MANUAL TRANSAXLE ASSEMBLY (for 1WW) INSTALLATION


  1. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A01IUP9

      Install the rear engine mounting bracket with the 5 bolts.

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

  2. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A01IPZU

      Install the front engine mounting bracket with the 4 bolts.

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

  3. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator with the bolt.

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

  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 transaxle.

    • 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. A01IRJY

      Make sure that the dowel pins are not loose, bent, damaged 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 to the engine with the contact surfaces of the engine and transaxle flat against each other.

    4. A01IPMBE01

      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 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. A01IQ3R

      Install the engine mounting bracket LH with the 4 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    7. A01ISYE

      Install the 4 bolts and engine mount insulator LH.

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

    8. 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 mount bracket LH.

    9. A01IP2U

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

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

  5. INSTALL NO. 2 MANIFOLD STAY


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

  6. INSTALL STARTER ASSEMBLY


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

  7. TIGHTEN ENGINE AND TRANSAXLE CONNECTING BOLT


    1. A01IPMBE02

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

      Torque:
      E14 "TORX" bolt A
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      E14 "TORX" bolt B
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt C
      24 N*m  { 245 kgf*cm, 17 ft.*lbf }
      Text in Illustration
      A01ISM9 E14 "TORX" bolt A
      A01ISER E14 "TORX" bolt B
      A01IQPE Bolt C

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

      Torque:
      21 N*m  { 218 kgf*cm, 16 ft.*lbf }

  8. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. 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. A01IRWIE01

      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. INSTALL ENGINE WIRE


    1. A01IRXD

      Connect the ground cable with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    2. A01IQ4Z

      Connect the back-up light switch connector, neutral switch connector and 2 bolts.

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

  12. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. 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. INSTALL NO. 1 CLUTCH HOUSING COVER


    1. A01IRB3

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

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

  14. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01IT9XE01
      Text in Illustration
      *a Anti-rotation Pin

      Attach the bracket of the transmission control cable assembly with the bolt.

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

      Tech Tips

      Make sure the anti-rotation pin is contacting the rear engine mount insulator.

    2. A01IQWYE01
      Text in Illustration
      *1 Clip
      *2 Metal Washer Plate

      Connect the 2 cables to the control cable bracket with 2 new clips.

      Note

      Do not bend the cable more than necessary.

    3. Connect the 2 cables to the manual transaxle assembly and install the 2 clips.

      Tech Tips

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

  15. REMOVE LOWER NO.1 INSTRUMENT PANEL FINISH PANEL

    Click here

  16. ADJUST TRANSMISSION CONTROL SELECT CABLE ASSEMBLY

    Tech Tips


    • After the shift lever or transmission control cable assembly is replaced, be sure to adjust the control select cable.

    • If the shift lever cannot be moved (or the shift lever is difficult to move) to 1 or 2, or if it is possible to move the shift lever to R without pulling up the slider shaft, the length of the cable must be adjusted.


    1. A01IPQME01
      Text in Illustration
      *1 Control Select Cable

      Pinch the areas indicated by the arrows and disconnect the control select cable.

    2. Release the lock of the cable length adjustment structure of the select cable.


      1. A01INGTE03
        Text in Illustration
        *1 Stopper
        *a 34°
        *b Turn

        Turn the stopper.

      2. A01IOTDE03
        Text in Illustration
        *1 Lock Piece
        *2 Case
        *a Pull Out

        Pull the lock piece outward from the case to release the lock.

      3. A01IS8RE02
        Text in Illustration
        *1 Stopper
        A01ISM9 Return

        Return the stopper.

    3. A01IT97E01

      While pressing the shift and select lever shaft (*1) and pin (*2), push in the pin (*3) and check that the shift and select lever shaft is secured at the 1st-2nd gear selected position (the shaft comes to a stop at the position 8 mm (0.315 in.) below the N position).

    4. Connect the control select cable to the shift lever assembly.

    5. A01IQCHE03
      Text in Illustration
      *1 Slider
      *2 Inhibitor Wall
      *3 Stopper
      *4 Lock Piece
      *a Turn
      *b Return
      *c Push
      *d Press with a force of 20 N*m (204 kgf*cm, 15 ft.*lbf)

      Push the slider against the inhibitor wall.

      Note


      • Press the slider against the inhibitor wall with a force of 20 N*m (204 kgf*cm, 15 ft.*lbf) as shown in the illustration.

      • Keep pressing the slider against the inhibitor wall until the cable adjustment is completed.

      • Do not pull up the slider.

      • When adjusting the cable, make sure that the shift lever is not in 1 or 2.

    6. Lock the cable length adjustment structure of the select cable.


      1. Turn the stopper.

      2. Push the lock piece into the case.

        Note

        Do not move the cable in the axial direction.

      3. Return the stopper to prevent the lock from being released.

        Note


        • Push the lock piece as far as it will go.

        • Confirm whether the cable length adjustment structure is locked securely.

    7. A01IS2T

      Release the pin that fixes the shift and select lever shaft.

      Text in Illustration
      A01ISM9 Pull

      1. Pull the pin toward the left front side of the vehicle.

  17. INSTALL LOWER NO.1 INSTRUMENT PANEL FINISH PANEL

    Click here

  18. INSTALL NO. 1 AIR TUBE ASSEMBLY


    1. Connect the No. 1 air tube assembly to the manual transaxle assembly with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the outlet heater water hose to the No. 2 radiator pipe, and slide the clamp to secure the hose.

    3. Connect the water hose sub-assembly to the No. 1 radiator pipe, and slide the clamp to secure the hose.

    4. Attach the clamp and connect the water hose sub-assembly to the compressor outlet elbow.

    5. Connect the water by-pass hose assembly to the No. 2 radiator pipe, and slide the clamp to secure the hose.

    6. Connect the radiator hose sub-assembly to the No. 1 radiator pipe, and slide the clamp to secure the hose.

  19. CONNECT INTERCOOLER AIR HOSE

    Note

    If replacing the intercooler air hose, check for deposits in the intercooler assembly and intercooler air hose. If necessary, wipe up deposits.


    1. Connect the intercooler air hose to the intercooler assembly, and tighten the hose clamp to secure the hose.

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

  20. CONNECT COMPRESSOR OUTLET ELBOW


    1. A01IUF1E01
      Text in Illustration
      *1 Retainer

      Connect the compressor outlet elbow to the turbocharger sub-assembly and lock the retainer as shown in the illustration.

  21. INSTALL NO. 4 WATER BY-PASS HOSE


    1. A01IPJHE01
      Text in Illustration
      *1 Retainer

      Install the No. 4 water by-pass hose to the No. 2 radiator pipe, and slide the clamp to secure the hose.

    2. Connect the No. 4 water by-pass hose to the EGR cooler assembly and lock the retainer as shown in the illustration.

  22. CONNECT WIRE HARNESS


    1. Connect the engine wire to the No. 1 air tube assembly with the 2 bolts.

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

    2. Attach the 2 clamps to the No. 1 air tube assembly.

  23. INSTALL AIR CLEANER BRACKET


    1. A01IOXLE01

      Install the air cleaner bracket with the 5 bolts.

      Torque:
      Bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      Bolt B
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
    2. A01IOXO

      Connect the wire harness with the 3 clamps.

  24. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly with the 3 bolts.

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

  25. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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


    1. A01ITKQE01
      Text in Illustration
      *1 Retainer

      Connect the air cleaner hose assembly to the turbocharger sub-assembly and lock the retainer as shown in the illustration.

    2. Attach the 2 clamps to install the air cleaner cap sub-assembly.

    3. Connect the ventilation hose to the cylinder head cover sub-assembly.

    4. Attach the clamp and connect the No. 2 fuel hose to the air cleaner hose assembly.

    5. Attach the clamp and connect the No. 1 fuel hose to the air cleaner hose assembly.

    6. Attach the clamp and connect the vacuum hose to the air cleaner hose assembly.

    7. Attach the clamp and connect the mass air flow meter sub-assembly connector.

  27. INSTALL DRIVE SHAFT ASSEMBLY

    Click here

  28. INSTALL NO. 1 ENGINE COVER


    1. A01IQK8E02
      Text in Illustration
      *a Installation Points

      Attach the 4 clips to install the No. 1 engine cover.

