CAUTION / NOTICE / HINT
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.
When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.
After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the intelligent tester (Click here).
PROCEDURE
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Only perform this procedure when replacement of the engine mounting insulator RH is necessary.
Temporarily tighten the engine mounting insulator RH with the 3 bolts.
Fully tighten the 3 bolts, in the order shown in the illustration.
| 52 N*m | 530 kgf*cm | 38 ft.*lbf |
INSTALL ENGINE MOUNTING INSULATOR LH
Only perform this procedure when replacement of the engine mounting insulator LH is necessary.
Temporarily tighten the engine mounting insulator LH with the 5 bolts.
Fully tighten the 5 bolts, in the order shown in the illustration.
| 52 N*m | 530 kgf*cm | 38 ft.*lbf |
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Install the No. 1 crankshaft position sensor plate.
| *1 | Mark "RR" | - | - |
| *a | Engine Block Side | - | - |
Install the plate with the concave surface facing the cylinder block, as shown in the illustration.
INSTALL FLYWHEEL SUB-ASSEMBLY
Using SST, hold the crankshaft.
| 09213-58014 |
| 09330-00021 |
Clean the 6 bolts and the 6 bolt holes.
Apply adhesive to the 2 or 3 end threads of the bolts.
| *1 | Adhesive |
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. |
Using several steps, uniformly install and tighten the 6 bolts in the order shown in the illustration (Procedure "A").
| 49 N*m | 500 kgf*cm | 36 ft.*lbf |
Mark the bolts with paint as shown in the illustration.
| *a | Paint Mark |
Retighten the bolts 90° in the same sequence as in procedure "A".
Check that the paint marks of each bolt are at a 90° angle from the original position.
INSTALL CRANKSHAFT POSITION SENSOR (w/ DPF)
Install the crankshaft position sensor with the 2 bolts.
| 7.0 N*m | 71 kgf*cm | 62 in.*lbf |
Engage the crankshaft position sensor wire harness clamp to the wire harness bracket.
Connect the crankshaft position sensor connector.
INSTALL CRANKSHAFT POSITION SENSOR (w/o DPF)
INSTALL ENGINE WIRE
Install the engine wire to the engine.
Install the 2 ground bolts.
| Bolt A | ||
| 8.4 N*m | 85 kgf*cm | 74 in.*lbf |
| Bolt B | ||
| 13 N*m | 130 kgf*cm | 9 ft.*lbf |
| *a | Engine side |
| *b | Transaxle side |
INSTALL CYLINDER BLOCK SIDE COVER
Install the cylinder block side cover with the bolt and washer plate.
| 7.0 N*m | 71 kgf*cm | 62 in.*lbf |
INSTALL EXHAUST MANIFOLD
TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY
INSTALL TURBOCHARGER SUB-ASSEMBLY
INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY
INSTALL MANIFOLD STAY
INSTALL TURBOCHARGER STAY
INSTALL NO. 2 MANIFOLD SUPPORT BRACKET (w/ DPF)
Install the No. 2 manifold support bracket with the 2 bolts.
| 37 N*m | 377 kgf*cm | 27 ft.*lbf |
INSTALL MANIFOLD SUPPORT BRACKET (w/ DPF)
Install the manifold support bracket with the 3 bolts.
| 37 N*m | 377 kgf*cm | 27 ft.*lbf |
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)
INSTALL NO. 1 TURBO INSULATOR (w/ DPF)
TEMPORARILY TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)
TEMPORARILY TIGHTEN MANIFOLD SUPPORT BRACKET (w/o DPF)
TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)
TIGHTEN MANIFOLD SUPPORT BRACKET (w/o DPF)
INSTALL NO. 1 TURBO INSULATOR (w/o DPF)
INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ DPF)
Install the differential pressure sensor with the nut.
| 8.0 N*m | 82 kgf*cm | 71 in.*lbf |
| *a | Paint Mark |
| *b | View A |
| *c | Rear Side |
Connect the 2 vacuum transmitting hoses.
Connect the differential pressure sensor connector.
