ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 front engine mounting insulator with the 2 nuts.

      Torque:
      76 N*m  { 775 kgf*cm, 56 ft.*lbf }

  2. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  3. REMOVE ENGINE FROM ENGINE STAND


    1. B001HGME01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Tech Tips

      Part No.

      No. 1 engine hanger 12284-30020
      No. 2 engine hanger 12282-67030
      Bolt 91552-81014 and 91642-81030
      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

    2. Attach an engine sling device and hang the engine with a chain block.

    3. Remove the engine from the engine stand.

  4. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. INSTALL PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)


    1. B001HZ4E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021
    2. B001DNME01
      Text in Illustration
      *1 Flywheel and Ring Gear
      *2 Pump Impeller Drive Plate
      *3 Rear Drive Plate Spacer
      *a Engine Side
      *b Transmission Side

      Install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

      Note

      Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer with the knock pin of the flywheel and ring gear, and then install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

      Tech Tips

      As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in the direction shown in the illustration.

    3. B001D2IE01

      Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

      Note

      Do not start the engine for at least an hour after installing the flywheel and ring gear.

      Torque:
      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

  6. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. Clean the bolts and their holes.

    2. Apply adhesive to 2 or 3 threads at the end of each bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B001HZ4E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    4. Install the flywheel to the crankshaft.

    5. B001HO1E02

      Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after installation.

  7. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  8. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  9. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  10. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Install the engine with the 4 bolts and 4 nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      For RHD vehicles only:

      B001I7ZE01

      When tightening the nut closer to the rear of the vehicle for the engine mounting bracket on the right side, make sure that the claw (stopper) of the bolt does not protrude past the rear edge of the bracket.

      Text in Illustration
      *1 Claw (Stopper)
      *2 Bracket
      *a Correct
      *b Incorrect

    3. Remove the 2 bolts and 2 engine hangers.

  11. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. Install the 4 bolts and rear No. 1 engine mounting insulator.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  12. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Install the automatic transmission Click here.

  13. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

    Click here

  14. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Install the manual transmission Click here.

  15. INSTALL OIL PAN INSULATOR


    1. Install the oil pan insulator with the 2 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

  16. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  17. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  19. INSTALL STARTER ASSEMBLY (for 2.2 kW Type)

    Click here

  20. INSTALL STARTER ASSEMBLY (for 2.7 kW Type)

    Click here

  21. INSTALL STARTER ASSEMBLY (for 3.0 kW Type)

    Click here

  22. CONNECT ENGINE WIRE


    1. B001EQ8E01
      Text in Illustration
      *1 Grommet
      *2 Wire Harness Support

      Attach the grommet to the wire harness support.

    2. B001EUKE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Pass the wire harness into the vehicle and install the wire harness support.

    3. B001F1OE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Connect the 9 connectors and attach the clamp.

    4. B001G0XE01
      Text in Illustration
      *A w/ KDSS
      *B w/o KDSS

      Install the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    5. B001FCP

      Connect the wire harness protector with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. B001HFS

      Connect the engine wire with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    7. B001FKG

      Install the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    8. B001EUU

      Attach the clamp and connect the connector.

    9. B001DVU

      Connect the 3 injection driver connectors and install the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    10. B001ER8

      Attach the 2 claws and install the nut.

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

    11. Install the No. 1 relay block cover.

  23. INSTALL GLOVE COMPARTMENT DOOR SUB-ASSEMBLY


    1. Install the glove compartment door Click here

  24. CONNECT FUEL HOSE


    1. Connect the No. 1 fuel hose and No. 2 fuel hose.

  25. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose.

  26. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose.

  27. CONNECT PRESSURE FEED TUBE ASSEMBLY


    1. Connect the pressure feed tube and a new gasket with the union bolt.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    2. Connect the power steering oil pressure switch connector.

  28. CONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY


    1. Temporarily install the vane pump oil reservoir with the 3 bolts.

    2. B001GHYE02

      Tighten the 3 bolts of the vane pump oil reservoir in the order shown in the illustration.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  29. INSTALL FUEL FILTER ASSEMBLY


    1. Install the fuel filter Click here.

  30. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install the diesel throttle body Click here.

  31. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Connect the cooler compressor with the 4 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    2. Connect the compressor connector.

  32. INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. Install the No. 1 viscous heater bracket with the 4 bolts.

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

  33. INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (for Cold Area Specification Vehicles)


    1. Install the viscous heater with magnet clutch with the 2 bolts.

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

    2. Connect the water by-pass hose and water hose.

    3. Connect the viscous heater connector.

  34. INSTALL COMPRESSOR OUTLET ELBOW

    Click here

  35. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  36. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  37. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  38. INSTALL NO. 1 AIR CLEANER HOSE

    Click here

  39. INSTALL BATTERY TRAY

  40. INSTALL BATTERY

  41. INSTALL BATTERY HOLD DOWN CLAMP


    1. Install the battery hold down clamp with the 2 nuts.

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

  42. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator Click here.

  43. ADD POWER STEERING FLUID

  44. ADD MANUAL TRANSMISSION OIL (for Manual Transmission)

    Click here

  45. INSPECT MANUAL TRANSMISSION OIL (for Manual Transmission)

    Click here

  46. ADD ENGINE OIL

    Click here

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  48. BLEED AIR FROM FUEL SYSTEM

    Click here

  49. ADD ENGINE COOLANT

    Click here

  50. INSPECT FOR COOLANT LEAK

    Click here

  51. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Install the cowl top ventilator louver Click here.

  52. INSTALL HOOD SUB-ASSEMBLY


    1. B001CHC

      Install the hood with the 8 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Text in Illustration
      B001CHY Bolt A
      B001DEF Bolt B

    2. Connect the washer nozzle hose.

  53. ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


    1. Add automatic transmission fluid Click here.

  54. INSPECT FOR POWER STEERING FLUID LEAK

  55. INSPECT FOR OIL LEAK

    Click here

  56. INSPECT FOR FUEL LEAK

    Click here

  57. INSPECT FOR EXHAUST GAS LEAK

    Click here

  58. INSPECT ENGINE IDLE SPEED AND MAXIMUMSPEED

    Click here

  59. INSPECT ENGINE OIL LEVEL

    Click here

  60. INSTALL REAR ENGINE UNDER COVER ASSEMBLY


    1. Install the rear engine under cover with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  61. INSTALL TRANSMISSION UNDER COVER


    1. Install the transmission under cover with the 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  62. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  63. INSTALL FRONT BUMPER LOWER COVER


    1. Install the lower front bumper cover with the clip and 5 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }