CAUTION / NOTICE / HINT
Note
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 HANGER
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tech Tips
Only perform this procedure when replacement of the engine mounting insulator sub-assembly RH is necessary.
Temporarily tighten the engine mounting insulator sub-assembly RH to the vehicle with the 3 bolts.
Fully tighten the 3 bolts, in the sequence shown in the illustration.
INSTALL ENGINE MOUNTING INSULATOR LH
Tech Tips
Only perform this procedure when replacement of the engine mounting insulator LH is necessary.
Temporarily tighten the engine mounting insulator LH to the vehicle with the 5 bolts.
Fully tighten the 5 bolts, in the sequence shown in the illustration.
REMOVE ENGINE STAND
Using a chain block and a sling device, secure the engine assembly.
Remove the engine stand from the engine assembly.
INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
Install the No. 1 crankshaft position sensor plate to the crankshaft.
| *a | Mark "RR" | *b | Cylinder Block Sub-assembly Side |
Note
Install the No. 1 crankshaft position sensor plate with the concave surface facing the cylinder block sub-assembly, as shown in the illustration.
INSTALL FLYWHEEL SUB-ASSEMBLY
Using SST, hold the crankshaft damper sub-assembly.
Clean the 6 bolts and 6 bolt holes.
| *a | Adhesive |
Apply adhesive to the 2 or 3 threads at the end of the 6 bolts.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. |
Note
To prevent contamination by foreign matter, install immediately after apply adhesive.
Using several steps, uniformly install and tighten the flywheel sub-assembly with the 6 bolts in the sequence shown in the illustration (Procedure "A").
| *a | Paint Mark |
Mark the bolts with paint as shown in the illustration.
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
INSTALL CYLINDER BLOCK SIDE COVER
Install the cylinder block side cover and plate washer to the cylinder block sub-assembly with the bolt.
INSTALL EXHAUST MANIFOLD
INSTALL TURBOCHARGER SUB-ASSEMBLY
INSTALL MANIFOLD STAY
INSTALL TURBOCHARGER STAY
INSTALL TURBO WATER PIPE SUB-ASSEMBLY
CONNECT NO. 2 TURBO WATER HOSE
CONNECT NO. 1 TURBO WATER HOSE
INSTALL MANIFOLD SUPPORT BRACKET
Install the manifold support bracket to the cylinder block sub-assembly with the 3 bolts.
INSTALL EXHAUST MANIFOLD
Install a new gasket to the turbocharger sub-assembly.
Temporarily install the exhaust manifold to the turbocharger sub-assembly, No. 1 converter support bracket, manifold stay and No. 2 converter support bracket with the 4 bolts and 3 new nuts.
Fully tighten the 4 bolts, 3 nuts, in the sequence shown in the illustration.
Engage the clamp to connect the exhaust gas temperature sensor wire to the wiring harness clamp bracket.
Engage the claw to connect the exhaust gas temperature sensor wire connector to the wiring harness clamp bracket.
Install the wiring harness clamp bracket to the timing chain cover assembly with the bolt.
Connect the exhaust gas temperature sensor connector.
Connect the camshaft position sensor connector.
INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY
INSTALL NO. 4 CONVERTER SUPPORT BRACKET
INSTALL NO. 5 CONVERTER SUPPORT BRACKET
INSTALL NO. 2 PIPE
INSTALL TURBO INSULATOR
INSTALL SENSOR BRACKET
INSTALL WIRING HARNESS CLAMP BRACKET
Install the wiring harness clamp bracket to the cylinder head cover sub-assembly.
INSTALL NO. 2 ENGINE COVER BRACKET
INSTALL DIFFERENTIAL PRESSURE SENSOR
INSTALL WIRING HARNESS CLAMP BRACKET
INSTALL NO. 1 WIRING HARNESS HEAT INSULATOR
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
INSTALL BLEEDER CLUTCH RELEASE TUBE
INSPECT CLUTCH PIPE LINE
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSTALL BLEEDER TO ACCUMULATOR TUBE
INSTALL ENGINE ASSEMBLY
Hook the outer select lever of the manual transaxle assembly to the reverse restrict pin assembly to secure it.
| *1 | Reverse Restrict Pin Assembly |
| *2 | Outer Select Lever |
Check that the 2 knock pins are installed on the engine assembly before installing the manual transaxle assembly.
Make sure that the knock pins are not loose, bent, damaged or scratched and then install the engine to the manual transaxle assembly with the contact surfaces of the engine assembly and manual transaxle assembly flat against each other.
Align the input shaft with the clutch disc and install the engine assembly to the manual transaxle assembly.
| *a | Knock Pin Hole |
Install the 8 bolts.