      Tech Tips

      When attaching the clips, press the protrusions on the top of the No. 1 engine cover at the clip installation points.

  29. INSTALL STARTER ASSEMBLY

    Click here

  30. INSTALL EXHAUST PIPE ASSEMBLY

    Click here

  31. ADD ENGINE COOLANT

    CAUTION:

    Do not remove the reservoir cap and air release valve while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Tighten the radiator drain cock plug by hand.

    2. A01IND9E02
      Text in Illustration
      *1 Air Release Valve
      *a Radiator Reservoir Assembly Filler Neck
      *b Pour Limit Line

      Remove the air release valve.

    3. Add engine coolant to the pour limit line of the radiator reservoir assembly.

      Standard Capacity
      Item Specified Condition
      w/o Combustion Type Power Heater 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      w/ Combustion Type Power Heater 7.3 liters (7.7 US qts, 6.4 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips

      Toyota recommends the use of approved "Toyota Premium Long Life Coolant for 1WW/2WW engines" or equivalent.

    4. Press the No. 2 radiator hose and radiator hose sub-assembly several times by hand, and then check the level of the engine coolant.

      If the coolant level is low, add engine coolant.

    5. Install the air release valve.

    6. Add engine coolant to the filler neck of the radiator reservoir assembly.

    7. Install the reservoir cap.

    8. Start the engine, and warm it up until the cooling fan operates.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the air conditioning temperature setting to MAX (HOT).

      • Adjust the air conditioning blower setting to Lo.

    9. Maintain the engine speed at 2000 to 2500 rpm and warm up the engine until the cooling fan operates.

      Note


      • Make sure that the radiator reservoir assembly still has some engine coolant in it.

      • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough engine coolant, the engine may burn out or overheat.

      • Immediately after starting the engine, if the radiator reservoir assembly does not have any coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the coolant is filled to the pour limit line.

      • Until the coolant level has stabilized, run the engine at 2000 rpm.

    10. Press the No. 2 radiator hose and radiator hose sub-assembly several times by hand to bleed air.

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the cooling fan.

    11. Stop the engine and wait until the coolant cools down to ambient temperature.

    12. Check that the coolant level is between the FULL and LOW line.

      If the coolant level is below the LOW line, repeat all of the procedures above.

      If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW line.

  32. ADD MANUAL TRANSAXLE OIL


    1. Add manual transaxle oil.

      Manual Transaxle Oil
      "Toyota Genuine Manual Transmission Gear Oil LV" or "API GL-4 and SAE 75W"
      Capacity (Reference)
      for 1WW
      2.1 liters (2.2 US qts, 1.8 Imp. qts)
      except 1WW
      2.3 liters (2.4 US qts, 2.0 Imp. qts)
    2. A01IQEZE49
      Text in Illustration
      *a 0 to 5 mm (0 to 0.196 in.)

      Check that the oil surface is within 5 mm (0.196 in.) of the bottom of the manual transmission filler plug opening.

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

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

      Note


      • When adding transaxle oil, make sure the vehicle is level.

      • An excessively large or small amount of oil may cause problems.

      • After adding oil, drive the vehicle and recheck the oil level.

  33. FOR COOLANT LEAK


    1. Remove the reservoir cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the reservoir cap 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.

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

    3. Warm up the engine.

    4. Pump the radiator cap tester to 143 kPa (1.5 kgf/cm2, 20.7 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leakage.

      If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

    5. Reinstall the reservoir cap.

  34. INSPECT FOR OIL LEAK

  35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  36. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  37. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 5 clips.

  38. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 5 clips.

  39. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Install the No. 1 engine under cover with the 11 clips and 6 bolts.