Operation CHARM: Car repair manuals for everyone.

Installation





1AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

2. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Installation

4. INSTALL FRONT FRAME ASSEMBLY

(a) Set the engine with transaxle to the front frame.

(b) Install the engine mounting insulators LH and RH with the 2 nuts.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(c) Install the front engine mounting insulator with the nut.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

5. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine with transaxle.

6. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque : 64 Nm (649 kgf-cm, 47 ft-lbf)

7. INSTALL STARTER ASSEMBLY Installation

8. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

9. INSTALL GENERATOR ASSEMBLY Installation

10. INSTALL FAN AND GENERATOR V BELT Installation

11. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine with transaxle on the engine lifter.

NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly.
* Do not position a height adjustment attachment or plate lift attachment onto the front frame.

HINT
Place the engine on wooden blocks or equivalents so that the engine is level.

(b) Remove the 2 bolts and 2 engine hangers.

(c) Install the engine with transaxle to the vehicle.

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

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

(d) Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.





Text in Illustration





Nut - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt A - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt B - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

(e) Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.

Nut - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt A - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt B - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

12. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST : 09213-54015

SST : 09330-00021

SST : 91551-80650

(b) Apply a few drops of adhesive to 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolt tips.





Text in Illustration





Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

(c) Tighten the 6 drive plate and torque converter clutch setting bolts.

Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

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

13. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover.

14. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

15. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

16. INSTALL FRONT LOWER SUSPENSION ARM LH Installation

17. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

18. CONNECT TIE ROD ASSEMBLY LH Installation

19. CONNECT TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

20. CONNECT FRONT SPEED SENSOR LH Installation

21. CONNECT FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

22. CONNECT FRONT STABILIZER LINK ASSEMBLY LH Installation

23. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

24. INSTALL FRONT AXLE SHAFT NUT LH Installation

25. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

26. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

27. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

28. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

29. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

30. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the engine moving control rod and No. 3 engine mounting stay to the engine moving control rod bracket with the 2 bolts.

HINT
Perform this procedure only when replacement of the engine moving control rod is necessary.

31. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) When replacing the engine moving control rod.

(1) Temporarily tighten the engine moving control rod sub-assembly with the 4 bolts.

(2) Fully tighten the 4 A bolts in the order shown in the illustration.





Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

(3) Fully tighten the bolt B.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

(4) Fully tighten the bolt C.

Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)

(b) When not replacing the engine moving control rod.





(1) Install the engine moving control rod sub-assembly with the 4 bolts in the order shown in the illustration.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

(c) Connect the ground wire with the bolt.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

32. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the 2 bolts.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

33. CONNECT INLET NO. 1 OIL COOLER HOSE

(a) Connect the inlet No. 1 oil cooler hose with the hose clip.

34. CONNECT OUTLET NO. 1 OIL COOLER HOSE

(a) Connect the outlet No. 1 oil cooler hose with the hose clip.

35. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the 2 union to check valve hoses with the 2 clips.

36. CONNECT FUEL TUBE SUB-ASSEMBLY Installation

37. INSTALL EFI FUEL PIPE CLAMP Installation

38. CONNECT INLET HEATER WATER HOSE





(a) Connect the inlet heater water hose with the hose clip.

Text in Illustration





NOTICE:
Install the clip so that its claws positioned as shown in the illustration.

39. CONNECT OUTLET HEATER WATER HOSE





(a) Connect the outlet heater water hose with the hose clip.

Text in Illustration





NOTICE:
Install the clip so that its claws positioned as shown in the illustration.

(b) Engage the hose clamp.

40. CONNECT NO. 2 RADIATOR HOSE





(a) Connect the No. 2 radiator hose with the hose clip.

Text in Illustration





NOTICE:
Install the clip so that its claws are within the clip installation range.

41. CONNECT NO. 1 RADIATOR HOSE





(a) Connect the No. 1 radiator hose with the hose clip.

