МЕХАНИЧЕСКАЯ ТРАНСМИССИЯ В СБОРЕ УСТАНОВКА

PROCEDURE


  1. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A01V7JMN01

      Temporarily install the rear engine mounting bracket with the 5 bolts.

    2. Tighten the 5 bolts of the rear engine mounting bracket in the order shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  2. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A01V82PN01

      Temporarily install the front engine mounting bracket with the 4 bolts.

    2. Tighten the 4 bolts of the front engine mounting bracket in the order shown in the illustration.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  4. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Note


    • Be extremely careful that the body, clutch pipe line and radiator cooling fan do not interfere with the manual transaxle assembly when installing the manual transaxle assembly.

    • When installing the manual transaxle assembly, it is necessary to move the engine assembly and manual transaxle assembly up and down, and back and forth. Therefore, continually confirm that the parts are properly supported and stable while performing this step.


    1. A01V7O8

      Make sure that the dowel pins are not loose, bent, damage or scratched.

    2. While adjusting the angle of the transmission jack raise the manual transaxle assembly until it is in line with the engine assembly.

      Note

      Be careful that the clutch pipe line does not interfere with the manual transaxle assembly.

    3. Adjust the height and angle of the transmission jack, align the input shaft with the clutch disc, and then install the manual transaxle assembly to the engine assembly with the contact surfaces of the engine assembly and manual transaxle assembly flat against each other.

    4. A01V6ST

      Temporarily install the manual transaxle assembly with the 6 bolts.

      Note

      Before tightening the bolts, insert the dowel pins into the dowel holes securely so that the end face of the manual transaxle assembly fits close against the engine assembly.

    5. Apply adhesive to the 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01VA48N01

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

    7. Tighten the 4 bolt of the engine mounting bracket LH in the order shown in the illustration.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    8. A01V9Y7

      Install the engine mounting insulator LH with the 4 bolts.

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

    9. Slowly raise the engine assembly and transmission assembly using a transmission jack, and then align the installation positions of the engine mounting insulator LH and engine mounting bracket LH.

    10. A01V8VF

      Install the nut and through bolt, and then connect the engine mounting insulator LH to the engine mounting bracket LH.

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

  5. TEMPORARILY INSTALL NO. 2 MANIFOLD STAY


    1. Temporarily install the No. 2 manifold stay with the 2 bolts and nut.

  6. TEMPORARILY INSTALL STARTER ASSEMBLY


    1. Temporarily install the starter assembly with the 2 bolts.

  7. TIGHTEN ENGINE AND TRANSAXLE CONNECTING BOLT


    1. A01V98SC01
      A01V9RL

      E14 "TORX" bolt

      Bolt length 100 mm (3.94 in.)
      A01V8SA

      E14 "TORX" bolt

      Bolt length 80 mm (3.15 in.)
      A01V7J0

      Hexagon Bolt

      Bolt length 40 mm (1.57 in.)

      Tighten the 10 bolts in the sequence shown in the illustration.

      Torque:
      for bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for bolt B
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      for bolt C
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      for bolt D
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    2. Tighten the nut of the No. 2 exhaust manifold stay.

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

  8. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. A01V70W

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

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

  9. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A01V7B8N01

      Install the front crossmember sub-assembly with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    2. Remove the transmission jack.

  10. INSTALL FRONT SUSPENSION MEMBER

    Click here

  11. CONNECT WIRE HARNESS


    1. A01V6YR

      Install the 3 bolts and connect the 2 connectors.

      Torque:
      19.1 N*m  { 195 kgf*cm, 14 ft.*lbf }

  12. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01V84D

      Connect the clutch release cylinder assembly and clutch flexible hose bracket with the 4 bolts.

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

  13. CONNECT GROUND CABLE


    1. A01VAUX

      Connect the ground cable with the bolt.

      Torque:
      8.35 N*m  { 85 kgf*cm, 74 in.*lbf }

  14. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. A01V8LP

      Install the No. 1 clutch housing cover with the 2 bolts.

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

  15. CONNECT TRANSAXLE CONTROL CABLE ASSEMBLY


    1. A01V9ATC01
      *1 Clip
      *2 Metal Washer Plate

      Connect the transaxle control cable assembly to the control cable bracket with 2 new clips.

      Note

      Do not bend the transaxle control cable assembly more than necessary.

    2. Connect the transaxle control cable assembly to the manual transaxle assembly and install the 2 clips.

      Tech Tips

      Make sure that the metal washer plate of the shift cable facing toward the outside of the vehicle.

  16. INSTALL NO. 1 AIR TUBE ASSEMBLY

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  17. CONNECT NO. 2 AIR HOSE

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  18. CONNECT COMPRESSOR OUTLET ELBOW

    Click here

  19. INSTALL NO. 4 WATER BY-PASS HOSE

    Click here

  20. CONNECT ENGINE WIRE

    Click here

  21. INSTALL AIR CLEANER BRACKET


    1. A01V7LWN01

      Install the air cleaner bracket with the 5 bolts.

      Torque:
      for bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for bolt B
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }
    2. A01V6RD

      Connect the wire harness with the 3 clamps.

  22. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  23. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  24. INSTALL DRIVE SHAFT ASSEMBLY

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  25. INSTALL STARTER ASSEMBLY

    Click here

  26. INSTALL EXHAUST PIPE ASSEMBLY

    Click here

  27. ADD ENGINE COOLANT

    Click here

  28. ADD MANUAL TRANSAXLE OIL

    Click here

  29. INSPECT FOR COOLANT LEAK

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  30. INSPECT FOR MANUAL TRANSAXLE OIL LEAK

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  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  32. INSPECT FOR EXHAUST GAS LEAK

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  33. INSTALL REAR ENGINE UNDER COVER LH

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  34. INSTALL REAR ENGINE UNDER COVER RH

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  35. INSTALL NO. 2 ENGINE UNDER COVER

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  36. INSTALL NO. 1 ENGINE UNDER COVER

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  37. INSTALL NO. 1 ENGINE COVER

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