Note
Insert knock pins into the knock pin holes securely so that the end face of the manual transaxle assembly fits close against the engine assembly before tightening the bolts.
INSTALL ENGINE WIRE
Connect all the wire harnesses and connectors.
Connect the engine wire to the engine assembly and manual transaxle assembly with the 4 bolts.
REMOVE STARTER ASSEMBLY (w/ Stop And Start System)
INSTALL STARTER ASSEMBLY (w/o Stop and Start System for Cold Area Specification Vehicles)
INSTALL STARTER ASSEMBLY (w/o Stop and Start System except Cold Area Specification Vehicles)
TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Temporarily install the front suspension crossmember sub-assembly to the engine moving control rod bracket with the bolt.
INSTALL NO. 2 AIR TUBE ASSEMBLY
| *a | View A |
| *b | Front of Vehicle |
| *c | RH of Vehicle |
Insert the No. 1 air hose to the diesel throttle body assembly.
Install the No. 2 air tube assembly to the cylinder block sub-assembly with the bolt.
Tighten the hose clamp.
Note
Perform the installation with the hose clip at the correct angle.
Tech Tips
Check the torque in an hour after tightening and confirm that it is 1.8 N*m or higher.
INSTALL NO. 2 RADIATOR HOSE
| *a | View A |
| *b | Upper of Vehicle |
| *c | RH of Vehicle |
Install the No. 2 radiator hose to the water inlet and slide the hose clip to secure it.
Note
Perform the installation with the hose clip at the correct angle.
INSTALL WATER BY-PASS HOSE ASSEMBLY
| *a | View A |
| *b | Upper of Vehicle |
| *c | RH of Vehicle |
Install the water by-pass hose assembly to the water inlet and slide the hose clip to secure it.
Note
Perform the installation with the hose clip at the correct angle.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Place height adjustment or plate lift attachments on an engine lifter, and then set the engine assembly with transaxle.
Note
Place the height adjustment 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 front suspension crossmember to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.
Connect the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut.
Tech Tips
Tighten by holding the nut and turning the through bolt.
Connect the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the bolt and 3 nuts.
Install the engine mounting stay to the engine mounting insulator sub-assembly and engine mounting bracket RH with the 2 bolts.
By inserting SST into the datum holes in the front suspension crossmember sub-assembly RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps.
| *a | Datum Hole | *b | Correct |
| *c | Incorrect | - | - |
|
Front of Vehicle | - | - |
Note
Insert SST into the datum hole vertically.
If impossible to insert SST vertically, loosen all bolts and then insert SST again.
Fully tighten the bolt of the engine moving control rod.
INSTALL OIL PAN COVER
Install the oil pan cover to the oil pan sub-assembly with the 2 plate washers and 2 bolts.
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 ENGINE WIRE (for LHD)
Engage the 2 claws and connect the engine wire to the engine room junction block.
Connect the 2 connectors to the engine room relay block.
Engage the clamp to connect the engine wire to the vehicle.
Connect the engine wire to the vehicle with the bolt.
Install the relay block cover.
Pull down the lever to engage the lock and connect the connector to the ECM.
Note
Make sure that the levers are securely locked.
Engage the clamp to connect the engine wire to the wiring harness clamp bracket.
Engage the clamp and connect the engine wire to the bracket.
Connect the current sensor connector.
Connect the 3 connectors to the positive (+) battery terminal.
CONNECT ENGINE WIRE (for RHD)
Engage the 2 claws and connect the engine wire to the engine room junction block.
Connect the 2 connectors to the engine room relay block.
Engage the clamp to connect the engine wire to the vehicle.
Connect the engine wire to the vehicle with the bolt.
Install the relay block cover.
Pull down the lever to engage the lock and connect the connector to the ECM.
Note
Make sure that the levers are securely locked.
Engage the clamp and connect the engine wire to the bracket.
Connect the current sensor connector.
Connect the 3 connectors to the positive (+) battery terminal.
INSTALL CLUTCH HOSE
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
INSTALL NO. 1 AIR TUBE
| *a | View A |
| *b | LH of Vehicle |
| *c | Front of Vehicle |
Insert the No. 1 air hose to the turbocharger sub-assembly.
Install the No. 1 air tube to the air tube support with the 2 nuts.
Tighten the hose clamp.
Connect the engine wire to the No. 1 air tube with the bolt and nut.
INSTALL NO. 3 AIR HOSE
| *a | View A |
| *b | View B |
| *c | Upper of Vehicle |
| *d | Front of Vehicle |
| *e | Rear of Vehicle |
Install the No. 3 air hose to the No. 2 air tube assembly and intercooler assembly and tighten the hose clamp to secure it.