INSTALL NO. 2 ENGINE COVER BRACKET
INSTALL NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ DPF)
INSTALL NO. 3 MANIFOLD SUPPORT BRACKET (w/ DPF)
INSTALL NO. 4 MANIFOLD SUPPORT BRACKET (w/ DPF)
INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY (w/ DPF)
INSTALL NO. 2 VACUUM PIPE (w/ DPF)
INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)
INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)
INSTALL BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)
INSTALL BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)
INSPECT CLUTCH PIPE LINE (for Manual Transaxle)
INSPECT CLUTCH PIPE LINE (for Multi-Mode Manual Transaxle)
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)
INSTALL BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)
INSTALL BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)
INSTALL ENGINE ASSEMBLY (for Manual Transaxle)
Hook the outer select lever of the manual transaxle to the reverse restrict pin assembly to secure it.
| *1 | Reverse Restrict Pin Assembly |
| *2 | Outer Select Lever |
Make sure that the knock pins are not loose, bent, damaged or scratched and then install the engine to the manual transaxle with the contact surfaces of the engine and manual transaxle flat against each other.
Align the input shaft with the clutch disc and install the engine to the manual transaxle.
Install the 8 bolts.
| *1 | Knock Pin Hole |
| for Flange Bolt | ||
| 37 N*m | 377 kgf*cm | 27 ft.*lbf |
| for Bolt with Washer | ||
| 33 N*m | 337 kgf*cm | 24 ft.*lbf |
Insert knock pins into the knock pin holes securely so that the end face of the transaxle fits close against the engine before tightening the bolts.
INSTALL ENGINE ASSEMBLY (for Multi-Mode Manual Transaxle)
Make sure that the knock pins are not loose, bent, damaged or scratched and then install the engine to the manual transaxle with the contact surfaces of the engine and transaxle flat against each other.
Align the input shaft with the clutch disc and install the engine to the manual transaxle.
Install the 8 bolts.
| *1 | Knock Pin Hole |
| for Flange Bolt | ||
| 37 N*m | 377 kgf*cm | 27 ft.*lbf |
| for Bolt with Washer | ||
| 33 N*m | 337 kgf*cm | 24 ft.*lbf |
Insert knock pins into the knock pin holes securely so that the end face of the transaxle fits close against the engine before tightening the bolts.
INSTALL STARTER ASSEMBLY (except Cold Area)
INSTALL STARTER ASSEMBLY (for Cold Area Specification Vehicles)
INSTALL NO. 2 AIR TUBE ASSEMBLY
Insert the No. 1 air hose to the throttle body.
Install the No. 2 air tube assembly with the bolt.
| 11 N*m | 112 kgf*cm | 8 ft.*lbf |
| *1 | No. 1 Air Hose |
| *a | View A |
| *b | Front Side |
| *c | RH Side |
Tighten the hose clamp.
| 6.0 N*m | 61 kgf*cm | 53 in.*lbf |
Check the torque in an hour after tightening and confirm that it is 1.8 N*m or higher.
INSTALL NO. 2 RADIATOR HOSE
Install the No. 2 radiator hose.
| *a | View A |
| *b | Upper Side |
| *c | RH Side |
INSTALL WATER BY-PASS HOSE ASSEMBLY
Install the water by-pass hose assembly.
| *a | View A |
| *b | Upper Side |
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Place wooden blocks or plate lift attachments on an engine lifter, and then set the engine assembly with transaxle.
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.
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.
Install the engine mounting insulator LH with the through bolt and nut.
| 52 N*m | 530 kgf*cm | 38 ft.*lbf |
Tighten by holding the nut and turning the bolt.
Install the engine mounting insulator RH with the bolt and 3 nuts.
| Bolt | ||
| 88 N*m | 897 kgf*cm | 65 ft.*lbf |
| Nut A | ||
| 52 N*m | 530 kgf*cm | 38 ft.*lbf |
| Nut B | ||
| 88 N*m | 897 kgf*cm | 65 ft.*lbf |
Install the engine mounting stay with the 2 bolts.
| 88 N*m | 897 kgf*cm | 65 ft.*lbf |
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.
| *a | Datum Hole | *b | OK |
| *c | NG | - | - |
|
Front of the Vehicle | - | - |
| 09670-00010 |
| Bolt A | ||
| 87 N*m | 887 kgf*cm | 64 ft.*lbf |
| Bolt B | ||
| 151 N*m | 1540 kgf*cm | 111 ft.*lbf |
| Bolt C | ||
| 98 N*m | 999 kgf*cm | 72 ft.*lbf |
Insert SST into the datum hole vertically.
