Installation (from 07/2011)
1NZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY (for Hatchback): INSTALLATION
NOTICE:
As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.
HINT
Perform "Inspection After Repairs" after replacing the engine assembly Programming and Relearning.
1. INSTALL ENGINE MOUNTING INSULATOR LH
HINT
Only perform this procedure when replacement of the engine mounting insulator LH is necessary.
(a) Install the engine mounting insulator LH with the 5 bolts.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
2. INSTALL ENGINE MOUNTING INSULATOR RH
HINT
Only perform this procedure when replacement of the engine mounting insulator RH is necessary.
(a) Install the engine mounting insulator RH with the 5 bolts.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
3. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY
(a) Install the drive shaft heat insulator sub-assembly with the bolt and nut.
Torque : 18 Nm (183 kgf-cm, 13 ft-lbf)
4. CONNECT INLET HEATER WATER HOSE A
(a) Connect inlet heater water hose A to the cylinder head.
5. FIX ENGINE ASSEMBLY
(a) Using an engine sling device and a chain block, hold the engine assembly.
(b) Use a belt with a tightening mechanism or a rope to secure the engine assembly with transaxle to the engine lifter.
NOTICE:
* Set plate lift attachments so that the engine assembly with transaxle is level.
* Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
* To prevent deformation of the oil pan, never set any attachments against the oil pan of the engine assembly.
6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)
(a) Using SST, hold the crankshaft.
SST : 09960-10010
09962-01000
09963-01000
(b) Clean the 6 bolts and their holes.
(c) Install the front drive plate spacer.
Text in Illustration
(d) Install the drive plate and rear drive plate spacer onto the crankshaft.
HINT
* The front drive plate spacer is reversible.
* As the drive plate and ring gear and the rear drive plate spacer are not reversible, make sure to install them in the direction as shown in the illustration.
(e) Apply adhesive to the end 2 or 3 threads of the 6 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(f) Install and uniformly tighten the 6 bolts in several steps, in the sequence shown in the illustration.
Torque : 88 Nm (897 kgf-cm, 65 ft-lbf)
NOTICE:
Do not start the engine for at least 1 hour after performing the installation.
7. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
(a) Hold the crankshaft with SST.
SST : 09960-10010
09962-01000
09963-01000
(b) Clean the 6 bolts and their holes.
(c) Apply adhesive to the end 2 or 3 threads of new bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Install the flywheel with the 6 bolts in the order shown in the illustration.
Torque : 49 Nm (500 kgf-cm, 38 ft-lbf)
(e) Mark a paint mark on each bolt head on the engine upper side.
Text in Illustration
(f) Tighten the bolts 90° in the sequence shown in the illustration.
NOTICE:
Do not start the engine for at least 1 hour after performing the installation.
8. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) Installation (from 07/2011)
9. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation (from 07/2011)
10. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation (from 07/2011)
11. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
(a) Apply clutch spline grease to the round of the crankshaft contact surface with the torque converter centerpiece.
Text in Illustration
Clutch spline grease:
Toyota Genuine Clutch Spline Grease or equivalent
Maximum spread:
Approximately 1 g (0.0353 oz)
(b) Keeping the engine and automatic transaxle assembly in a horizontal position, align the knock pins with each hole on the automatic transaxle assembly and tighten the 7 bolts.
Text in Illustration
Torque : 30 Nm (301 kgf-cm, 22 ft-lbf)
NOTICE:
* Confirm that 2 knock pins are on the transaxle fitting surface of the engine block before transaxle installation.
* After installing the transmission, confirm that the torque converter rotates smoothly.
(c) Install the wire harness bracket with the bolt.
Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)
12. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
(a) Align the input shaft with the clutch disc and install the manual transaxle assembly onto the engine.
(b) Install the 7 bolts.
Torque : 33 Nm (336 kgf-cm, 24 ft-lbf)
NOTICE:
* Insert knock pins into the knock pin holes securely so that the end face of the manual transaxle fits close against the engine before tightening the bolts.
* Be careful not to pinch wire harness, etc.
* To avoid damage to the input shaft, do not forcefully shake the manual transaxle.
13. INSTALL CONTROL CABLE BRACKET (for Manual Transaxle) Installation (from 07/2011)
14. INSTALL STARTER ASSEMBLY Installation
15. INSTALL FLYWHEEL HOUSING SIDE COVER Installation
16. INSTALL EXHAUST MANIFOLD
(a) Tighten the exhaust manifold nuts and bolts, in the order shown in the illustration, through a new gasket.
Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)
17. INSTALL MANIFOLD SUPPORT BRACKET
(a) Install the manifold support bracket with the 3 bolts.
