with the mark on the windshield glass, as shown in the illustration.

5. Tighten the nut of the front wiper arm.

   Torque:

   26 N*m{265 kgf*cm, 19 ft.*lbf}

1. Engage the claw and install the 2 front wiper arm head caps.

1. Engage the claw and install the 2 front wiper arm head caps.

1. Install the battery onto the vehicle with the battery clamp.

   Torque:

   3.5 N*m{36 kgf*cm, 31 in.*lbf}

2. Connect the cable to the battery terminal.

   Torque:

   5.4 N*m{55 kgf*cm, 48 in.*lbf}

1. Tighten all the plugs.

2. Pour engine coolant into the radiator assembly until it overflows.

   Capacity:

   M/T 4.8 liters (5.1 USqts, 4.5 lmp. qts)
   

   A/T 4.7 liters (5.0 USqts, 4.4 lmp. qts)
   

   NOTICE:

   Do not substitute water for engine coolant.

   HINT:

   1. Use of improper engine coolant may damage the engine coolant system.
      
   2. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
      

3. Check the engine coolant level inside the radiator assembly by squeezing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

4. Install the radiator cap sub-assembly securely.

5. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

6. Warm up the engine until the cooling fan operates.
   

   1. Set the air conditioning as follows while warming up the engine.
      

      Item	Manual air conditioning system	Automatic air conditioning system
      Set control as follows	Fan speed - Any setting except "OFF" Temperature - Toward WARM Air conditioning switch "OFF"	Fan speed - Any setting except "OFF" Temperature - To the highest temperature Air conditioning switch "OFF" "AUTO" switch "OFF"

   2. Maintain the engine speed at 2,000 to 2,500 rpm and warm up the engine until the cooling fan operates.

7. Stop the engine and wait until the coolant cools down.

8. If the engine coolant level is below the full level, perform steps (b) through (g) again and repeat the operation until the engine coolant level stays at the full level.

9. Recheck the engine coolant level inside the radiator reservoir tank assembly. If it is below the full level, add the engine coolant.

10. Visually check for engine coolant leakage.

Automatic transaxle fluid type:

Toyota Genuine ATF WS

HINT:

Drive the vehicle until the engine and transaxle are at normal operating temperature.

Fluid temperature:

70 to 80 °C (158 to 176 °F)

1. Park the vehicle on a level surface and engage the parking brake.

2. With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L, and then return it to the P position.

3. Pull out the oil level gauge and wipe it clean.

4. Push it fully back into the pipe.

5. Pull it out and check that the fluid level is within the HOT range.
   If there is any leakage, repair or replace O-rings, FIPGs, oil seals, plugs or other parts.

1. Stop the vehicle in a level place.

2. Remove the transmission filler plug and the gasket.

3. Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the transmission filler plug opening.

   NOTICE:

   1. Excessively large or small amounts of oil may cause problems.
      
   2. After replacing the oil, drive the vehicle and check the oil level again.
      

4. Check for oil leakage when the oil level is low.

5. Install the transmission filler plug and a new gasket.

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

1. Check the V belt deflection and tension.

   Deflection:

   Item	Specified Condition
   New belt	8.0 to 9.0 mm (0.31 to 0.35 in)
   Used belt	12.5 to 13.5 mm (0.49 to 0.53 in)

   Tension:

   Item	Specified Condition
   New belt	700 to 800 N (71 to 82 kg, 157 to 180 lb)
   Used belt	300 to 400 N (31 to 41 kg, 67 to 90 lb)

   If the belt deflection is not as specified, adjust it.
   

   HINT:

   1. Perform the V belt inspection and adjustment while the engine is cold.
      
   2. V-ribbed belt tension and deflection should be checked immediately after installation of a new belt, and after cranking the engine when inspecting a used belt.
      
   3. Check the V belt deflection at the point between the specified pulleys where the deflection is greatest.
      
   4. When installing a new belt, set its tension to the intermediate value of the specification.
      
   5. When inspecting a belt which has been used for over 5 minutes, apply the Used Belt specifications.
      
   6. When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the intermediate values of each Used Belt specification.
      
   7. V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking.
      
   8. When using a belt tension gauge, confirm its accuracy by using a master gauge first.
      

1. When using the intelligent tester.
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch on (IG) and the intelligent tester main switch on.

      NOTICE:

      Do not start the engine.

   3. Select the Active Test mode on the intelligent tester.

      HINT:

      Refer to the intelligent tester operator's manual for further details.

2. Check that there is no fuel leakage anywhere in the fuel system after doing maintenance.

CAUTION:

To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

1. Fill the radiator assembly with engine coolant, then attach a radiator cap tester.

2. Pump the tester to 137 kPa (1.4 kgf/cm², 19.9 psi), then check that the pressure does not drop.
   If the pressure drops, check the hoses, radiator assembly and water pump assembly for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Torque:

103 N*m{1,050 kgf*cm, 76 ft.*lbf}

1. When using an intelligent tester:
   

   1. Warm up and stop the engine.

   3. Connect the intelligent tester to the DLC3.

   4. Turn the ignition switch on (IG).

   5. Select the following menu items:
      Powertrain / Engine and ECT / Active Test / TC (TE1) / ON.

      HINT:

      Refer to the intelligent tester operator's manual for further details.

   6. Inspect the ignition timing during idling.

      Ignition timing:

      8 to 12 degrees BTDC
      

      NOTICE:

      1. Turn all the electrical systems and the A/C off.
         
      2. Inspect the ignition timing with the cooling fan off.
         
      3. When checking the ignition timing, shift the transmission to the neutral position.
         

   7. Select the following menu items: TC (TE1) / OFF

   8. Turn the ignition switch off.

   9. Disconnect the intelligent tester from the DLC3.

2. When not using an intelligent tester:
   

   1. Remove cylinder head cover No. 2 (Click here).

   3. Pull out the wire harness (brown) shown in the illustration.

      NOTICE:

      After checking, wrap the wire harness with tape.

   4. Warm up and stop the engine.

   5. Connect the clip of the timing light to the wire harness.

      NOTICE:

      Use a timing light that detects the first signal.

   6. Turn the ignition switch on (IG).

   8. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      SST

      09843-18040
      

      NOTICE:

      Examine the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

   9. Inspect the ignition timing during idling.

      Ignition timing:

      8 to 12 degrees BTDC
      

      NOTICE:

      1. Turn all the electrical systems and the A/C off.
         
      2. Inspect the ignition timing with the cooling fan off.
         
      3. When checking the ignition timing, shift the transmission to the neutral position.
         

   10. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

   11. Turn the ignition switch off.

   12. Remove the timing light.

   13. Install cylinder head cover No. 2 (Click here).

1. When using an intelligent tester:
   

   1. Warm up and stop the engine.

   3. Connect the intelligent tester to the DLC3.

   4. Turn the ignition switch on (IG).

   5. Select the following menu items: Powertrain / Engine and ECT /Data List / Engine Speed.

      HINT:

      Refer to the intelligent tester operator's manual for further details.

   6. Inspect the engine idling speed.

      Idling speed:

      600 to 700rpm for manual transaxle
      

      650 to 750rpm for automatic transaxle
      

      NOTICE:

      1. Turn all the electrical systems and the A/C off.
         
      2. Inspect the idling speed with the cooling fan off.
         
      3. When checking the idling speed, shift the transmission to either the neutral position or the parking position.
         

   7. Turn the ignition switch off.

   8. Disconnect the intelligent tester from the DLC3.

2. When not using an intelligent tester.
   

   1. Warm up and stop the engine.

   3. Install SST to terminal 9 (TAC) of the DLC3, then connect a tachometer.

      SST

      09843-18040
      

      NOTICE:

      Examine the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

   4. Turn the ignition switch on (IG).

   5. Inspect the engine idling speed.

      Idling speed:

      600 to 700rpm for manual transaxle
      

      650 to 750rpm for automatic transaxle
      

   6. Turn the ignition switch off.

   7. Disconnect the tachometer.

   8. Remove SST from terminal 9 (TAC).

1. Start the engine.

2. Run the engine at 2,500 rpm for approximately 180 seconds.

3. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe while idling.

4. Check the CO/HC concentration during idling and when running at 2,500 rpm.

   HINT:

   When doing the 2 mode (with the engine idling/running at 2,500 rpm) test, the measuring procedures are determined by applicable local regulations.

   If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.
   

   1. Check the heated oxygen sensor operation (Click here).

   2. See the table below for possible causes, then inspect the applicable parts and repair them if necessary.
      

      CO	HC	Problems	Possible Causes
      Normal	High	Rough idling	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leakage from intake and exhaust valves Leakage from cylinders
      Low	High	Rough idling (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
      High	High	Rough idling (Black smoke from exhaust)	Restricted air cleaner filter element Plugged PCV valve Faulty EFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Throttle body