If impossible to insert SST vertically, loosen all bolts and then insert SST again.
INSTALL OIL PAN COVER
INSTALL FRONT DRIVE SHAFT ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY
INSTALL FRONT FLOOR CENTER BRACE
INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
INSTALL COLUMN HOLE COVER SILENCER SHEET
CONNECT TRANSAXLE WIRE (for Multi-Mode Manual Transaxle)
Connect the 5 connectors and 2 clamps.
CONNECT ENGINE WIRE
Engage the 2 claws and connect the wire harness to the junction block.
Connect the 2 connectors to the engine junction block.
Engage the wire harness clamp.
Connect the ground wire with the bolt.
| 8.4 N*m | 85 kgf*cm | 74 in.*lbf |
Install the engine room junction block cover.
Connect the ECM connector and engage the harness clamp.
Engage the wire harness clamp and connect the current sensor connector and glow relay connector.
Connect the 3 connectors to the positive (+) battery terminal.
INSTALL CLUTCH HOSE
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
INSTALL NO. 1 AIR TUBE
Insert the No. 1 air hose to the turbocharger.
| *1 | No. 1 Air Hose |
| *a | View A |
| *b | Front Side |
| *c | RH Side |
Install the No. 1 air tube with the 2 nuts.
| 20 N*m | 199 kgf*cm | 14 ft.*lbf |
Tighten the hose clamp.
| 6.0 N*m | 61 kgf*cm | 53 in.*lbf |
Connect the wire harness with the bolt.
| 8.4 N*m | 85 kgf*cm | 74 in.*lbf |
INSTALL NO. 3 AIR HOSE
Install the No. 3 air hose.
| 6.0 N*m | 61 kgf*cm | 53 in.*lbf |
| *a | View A |
| *b | View B |
| *c | Upper Side |
| *d | Rear Side |
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose.
| *a | View A |
| *b | Upper Side |
| *c | RH Side |
INSTALL NO. 1 RADIATOR HOSE
Install the No. 1 radiator hose.
| *a | View A |
| *b | View B |
| *c | Upper Side |
| *d | LH Side |
INSTALL NO. 2 AIR HOSE
| *a | View A |
| *b | View B |
| *c | Upper Side |
| *d | Rear Side |
Install the No. 2 air hose with the hose clamp.
| 6.0 N*m | 61 kgf*cm | 53 in.*lbf |
CONNECT INLET HEATER WATER HOSE
Connect the inlet heater water hose.
| *a | View A |
| *b | Upper Side |
| *c | Front Side |
CONNECT OUTLET HEATER WATER HOSE
Connect the outlet heater water hose.
| *a | View A |
| *b | Upper Side |
| *c | LH Side |
CONNECT NO. 2 FUEL HOSE SUB-ASSEMBLY
Connect the No. 2 fuel hose sub-assembly.
| *a | View A |
| *b | View B |
| *c | Upper Side |
| *d | Front Side |
CONNECT UNION TO CONNECTOR TUBE HOSE
Connect the union to connector tube hose.
INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)
CONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (w/ Air Conditioning System)
INSTALL FAN AND GENERATOR V BELT
INSPECT FAN AND GENERATOR V BELT
INSTALL BATTERY CARRIER (for LHD)
Install the battery carrier with the 5 bolts.
| 17 N*m | 175 kgf*cm | 13 ft.*lbf |
Engage the 3 clamps and connect the wire harness onto the battery carrier.
INSTALL BATTERY CARRIER (for RHD)
Install the battery carrier with the 5 bolts.
| 17 N*m | 175 kgf*cm | 13 ft.*lbf |
Engage the 4 clamps and connect the wire harness onto the battery carrier.
INSTALL BATTERY TRAY
Install the battery tray onto the battery carrier.
INSTALL BATTERY
Install the battery onto the battery tray.