Torque : 44 Nm (449 kgf-cm, 33 ft-lbf)
18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the No. 1 exhaust manifold heat insulator.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
19. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.
(b) Provisionally tighten the intake manifold 2 nuts and 3 bolts in the order shown in the illustration, and then tighten them to the specified torque.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
(c) Connect the water by-pass hose to No. 1 water bypass pipe.
(d) Connect the water by-pass hose to the cylinder head with the hose clamp.
(e) Connect the union to connector tube hose to the booster vacuum tube with the hose clamp.
20. INSTALL WATER FILLER SUB-ASSEMBLY
(a) Install the water filler sub-assembly with the 2 nuts.
Torque : 7.5 Nm (76 kgf-cm, 66 in-lbf)
(b) Connect the No. 1 radiator hose to the cylinder head with the hose clamp.
21. INSTALL VENTILATION HOSE
(a) Install the ventilation hose with the 2 hose clamps.
22. INSTALL ENGINE WIRE
(a) Connect all the wire harnesses and connectors.
(b) Install the 2 ground bolts.
Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)
23. INSTALL NO. 1 IGNITION COIL Removal (from 07/2011)
24. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Install the engine moving control rod with the through bolt.
Torque : 120 Nm (1244 kgf-cm, 89 ft-lbf)
25. REMOVE NO. 1 ENGINE HANGER
(a) Remove the 2 bolts and the No. 1 engine hanger.
26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Place wooden blocks or plate lift attachments on an engine lifter, and then set the engine assembly with transaxle.
NOTICE:
* Place the wooden blocks or plate lift attachments so that the engine assembly with transaxle is level.
* As the engine assembly with transaxle is very heavy, be sure to support it securely.
(b) Operate the engine lifter and lift the engine assembly with transaxle and the front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.
(c) Install the engine mounting insulator LH with the through bolt and nut.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
HINT
Tighten by holding the nut and turning the bolt.
(d) Install the engine mounting insulator RH with the bolt and 2 nuts.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
(e) By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps.
Text in Illustration
SST : 09670-00010
Bolt A - Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)
Bolt B - Torque : 151 Nm (1540 kgf-cm, 111 ft-lbf)
Bolt C - Torque : 98 Nm (999 kgf-cm, 72 ft-lbf)
NOTICE:
* Insert SST into the datum hole vertically.
* If impossible to insert SST vertically, loosen all bolts and then insert SST again.
27. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation (from 07/2011)
28. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY Installation (from 07/2011)
29. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation (from 07/2011)
30. INSTALL TORQUE CONVERTER SETTING BOLT (for Automatic Transaxle)
(a) Remove any adhesive remaining in the 6 bolt holes of the torque converter clutch and 6 bolts.
(b) Apply adhesive to 2 or 3 threads on the end of the 6 bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install the 6 torque converter set bolts while holding the crankshaft pulley bolt with a wrench.
Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)
31. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover.
32. INSTALL FRONT DRIVE SHAFT ASSEMBLY
Installation (from 07/2011)
33. INSTALL EXHAUST PIPE GASKET Installation (from 07/2011)
34. INSTALL NO. 2 EXHAUST PIPE GASKET Installation (from 07/2011)
35. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation (from 07/2011)
36. INSTALL FRONT FLOOR CENTER BRACE Installation (from 07/2011)
37. INSTALL REAR CONSOLE BOX ASSEMBLY
Installation (from 07/2011)
38. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Installation (from 07/2011)
39. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Installation (from 07/2011)
40. CONNECT ENGINE WIRE
(a) for Automatic Transaxle:
(1) Engage the clamp and connect the wire harness to the automatic transaxle.
(2) Install the wire harness to the automatic transaxle with the bolt.
Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)
(b) Connect the 2 connectors to the battery positive terminal.
(c) Engage the 2 claws and connect the wire harness to the engine room relay block.
(d) Connect the connector to the engine room relay block.
(e) Engage the clamp and connect the wire harness to the body.
(f) Pull down the lever to engage the lock and connect the connector to the ECM.
(g) Engage the clamp and connect the wire harness to the wire harness bracket.
(h) Connect all the wire harness and connectors.
41. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System) Installation (from 07/2011)
42. INSTALL FAN AND GENERATOR V BELT Installation (from 07/2011)
43. ADJUST FAN AND GENERATOR V BELT Installation (from 07/2011)
44. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Installation (from 07/2011)
45. CONNECT INLET OIL COOLER HOSE (for Automatic Transaxle)
(a) Connect the oil cooler inlet hose with the clip.
46. CONNECT OUTLET OIL COOLER HOSE (for Automatic Transaxle)
(a) Connect the oil cooler outlet hose with the clip.
