ENGINE ASSEMBLY(w/o DPF) INSTALLATION

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


  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    B0045YKE03

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator RH is necessary.


    1. Temporarily tighten the engine mounting insulator RH with the 3 bolts.

    2. Fully tighten the 3 bolts, in the order shown in the illustration.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  2. INSTALL ENGINE MOUNTING INSULATOR LH

    B00485UE03

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator LH is necessary.


    1. Temporarily tighten the engine mounting insulator LH with the 5 bolts.

    2. Fully tighten the 5 bolts, in the order shown in the illustration.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Install the No. 1 crankshaft position sensor plate.

      B00460BE05
      Text in Illustration
      *1 Mark "RR" - -
      *a Engine Block Side - -

      Note

      Install the plate with the concave surface facing the cylinder block, as shown in the illustration.

  4. INSTALL FLYWHEEL SUB-ASSEMBLY

    B0047QME01

    1. Using SST, hold the crankshaft.

      SST
      09213-58014
      09330-00021

    2. Clean the 6 bolts and the 6 bolt holes.

    3. B00484KE52
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the 2 or 3 end threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    4. B0045R8E02

      Using several steps, uniformly install and tighten the 6 bolts in the order shown in the illustration (Procedure "A").

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    5. B0047FSE03
      Text in Illustration
      *a Paint Mark

      Mark the bolts with paint as shown in the illustration.

    6. Retighten the bolts 90° in the same sequence as in procedure "A".

    7. Check that the paint marks of each bolt are at a 90° angle from the original position.

  5. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  6. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

    2. B0045JNE14
      Text in Illustration
      *a Engine side
      *b Transaxle side

      Install the 2 ground bolts.

      Torque:
      Bolt A
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }
      Bolt B
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  7. INSTALL CYLINDER BLOCK SIDE COVER


    1. Install the cylinder block side cover with the bolt and washer plate.

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

  8. INSTALL EXHAUST MANIFOLD

    Click here

  9. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  10. INSTALL MANIFOLD STAY

    Click here

  11. INSTALL TURBOCHARGER STAY

    Click here

  12. TEMPORARILY TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  13. TEMPORARILY TIGHTEN MANIFOLD SUPPORT BRACKET

    Click here

  14. TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  15. TIGHTEN MANIFOLD SUPPORT BRACKET

    Click here

  16. INSTALL NO. 1 TURBO INSULATOR

    Click here

  17. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  18. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  19. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  20. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  21. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  22. INSTALL BLEEDER CLUTCH RELEASE TUBE

    Click here

  23. INSPECT CLUTCH PIPE LINE

    Click here

  24. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  25. INSTALL BLEEDER TO ACCUMULATOR TUBE

    Click here

  26. INSTALL ENGINE ASSEMBLY

    B00464WE01
    Text in Illustration
    *1 Reverse Restrict Pin Assembly
    *2 Outer Select Lever

    1. Hook the outer select lever of the manual transaxle to the reverse restrict pin assembly to secure it.

    2. 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.

    3. Align the input shaft with the clutch disc and install the engine to the manual transaxle.

    4. B00484QE01
      Text in Illustration
      *1 Knock Pin Hole

      Install the 8 bolts.

      Torque:
      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 }

      Note

      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.

  27. INSTALL STARTER ASSEMBLY (w/o Stop and Start System for Cold Area Specification Vehicles)

    Click here

  28. INSTALL STARTER ASSEMBLY (w/o Stop and Start System except Cold Area Specification Vehicles)

    Click here

  29. INSTALL NO. 2 AIR TUBE ASSEMBLY


    1. Insert the No. 1 air hose to the throttle body.

    2. B0047AYE01
      Text in Illustration
      *1 No. 1 Air Hose
      *a View A
      *b Front Side
      *c RH Side

      Install the No. 2 air tube assembly with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    3. Tighten the hose clamp.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Tech Tips

      Check the torque in an hour after tightening and confirm that it is 1.8 N*m or higher.