Install the battery clamp with the 2 nuts.
| 3.5 N*m | 36 kgf*cm | 31 in.*lbf |
Connect the cable to the positive (+) battery terminal.
| 5.4 N*m | 55 kgf*cm | 48 in.*lbf |
INSTALL AIR CLEANER BRACKET
Install the air cleaner No. 1 bracket with the 3 bolts.
| 20 N*m | 199 kgf*cm | 14 ft.*lbf |
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
| 5.4 N*m | 55 kgf*cm | 48 in.*lbf |
FILL CLUTCH ACTUATOR RESERVOIR WITH BRAKE FLUID (for Multi-Mode Manual Transaxle)
BLEED CLUTCH LINE
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE
Connect the No. 1 air cleaner hose to the turbocharger and fasten the air cleaner hose clamp.
| *a | Front Side |
| *b | RH Side |
| *c | Upper Mark |
Connect the ventilation hose to the cylinder head cover.
Connect the fuel hose to the hose clamp.
Install the air cleaner cap onto the air cleaner case, then hang the 2 lock clamps.
Fit the wire harness into the air cleaner cap.
Engage the 4 wire harness clamps.
Connect the mass air flow meter connector.
INSTALL RADIATOR RESERVE TANK BRACKET
Install the radiator reserve tank bracket with the bolt.
| 20 N*m | 199 kgf*cm | 14 ft.*lbf |
INSTALL RADIATOR RESERVE TANK ASSEMBLY
Install the reserve tank with the bolt.
| 20 N*m | 199 kgf*cm | 14 ft.*lbf |
Engage the hose clamp and connect the water by-pass hose assembly.
| *1 | No. 4 Water By-pass Hose |
| *2 | Water By-pass Hose Assembly |
| *a | View A |
| *b | View B |
| *c | Upper Side |
| *d | Rear Side |
| *e | Paint Mark |
Align the water by-pass hose assembly paint mark with the clamp center.
Connect the No. 4 water by-pass hose.
INSTALL OUTER COWL TOP PANEL (for LHD)
INSTALL OUTER COWL TOP PANEL (for RHD)
INSTALL INNER COWL TOP TO COWL BRACE (for LHD)
INSTALL INNER COWL TOP TO COWL BRACE (for RHD)
INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)
INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)
INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)
INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)
INSTALL FRONT WIPER MOTOR AND LINK
ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
ADD MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)
FILL RESERVOIR WITH BRAKE FLUID
INSPECT FLUID LEVEL
ADD ENGINE OIL
ADD ENGINE COOLANT
BLEED AIR FROM FUEL SYSTEM
INITIALIZATION AND REGISTRATION
INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE ECU (for Multi-Mode Manual Transaxle)
LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM (for Multi-Mode Manual Transaxle)
SYNCHRONIZATION POSITION CALIBRATION (for Multi-Mode Manual Transaxle)
CHARGE REFRIGERANT (w/ Air Conditioning System)
INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle)
INSPECT MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)
CHECK ENGINE OIL LEVEL
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
CHECK FUEL LEAK
INSPECT FOR EXHAUST GAS LEAK
WARM UP ENGINE (w/ Air Conditioning System)
INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)
INSTALL NO. 1 ENGINE COVER
Attach the No. 1 engine cover hooks to the bracket. Then align the No. 1 engine cover grommets with the 2 pins, and press down on the No. 1 engine cover to attach the pins.
| *1 | Pin |
| *2 | Grommet |
| *3 | Hook |
| *4 | Bracket |
INSTALL ENGINE UNDER COVER RH
| 5.0 N*m | 51 kgf*cm | 44 in.*lbf |
INSTALL ENGINE UNDER COVER LH
| 5.0 N*m | 51 kgf*cm | 44 in.*lbf |
INSTALL CENTER ENGINE UNDER COVER
| 5.0 N*m | 51 kgf*cm | 44 in.*lbf |
INSTALL FRONT WHEELS
| 103 N*m | 1050 kgf*cm | 76 ft.*lbf |
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
CHECK SPEED SENSOR SIGNAL (w/o VSC)
CHECK SPEED SENSOR SIGNAL (w/ VSC)