47. CONNECT INLET HEATER WATER HOSE A
(a) Connect inlet heater water hose A to the heater unit with the hose clamp.
48. CONNECT OUTLET HEATER WATER HOSE A
(a) Connect outlet heater water hose A to the heater unit with the hose clamp.
49. CONNECT UNION TO CHECK VALVE HOSE
(a) Connect the union to check valve hose to the booster vacuum tube with the hose clamp.
50. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) 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 the pipe and connector to make sure that they are securely connected.
51. INSTALL EFI FUEL PIPE CLAMP
(a) Install the EFI fuel pipe clamp.
52. CONNECT NO. 2 RADIATOR HOSE
(a) Connect the No. 2 radiator hose to the water inlet with the hose clamp.
53. CONNECT NO. 3 RADIATOR HOSE
(a) Connect No. 3 radiator hose to the water filler with the hose clamp.
54. CONNECT RADIATOR RESERVOIR TANK HOSE
(a) Connect the radiator reservoir tank hose to the water filler.
55. INSTALL FUEL VAPOR FEED HOSE ASSEMBLY
(a) Install fuel vapor feed hose assembly with the 2 hose clamps.
56. INSTALL BATTERY CARRIER
(a) Install the battery carrier with the 5 bolts.
Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)
(b) Engage the 6 clamps and connect the wire harness to the battery carrier.
57. INSTALL AIR CLEANER BRACKET
(a) Install the air cleaner bracket with the 2 bolts.
Torque : 20 Nm (199 kgf-cm, 14 ft-lbf)
(b) Engage the clamp and connect the wire harness to the air cleaner bracket.
58. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case onto the air cleaner bracket with the 2 bolts.
Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
(b) Engage the clamp and connect the wire harness to the air cleaner case.
(c) Install the air cleaner element onto the air cleaner case.
(d) Install the air cleaner cap sub-assembly with No. 1 air cleaner hose onto the throttle body assembly
(e) Engage the 2 clamps and connect the air cleaner cap sub-assembly to the air cleaner case sub-assembly.
(f) Tighten the hose clamp.
Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf)
(g) Connect the vacuum switching valve assembly connector.
(h) Connect the mass air flow meter connector.
(i) Engage the 2 clamps and connect the wire harness to the air cleaner cap sub-assembly and vacuum switching valve assembly.
(j) Connect the No. 2 fuel vapor feed hose to the intake manifold.
(k) Connect the fuel vapor feed hose assembly to the No. 1 air cleaner hose and vacuum switching valve assembly with the 2 hose clamps.
(l) Engage the clamp and connect the fuel vapor feed hose assembly to the No. 1 air cleaner hose.
59. INSTALL BATTERY TRAY
60. INSTALL BATTERY
(a) Install the battery onto the battery tray with the battery clamp.
Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
(b) Connect the cable to the battery terminal.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
61. INSTALL OUTER COWL TOP PANEL Installation (from 07/2011)
62. INSTALL INNER COWL TOP TO COWL BRACE Installation (from 07/2011)
63. INSTALL FRONT NO. 1 VENTILATOR SEAL Installation (from 07/2011)
64. INSTALL FRONT AIR SHUTTER SEAL RH Installation (from 07/2011)
65. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Installation (from 07/2011)
66. INSTALL FRONT WHEELS
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
67. ADD ENGINE COOLANT Service and Repair
68. INSPECT ENGINE OIL LEVEL Testing and Inspection
69. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Installation (from 07/2011)
70. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) On-Vehicle Inspection
71. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) Service and Repair
72. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) Testing and Inspection
73. INSPECT FOR FUEL LEAK Testing and Inspection
74. INSPECT FOR COOLANT LEAK Testing and Inspection
75. INSPECT FOR ENGINE OIL LEAK
76. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK (for Automatic Transaxle)
77. INSPECT FOR MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)
78. INSPECT FOR EXHAUST GAS LEAK
HINT
Perform "Inspection After Repairs" after repairing or replacing the exhaust system Programming and Relearning.
79. INSPECT FAN AND GENERATOR V BELT Testing and Inspection
80. INSPECT IGNITION TIMING Engine (for Hatchback)
81. INSPECT ENGINE IDLING SPEED Engine (for Hatchback)
82. INSPECT CO/HC Engine (for Hatchback)
83. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Front Wheel Alignment (for Hatchback) (from 07/2011)
84. INSTALL ENGINE UNDER COVER RH
85. INSTALL ENGINE UNDER COVER LH
86. INSTALL NO. 2 CYLINDER HEAD COVER Installation (from 07/2011)
87. INSPECT ABS SENSOR SIGNAL (w/o VSC)
88. INSPECT VSC SPEED SENSOR SIGNAL (w/ VSC)