Engine Assembly Installation

Using SST, hold the crankshaft.

SST

09213-58014(91551-80840)
09330-00021

NOTICE:

Check the SST installation positions when installing them to prevent the SST fixing bolts from coming into contact with the timing chain cover sub-assembly.

Apply adhesive to 2 or 3 threads of the bolt ends.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque:

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

Mark the top of the bolts with paint.

Further tighten the 8 bolts an additional 90° in the same sequence.

Check that the paint marks are now at a 90° angle to the top.

Check that the crankshaft turns smoothly.

Using SST, hold the crankshaft.

SST

09213-58014(91551-80840)
09330-00021

NOTICE:

Check the SST installation positions when installing them to prevent the SST fixing bolts from coming into contact with the timing chain cover sub-assembly.

Clean the bolts and the bolt holes.

Apply a few drops of adhesive to 2 or 3 threads of the 8 bolts tip.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the front spacer, drive plate and rear spacer with the 8 bolts. uniformly tighten the 8 bolts in the sequence shown in the illustration.

Torque:

88 N*m{897 kgf*cm, 65 ft.*lbf}

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

SST

09301-00110

NOTICE:

Insert the clutch disc assembly in the correct direction.

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

Following the procedure 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

09301-00110

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

Maximum non-alignment:

0.9 mm (0.0354 in.)

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

SST

09333-00013

Install the starter assembly with the 2 bolts.

Torque:

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

Connect the connector.

Connect terminal 30 with the nut.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Close the terminal cap.

Install the front engine mounting insulator with the nut and bolt.

Torque:

73 N*m{744 kgf*cm, 54 ft.*lbf}

Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

Torque:

except TMC made:

65 N*m{663 kgf*cm, 48 ft.*lbf}

for TMC made:

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

Temporarily install the engine mounting insulator LH with the 4 bolts.

Tighten the 4 bolts.

Torque:

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

HINT:

Perform this procedure only when replacement of the engine mounting insulator is necessary.

Install the engine mounting insulator RH with the 3 bolts.

HINT:

Perform this procedure only when replacement of the engine mounting insulator is necessary.

Torque:

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

Install the radiator reserve tank with the 3 bolts.

Torque:

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

Install the relay block assembly.

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

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

CAUTION:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

1. Make sure that the engine is clear of all wiring and hoses.
   
2. While raising the engine into the vehicle, do not allow it to contact the vehicle.
   

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

Torque:

56 N*m{571 kgf*cm, 41 ft.*lbf}

Install the engine mounting insulator RH with the bolt and 2 nuts.

Torque:

Nut A:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Nut B:

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

Bolt:

95 N*m{969 kgf*cm, 70 ft.*lbf}

Temporarily install the center engine mounting member sub-assembly with the 4 bolts.

While alternately inserting SST into the guide holes on both sides of the front suspension crossmember RH and LH, tighten 2 bolts (A), 2 bolts (B), 3 bolts (C), and 3 nuts (D) on the RH and LH sides to the respective specified torque in several steps.

SST

09670-00010

Torque:

Bolt A:

113 N*m{1152 kgf*cm, 83 ft.*lbf}

Bolt B:

157 N*m{1600 kgf*cm, 116 ft.*lbf}

Bolt C:

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

Nut D:

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

Fully tighten the center engine mounting member sub-assembly with the 4 bolts.

Torque:

Bolt A (TMC Made):

39 N*m{398 kgf*cm, 29 ft.*lbf}

Bolt A (except TMC Made):

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

Bolt B (TMC Made):

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

Bolt B (except TMC Made):

81 N*m{826 kgf*cm, 60 ft.*lbf}

Remove the 2 bolts and 2 engine hangers.

Install the wire harness bracket with the bolt.

Torque:

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

Apply a few drops of adhesive to 2 or 3 threads of the 6 torque converter assembly setting bolts tip.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the 6 torque converter assembly setting bolts while holding the crankshaft pulley bolt with a wrench.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

NOTICE:

Install the black colored bolt first, and then the silver colored 5 bolts.

Install the flywheel housing under cover to the automatic transaxle.

Install a new front drive shaft hole snap ring LH to the front drive inboard joint assembly.

Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

NOTICE:

1. Face the end gap 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.

Align the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.

Install the front lower suspension arm to the lower ball joint with the bolt and 2 nuts.

Torque:

89 N*m{908 kgf*cm, 66 ft.*lbf}

Install the front stabilizer link assembly to the front shock absorber with coil spring with the nut.

Torque:

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

NOTICE:

If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

Connect the tie rod end sub-assembly LH to the steering knuckle with the nut.

Torque:

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

NOTICE:

Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

Install a new cotter pin.

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

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

NOTICE:

Install the flexible hose and speed sensor without twisting them.

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

Torque:

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

Clean the threaded parts on the drive shaft and front axle shaft nut using a non-residue solvent.

NOTICE:

1. Be sure to perform this work for a new drive shaft.
   
2. Keep the threaded parts free of oil and foreign matter.
   

Using a socket wrench (30 mm), install a new front axle shaft nut.