Note
Perform the installation with the hose clamp at the correct angle.
CONNECT NO. 2 RADIATOR HOSE
INSTALL NO. 1 RADIATOR HOSE
| *a | View A |
| *b | View B |
| *c | Upper of Vehicle |
| *d | LH of Vehicle |
Install the No. 1 radiator hose to the water outlet sub-assembly and radiator assembly and slide the 2 hose clips to secure it.
Note
Perform the installation with the hose clips at the correct angle.
INSTALL NO. 2 AIR HOSE
| *a | View A |
| *b | View B |
| *c | Upper of Vehicle |
| *d | RH of Vehicle |
| *e | Front of Vehicle |
Install the No. 2 air hose to the No. 1 air tube and intercooler assembly and tighten the hose clamp to secure it.
Note
Perform the installation with the hose clamp at the correct angle.
CONNECT OUTLET HEATER WATER HOSE
| *a | View A |
| *b | Upper of Vehicle |
| *c | LH of Vehicle |
Connect the outlet heater water hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.
Note
Perform the installation with the hose clip at the correct angle.
CONNECT INLET HEATER WATER HOSE
| *a | View A |
| *b | Upper of Vehicle |
| *c | LH of Vehicle |
Connect the inlet heater water hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.
Note
Perform the installation with the hose clip at the correct angle.
CONNECT NO. 1 FUEL HOSE SUB-ASSEMBLY
CONNECT UNION TO CONNECTOR TUBE HOSE
Connect the union to connector tube hose to the vacuum pump assembly and slide the hose clip to secure it.
INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)
CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (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 to the engine mounting insulator and vehicle with the 5 bolts.
Engage the 3 clamps and connect the engine wire to the battery carrier.
INSTALL BATTERY CARRIER (for RHD)
Install the battery carrier to the engine mounting insulator and vehicle with the 5 bolts.
Engage the 4 clamps and connect the engine wire to the battery carrier.
INSTALL BATTERY TRAY
Install the battery tray to the battery carrier.
INSTALL BATTERY
Install the battery to the battery tray.
Install the battery clamp to the battery carrier with the 2 nuts.
Connect the cable to the positive (+) battery terminal with the nut.
INSTALL AIR CLEANER BRACKET
Install the air cleaner bracket to the vehicle with the 3 bolts.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
BLEED CLUTCH LINE
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE
| *a | View A |
Connect the No. 1 air cleaner hose to the compressor inlet elbow sub-assembly with the hose clamp.
Note
Perform the installation with the hose clamp at the correct angle.
Connect the ventilation hose to the cylinder head cover sub-assembly and slide the hose clip to secure it.
Note
Make sure the claw of the hose clip does not interfere with the fuel temperature sensor.
Connect the fuel hose clamp to the air cleaner hose.
Engage the 2 clamps and 2 guides to install the air cleaner cap to the air cleaner case sub-assembly.
Engage the 4 clamps to connect the wire harness to the air cleaner cap.
Connect the mass air flow meter connector.
INSTALL RADIATOR RESERVE TANK BRACKET
Install the radiator reserve tank bracket to the engine mounting insulator sub-assembly RH with the bolt.
INSTALL RADIATOR RESERVE TANK ASSEMBLY
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
FILL RESERVOIR WITH BRAKE FLUID
INSPECT FLUID LEVEL
ADD ENGINE OIL
ADD ENGINE COOLANT
BLEED AIR FROM FUEL SYSTEM
INITIALIZATION AND REGISTRATION
CHARGE REFRIGERANT (w/ Air Conditioning System)
INSPECT MANUAL TRANSAXLE OIL
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
| *1 | Pin |
| *2 | Grommet |
| *3 | No. 2 Engine Cover Bracket |
| *a | No. 1 Engine Cover Hook |
Attach the No. 1 engine cover hooks to the No. 2 engine cover bracket. Then align the 2 No. 1 engine cover grommets with the 2 pins, and press down on the No. 1 engine cover to attach the pins.
INSTALL ENGINE UNDER COVER RH
Install the engine under cover RH to the vehicle with the 2 bolts.
INSTALL ENGINE UNDER COVER LH
Install the engine under cover LH to the vehicle with the 2 bolts.
INSTALL CENTER ENGINE UNDER COVER
Install the center engine under cover to the vehicle with the bolt, 2 clips and 7 screws.
INSTALL FRONT WHEELS
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
CHECK SPEED SENSOR SIGNAL (w/o VSC)
CHECK SPEED SENSOR SIGNAL (w/ VSC)