Manual Transaxle Unit: Removal

HINT:

At the time of installation, please refer to the following item. Adjust the hood (See ADJUSTMENT ).

Remove the 4 bolts and No. 2 cylinder head cover.

Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 

Remove the bolt and disconnect the radiator reservoir.

Torque: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

1. Remove the 2 bolts and ECM cover.

   Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf) 

2. Disconnect the ECM connectors from the ECM.
3. Remove the ECM outlet duct.
4. Remove the air cleaner case assembly with the air hose.
5. Remove the 3 bolts and ECM box.

   Torque: 6.9 N.m (70 kgf.cm, 61 in.lbf) 

6. Disconnect the wire harness, and remove the 2 nuts, bolt and battery carrier.

Torque: 

Bolt: 18 N.m (185 kgf.cm, 13 ft.lbf) 

Nut: 12 N.m (120 kgf.cm, 9 ft.lbf) 

1. Remove the 2 clips and washers.
2. Remove the 2 clips and disconnect the control cables from the transaxle.

Remove the 2 set bolts of the 2 ground cables from the transaxle.

1. Remove the 4 set bolts of the clutch line.

   Torque: 

   Bolt A: 12 N.m (120 kgf.cm, 9 ft.lbf) 

   Bolt B: 4.9 N.m (50 kgf.cm, 43 in.lbf) 

2. Remove the 2 set bolts of the clutch release cylinder and clutch line bracket.

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 

Fig 2: Removing 4 Set Bolts Of Clutch Line

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the starter connector.
2. Remove the nut and disconnect the starter wire.
3. Remove the 2 bolts and starter.

Torque: 37 N.m (378 kgf.cm, 28 ft.lbf) 

Fig 3: Removing 2 Bolts & Starter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the wire harness from the clamp.
2. Remove the 2 bolts, clamp and control cable bracket from the transaxle.

Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

Fig 4: Removing 2 Bolts, Clamp & Control Cable Bracket From Transaxle

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 

Using SST, disconnect the pressure feed and return tubes. SST 09023-38400

Torque: 40 N.m (410 kgf.cm, 30 ft.lbf) 

HINT:

• Use torque wrench with a fulcrum length of 345 mm (13.58 in.).
• This torque value is effective in case that SST is parallel to a torque wrench.

Fig 6: Disconnecting Pressure Feed & Return Tubes Using SST

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the bolt and disconnect the tube clamp.

Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf) 

Fig 7: Removing Bolt & Disconnecting Tube Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the 2 PCV hoses.
2. Install the No. 1 and No. 2 engine hangers in the correct direction.

   Parts No.: 

   No. 1 engine hanger: 12281-88600 

   No. 2 engine hanger: 12282-88600 

   Bolt: 91512-61020 

   Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 

   Fig 8: Installing No. 1 & No. 2 Engine Hangers In Correct Direction

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Attach the engine chain hoist to the engine hangers.

Torque: 

Bolt A: 60 N.m (610 kgf.cm, 44 ft.lbf) 

Nut B: 80 N.m (820 kgf.cm, 59 ft.lbf) 

Fig 9: Removing Engine Left Mounting Bracket 3 Set Bolts & Nut

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Lower the transaxle side, and remove the bolt and engine left mounting bracket.

Torque: 60 N.m (610 kgf.cm, 44 ft.lbf) 

Oil grade: API GL-4 or GL-5 

Viscosity: SAE 75W-90 

Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts) 

Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

1. Disconnect the 2 heated oxygen sensors.

   Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) 

   Fig 11: Identifying Filler Plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT:

   At the time of installation, please refer to the following items.

   • Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
   • After installing the heated oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.
2. Remove the 4 bolts, compression springs and 2 gaskets.

   Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 

3. Disconnect the front exhaust pipe from the pipe supports and remove it.

1. Remove the nut and disconnect the stabilizer bar link.

   Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) 

2. Employ the same manner described above to the other side.

Remove the bolt (bolt A) and 3 nuts, and disconnect the engine rear mount insulator and front suspension member.

Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

Remove the 2 bolts (bolt B) and disconnect the engine front mount insulator and front suspension member.

Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

Using a transmission jack, support the front suspension member with lower suspension arm.

Remove the 6 bolts (bolt C, D and E) and front suspension member with lower suspension arm and PS gear assembly.

Fig 12: Removing Bolts & Disconnecting Engine Front Mount Insulator & Front Suspension Member

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 

Bolt C: 157 N.m (1,600 kgf.cm, 116 ft.lbf) 

Bolt D: 157 N.m (1,600 kgf.cm, 116 ft.lbf) 

Bolt E: 39 N.m (400 kgf.cm, 29 ft.lbf) 

1. Remove the bolt and engine rear mounting insulator.

   Torque: 87 N.m (890 kgf.cm, 64 ft.lbf) 

2. Remove the 3 bolts and engine rear mounting bracket.

Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 

Using a transmission jack, support the transaxle.

Fig 13: Removing Bolt & Engine Rear Mounting Insulator

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 

Bolt A: 47 N.m (480 kgf.cm, 35 ft.lbf) 

Bolt B: 23 N.m (230 kgf.cm, 17 ft.lbf) 

Lower the engine left side and remove the transaxle from the engine.

Fig 14: Removing 4 Transaxle Lower Side Mounting Bolts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

HINT:

At the time of installation, please refer to the following items.

• Align the input shaft with the clutch disc and install the transaxle to the engine.
• Temporarily tighten the transaxle mounting bolts.