Torque:

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

Using a chisel and hammer, caulk the axle hub nut.

Using a vernier caliper, measure the free length of the compression springs.

HINT:

If the free length is less than the minimum, replace the compression spring.

Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

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

NOTICE:

1. Be careful with the installation direction of the gaskets.
   
2. Do not reuse the gaskets.
   
3. Do not damage the gaskets.
   
4. Do not push in the gaskets by using the exhaust pipe when connecting it.
   

Connect the front exhaust pipe assembly to the 2 exhaust pipe supports.

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

Torque:

43 N*m{440 kgf*cm, 32 ft.*lbf}

Connect the heated oxygen sensor connector.

Engage clip B onto the body and install the No. 1 steering column hole cover sub-assembly onto the body with clips A.

NOTICE:

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

Align the matchmarks on the No. 2 steering intermediate shaft assembly and the steering intermediate shaft assembly.

Install the bolt.

Torque:

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

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

Install the floor carpet.

Install the earth wire to the engine compartment with the bolt and clamp (for Manual Transaxle).

Torque:

13 N*m{130 kgf*cm, 10 ft.*lbf}

Install the earth wire to the engine compartment with the bolt and clamp (for Automatic Transaxle).

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install the wire harness with the 2 nuts.

Torque:

8.4 N*m{85 kgf*cm, 74 in.*lbf}

Connect the 3 connectors and 2 wire harness clamps to the engine room junction block.

Connect the connector to the ECU with the lock lever and connect the clamp.

Install the clutch release cylinder assembly with the 4 bolts and clutch tube bracket.

Torque:

Bolt A:

12 N*m{120 kgf*cm, 9 ft.*lbf}

Bolt B:

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

Bolt C:

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

Using a "TORX" socket wrench (E8), install the compressor assembly with pulley with the 2 stud bolts.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the compressor assembly with pulley with the 2 bolts and the 2 nuts.

HINT:

Tighten the bolts and the nuts in the order shown in the illustration.

Torque:

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

Engage the clamp.

Connect each connector.

Install the bolt and fan belt adjusting bar.

Torque:

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

Install the wire harness clamp bracket with the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Temporarily install the generator assembly with the 2 bolts.

Torque:

Bolt A:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Bolt B:

19 N*m{190 kgf*cm, 14 ft.*lbf}

Install the connector and wire harness clamp.

Install the wire harness to terminal B with the nut and install the terminal cap.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Install the belt.

Turn bolt C to adjust the tension of the V-ribbed belt.

Tighten bolts A and B.

Torque:

Bolt A:

19 N*m{190 kgf*cm, 14 ft.*lbf}

Bolt B:

43 N*m{438 kgf*cm, 32 ft.*lbf}

NOTICE:

Confirm that bolt D is not loosened.

Check the belt for wear, cracks or other signs of damage.
If any of the following defects is found, replace the V-ribbed belt.

1. The belt is cracked.
   
2. The belt is worn out to the extent that the cords are exposed.
   
3. The belt has chunks missing from the ribs.
   

Check that the belt fits properly in the ribbed grooves.

HINT:

Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

Check the V belt deflection and tension.

Deflection:

Item	Specified Condition
New belt	7.0 to 8.2 mm (0.276 to 0.323 in.)
Used belt	7.6 to 10.0 mm (0.299 to 0.394 in.)

Tension:

Item	Specified Condition
New belt	700 to 800 N (71 to 82 kg, 157 to 180 lb)
Used belt	550 to 750 N (56 to 77 kg, 124 to 169 lb)

HINT:

1. When inspecting the V belt deflection, apply 98 N (10 kgf) tensile force to it.
   
2. After installing a new belt, run the engine for approximately 5 minutes and then readjust the tension to (new belt) specifications.
   
3. Check the V-ribbed belt deflection and tension at the specified point.
   
4. V-ribbed belt tension and deflection should be checked after 2 revolutions of the engine.
   
5. V-ribbed belt tension and deflection should be checked at TDC crank angle and cold condition.
   
6. When adjusting a belt, adjust its deflection and tension to the intermediate values of the specification.
   
7. When reinstalling a belt which has been used for over 5 minutes, adjust its deflection and tension to the used belt specification.
   
8. When using a belt tension gauge, confirm its accuracy by using a master gauge first.
   
9. If using a sonic tension meter:
   

Weight:

15 g/rib*m

Width:

6 ribs

Span:

188 mm (7.40 in.) (w/ air Conditioning)

282 mm (11.1 in.) (w/o air Conditioning)

Connect the fuel tube connector and fuel pipe.

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 on the pipe and connector to make sure that they are securely connected.

Engage the claw and install the No. 1 fuel pipe clamp.

Connect the inlet heater water hose with the clamp.

Connect the outlet heater water hose with the clamp.

Connect the 2 oil cooler hoses with the clamps.

Connect the union to connector tube hose.

Connect the fuel vapor feed hose assembly.

Install the transmission control cable to the control cable bracket with 2 new clips.

Install the transmission control cable to the transaxle with the 2 clips.

Secure the control cable onto the control cable bracket with a new clip.

Connect the control cable onto the control shaft lever with the nut.