  30. INSTALL NO. 2 RADIATOR HOSE


    1. B0046AIE01
      Text in Illustration
      *a View A
      *b Upper Side
      *c RH Side

      Install the No. 2 radiator hose.

  31. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. B00483FE01
      Text in Illustration
      *a View A
      *b Upper Side

      Install the water by-pass hose assembly.

  32. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Place wooden blocks or plate lift attachments on an engine lifter, and then set the engine assembly with transaxle.

      Note


      • 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.

    2. 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.

    3. Install the engine mounting insulator LH with the through bolt and nut.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

      Tech Tips

      Tighten by holding the nut and turning the bolt.

    4. B00487SE02

      Install the engine mounting insulator RH with the bolt and 3 nuts.

      Torque:
      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 }

    5. Install the engine mounting stay with the 2 bolts.

      Torque:
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }

    6. 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.

      B0046G1E04
      Text in Illustration
      *a Datum Hole *b OK
      *c NG - -
      B0046MU Front of the Vehicle - -
      SST
      09670-00011
      Torque:
      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 }

      Note


      • Insert SST into the datum hole vertically.

      • If impossible to insert SST vertically, loosen all bolts and then insert SST again.

  33. INSTALL OIL PAN COVER

    Click here

  34. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  35. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  36. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  37. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  38. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  39. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  40. CONNECT ENGINE WIRE


    1. Engage the 2 claws and connect the wire harness to the junction block.

    2. Connect the 2 connectors to the engine junction block.

    3. Engage the wire harness clamp.

    4. Connect the ground wire with the bolt.

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

    5. Install the engine room junction block cover.

    6. B0046ND

      Connect the ECM connector and engage the harness clamp.

    7. Engage the wire harness clamp and connect the current sensor connector and glow relay connector.

    8. Connect the 3 connectors to the positive (+) battery terminal.

  41. INSTALL CLUTCH HOSE

    Click here

  42. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  43. INSTALL NO. 1 AIR TUBE

    B0046G8E03
    Text in Illustration
    *1 No. 1 Air Hose
    *a View A
    *b Front Side
    *c RH Side

    1. Insert the No. 1 air hose to the turbocharger.

    2. Install the No. 1 air tube with the 2 nuts.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

    3. Tighten the hose clamp.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    4. Connect the wire harness with the bolt.

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

  44. INSTALL NO. 3 AIR HOSE

    B0045SGE03
    Text in Illustration
    *a View A
    *b View B
    *c Upper Side
    *d Rear Side

    1. Install the No. 3 air hose.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  45. CONNECT NO. 2 RADIATOR HOSE


    1. B004642E05
      Text in Illustration
      *a View A
      *b Upper Side
      *c RH Side

      Connect the No. 2 radiator hose.

  46. INSTALL NO. 1 RADIATOR HOSE


    1. B0047R4E02
      Text in Illustration
      *a View A
      *b View B
      *c Upper Side
      *d LH Side

      Install the No. 1 radiator hose.

  47. INSTALL NO. 2 AIR HOSE

    B0045O4E02
    Text in Illustration
    *a View A
    *b View B
    *c Upper Side
    *d Rear Side

    1. Install the No. 2 air hose with the hose clamp.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  48. CONNECT INLET HEATER WATER HOSE


    1. B00468TE02
      Text in Illustration
      *a View A
      *b Upper Side
      *c Front Side

      Connect the inlet heater water hose.

  49. CONNECT OUTLET HEATER WATER HOSE


    1. B00484GE02
      Text in Illustration
      *a View A
      *b Upper Side
      *c LH Side

      Connect the outlet heater water hose.

  50. CONNECT NO. 2 FUEL HOSE SUB-ASSEMBLY

    B0046XUE01
    Text in Illustration
    *a View A
    *b View B
    *c Upper Side
    *d Front Side

    1. Connect the No. 2 fuel hose sub-assembly.

  51. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose.