Text in Illustration





NOTICE:
Install the clip so that its claws are within the clip installation range.

42. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install a new clip to the control cable bracket.

(b) Install the control cable to the control cable bracket.





Text in Illustration





NOTICE:
* Make sure that the claws (A) on the clip are securely fit into the bracket holes.
* Make sure that the cable is securely installed inside of the claws (B) of the clip.

(c) Connect the transmission control cable to the control shaft lever with the nut.





Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

NOTICE:
Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.

43. CONNECT ENGINE WIRE

(a) Connect the wire harness to the positive (+) battery terminal with the nut.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(b) Engage the wire harness clamp to the battery carrier.

(c) Engage the claw and connect the engine wire to the engine room relay block.

(d) Engage the wire harness clamp to the vehicle.

(e) Install the engine wire with the nut and 3 connectors.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(f) Install the ground wire with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(g) Install the engine room relay block cover.

(h) Connect the connector to the ECM with the lock lever.





(i) Engage the wire 2 harness clamps.

44. INSTALL AIR CLEANER HOSE

NOTICE:
Install the clip so that its claws are within the clip installation range.

(a) Install the air cleaner hose with the hose clip.





Text in Illustration





(b) Engage the 2 hose clamps and install the vacuum hose.

(c) Connect the ventilation hose with the hose clip.

(d) Connect the No. 1 air hose with the hose clip.

(e) Engage the hose clamp and connect the No. 2 fuel vapor feed hose.

(f) Connect the No. 2 fuel vapor feed hose with the hose clip.

(g) Connect the No. 1 fuel vapor feed hose with the hose clip.

45. INSTALL AIR CLEANER ASSEMBLY





(a) Insert the tab of the air cleaner to the hole of the vehicle as shown in the illustration.

Text in Illustration





(b) Install the air cleaner with the 2 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(c) Tighten the hose clamp.

(d) Connect the vacuum hose and engage the hose clamp.

(e) Connect the vacuum switching valve connector and engage the wire harness clamp.

(f) Connect the mass air flow meter connector.

46. INSTALL BATTERY

(a) Install the battery and battery tray.

(b) Install the battery clamp with the bolt and nut.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(c) Connect the positive (+) cable to the positive (+) battery terminal.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

47. INSTALL AIR CLEANER INLET ASSEMBLY

(a) Install the air cleaner inlet with the 2 bolts.

Torque : 6.0 Nm (61 kgf-cm, 53 in-lbf)

48. INSTALL COWL PANEL SUB-ASSEMBLY Installation

49. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

50. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

51. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

52. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

53. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

54. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

55. INSTALL FRONT WIPER ARM HEAD CAP Installation

56. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

57. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

58. ADD ENGINE OIL Replacement

59. ADD ENGINE COOLANT Service and Repair

60. ADD AUTOMATIC TRANSAXLE FLUID

Procedures

61. WARM UP ENGINE

62. INSPECT ENGINE OIL LEVEL Testing and Inspection

63. INSPECT ENGINE COOLANT LEVEL Testing and Inspection

64. CHARGE WITH REFRIGERANT Service and Repair

65. INSPECT FOR FUEL LEAK Fuel System

66. INSPECT FOR COOLANT LEAK Testing and Inspection

67. INSPECT FOR OIL LEAK

68. INSPECT FOR EXHAUST GAS LEAK

69. INSPECT IGNITION TIMING Engine

70. INSPECT ENGINE IDLE SPEED Engine

71. INSPECT CO/HC Engine

72. CHECK FOR SPEED SENSOR SIGNAL

Test Mode Procedure

73. INSPECT SHIFT LEVER POSITION Installation

74. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

75. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the No. 1 engine cover.

76. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 bolts and clip.

77. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.

78. INSTALL NO. 2 ENGINE UNDER COVER

79. INSTALL NO. 1 ENGINE UNDER COVER Installation