Torque:

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

Connect the control cable to the cable support.

Connect the clamp of the control cable with the bolt.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the No. 2 radiator hose with the clamp.

Connect the No. 1 radiator hose with the clamp.

Connect the clamp.

Install the battery carrier with the 4 bolts.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Connect the radiator pipe with the 2 bolts.

Torque:

8.8 N*m{90 kgf*cm, 78 in.*lbf}

Connect the 2 wire harness clamps.

Install the battery clamp with the bolt and nut.

Torque:

for bolt:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

for nut:

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

Connect the battery cables.

Torque:

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

Install the air cleaner case with the 3 bolts.

Torque:

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

Install the wire harness clamp to the air cleaner case.

Install the air cleaner filter element.

Install the air cleaner cap sub-assembly with hose with the 2 clamps.

Tighten the hose clamp to the specified torque.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Connect the ventilation hose.

Connect the 2 wire harness clamps and mass air flow meter connector.

Tighten the lower radiator drain cock plug.

Loosen the upper radiator drain cock plug.

Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Standard Capacity:

Item	Capacity
Engine coolant	5.5 liters (5.8 US qts, 4.8 lmp. qts)

HINT:

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

NOTICE:

Never use water as a substitute for engine coolant.

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Tighten the upper radiator drain cock plug.

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

Install the radiator cap sub-assembly and reservoir tank cap.

Start the engine and warm it up.

Bleed air from the cooling system.

NOTICE:

1. Before starting the engine, turn the A/C switch off.
   
2. Adjust the air conditioning temperature setting to MAX (HOT).
   
3. Adjust the air conditioning blower setting to LO.
   

1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
   

   HINT:

   Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

   CAUTION:

   When squeezing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

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

Add engine coolant to the FULL line on the radiator reservoir.

Add fresh engine oil and install the oil filler cap.

Warm up and stop the engine, then wait for 5 minutes.

Check that the engine oil level is between the low level and full level marks on the level gauge.
If low, check for engine oil leaks and add oil up to the full level mark.

NOTICE:

Do not fill with engine oil to above the full level mark.

HINT:

Engine oil is always being consumed when driving the vehicle.

Generally, engine oil is consumed at a rate of 1 liter every 3000 km, or 1 US qts. every 2000 miles.

In the following situations, oil consumption may increase and it may be necessary to add oil between maintenances.

1. The engine is new.
   
2. The oil quality is poor or the viscosity is inappropriate.
   
3. The engine speed or load is high, the vehicle is towing something or the vehicle is being accelerated and decelerated frequently.
   
4. The engine is idled for a very long time or the vehicle is frequently driven in traffic.
   

Check fuel pump operation.

1. Connect the Techstream to the DLC3.
   

2. Turn the ignition switch ON and turn the Techstream on.
   

   NOTICE:

   Do not start the engine.

3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
   

4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.
   

Inspect for fuel leaks.

1. Check that there are no fuel leakage after performing maintenance anywhere on the fuel system. If there is a fuel leak, repair or replace parts as necessary.
   

Turn the ignition switch off.

Disconnect the Techstream from the DLC3.

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

Pump it to 118 kPa (1.2 kgf/cm², 17.0 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.

When using the Techstream:

1. Warm up and stop the engine.
   

2. Connect the Techstream to the DLC3.
   

3. Turn the ignition switch to ON.
   

4. Enter Data List Mode on the Techstream.
   

   HINT:

   Refer to the Techstream operator's manual for further details.

5. Inspect the ignition timing at idle.
   

   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 fans off.
      
   3. When checking the ignition timing, shift the transmission to the neutral position.
      

6. Enter the following menus : TC (TE1) / OFF.
   

7. Turn the ignition switch off.
   

8. Disconnect the Techstream from the DLC3.
   

When not using the Techstream:

1. Remove the No. 2 cylinder head cover (COROLLA_ZRE142 RM000002WH607RX.html).
   

Warm up and stop the engine.

Connect the Techstream to the DLC3.

Turn the ignition switch to ON.

Enter Data List Mode on the Techstream.

HINT:

Refer to the Techstream operator's manual for further details.

Inspect the engine idle speed.

Idle speed:

600 to 700 rpm

NOTICE:

1. Turn all the electrical systems and the A/C off.
   
2. Inspect the idle speed with the cooling fans off.
   
3. When checking the idle speed, shift the transmission to either neutral or park.
   

Turn the ignition switch off.

Disconnect the Techstream from the DLC3.

Start the engine.

Run the engine at 2500 rpm for approximately 180 seconds.

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

Check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

HINT:

When doing the 2 mode (with the engine idling/ running at 2500 rpm) test, the measuring procedures are determined by applicable local regulations.

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

1. Check the A/F sensor and heated oxygen sensor operation.
   

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

   CO	HC	Problem	Possible Cause
   Normal	High	Rough idle	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 idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
   High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element Plugged PCV valve Faulty EFI system: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Throttle body

Engage the 4 clips to install the No. 2 cylinder head cover.

NOTICE:

1. Be sure to engage the clips securely.
   
2. Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.