  52. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  53. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

    Click here

  54. CONNECT COOLER REFRIGERANT SUCTION HOSE NO.1 (w/ Air Conditioning System)

    Click here

  55. INSTALL FAN AND GENERATOR V BELT

    Click here

  56. INSPECT FAN AND GENERATOR V BELT

    Click here

  57. INSTALL BATTERY CARRIER (for LHD)


    1. Install the battery carrier with the 5 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Engage the 3 clamps and connect the wire harness onto the battery carrier.

  58. INSTALL BATTERY CARRIER (for RHD)


    1. Install the battery carrier with the 5 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Engage the 4 clamps and connect the wire harness onto the battery carrier.

  59. INSTALL BATTERY TRAY


    1. Install the battery tray onto the battery carrier.

  60. INSTALL BATTERY


    1. Install the battery onto the battery tray.

    2. Install the battery clamp with the 2 nuts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  61. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner No. 1 bracket with the 3 bolts.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  63. BLEED CLUTCH LINE

    Click here

  64. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  65. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  66. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE

    B0046S0E01
    Text in Illustration
    *a Front Side
    *b RH Side
    *c Upper Mark

    1. Connect the No. 1 air cleaner hose to the turbocharger and fasten the air cleaner hose clamp.

    2. Connect the ventilation hose to the cylinder head cover.

    3. Connect the fuel hose to the hose clamp.

    4. Install the air cleaner cap onto the air cleaner case, then hang the 2 lock clamps.

    5. Fit the wire harness into the air cleaner cap.

    6. Engage the 4 wire harness clamps.

    7. Connect the mass air flow meter connector.

  67. INSTALL RADIATOR RESERVE TANK BRACKET


    1. Install the radiator reserve tank bracket with the bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

  68. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. Install the reserve tank with the bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }
    2. B0047ELE03
      Text in Illustration
      *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

      Engage the hose clamp and connect the water by-pass hose assembly.

      Note

      Align the water by-pass hose assembly paint mark with the clamp center.

    3. Connect the No. 4 water by-pass hose.

  69. INSTALL OUTER COWL TOP PANEL (for LHD)

    Click here

  70. INSTALL OUTER COWL TOP PANEL (for RHD)

    Click here

  71. INSTALL INNER COWL TOP TO COWL BRACE (for LHD)

    Click here

  72. INSTALL INNER COWL TOP TO COWL BRACE (for RHD)

    Click here

  73. INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)

    Click here

  74. INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)

    Click here

  75. INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)

    Click here

  76. INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)

    Click here

  77. INSTALL FRONT WIPER MOTOR AND LINK

    Click here

  78. ADD MANUAL TRANSAXLE OIL

    Click here

  79. FILL RESERVOIR WITH BRAKE FLUID

    Click here

  80. INSPECT FLUID LEVEL

    Click here

  81. ADD ENGINE OIL

    Click here

  82. ADD ENGINE COOLANT

    Click here

  83. BLEED AIR FROM FUEL SYSTEM

    Click here

  84. INITIALIZATION AND REGISTRATION

    Click here

  85. CHARGE REFRIGERANT (w/ Air Conditioning System)

    Click here

  86. INSPECT MANUAL TRANSAXLE OIL

    Click here

  87. CHECK ENGINE OIL LEVEL

    Click here

  88. INSPECT FOR OIL LEAK

    Click here

  89. INSPECT FOR COOLANT LEAK

    Click here

  90. CHECK FUEL LEAK

    Click here

  91. INSPECT FOR EXHAUST GAS LEAK

  92. WARM UP ENGINE (w/ Air Conditioning System)

  93. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

    Click here

  94. INSTALL NO. 1 ENGINE COVER

    B0045SVE02
    Text in Illustration
    *1 Pin
    *2 Grommet
    *3 Hook
    *4 Bracket

    1. 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.

  95. INSTALL ENGINE UNDER COVER RH

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

  96. INSTALL ENGINE UNDER COVER LH

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

  97. INSTALL CENTER ENGINE UNDER COVER

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

  98. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  99. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  100. CHECK SPEED SENSOR SIGNAL (w/o VSC)

    Click here

  101. CHECK SPEED SENSOR SIGNAL (w/ VSC)

    Click here