ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 front engine mounting insulators to the 2 front engine mounting brackets with the 2 nuts.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  2. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  3. INSTALL NO. 2 ENGINE HANGER

    Click here

  4. REMOVE ENGINE FROM ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.


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

    2. Remove the engine assembly from the engine stand.

  5. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine assembly into the engine compartment.

    2. Install the engine assembly to the body with the 4 bolts and 4 nuts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Tech Tips


      • Make sure to tighten the side with the nut.

      • When installing a bolt with a claw (stopper), make sure that the claw (stopper) does not damage the body of the vehicle.

    3. Remove the bolt and No. 2 engine hanger.

  6. INSTALL FLYWHEEL HOUSING DUST SEAL

  7. INSTALL REAR END PLATE


    1. Install the rear end plate with the 2 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  8. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Clean the bolts and bolt holes.

    2. B0025PIE02

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Temporarily install the flywheel sub-assembly to the crankshaft with the 8 bolts.

    5. B00290SE02

      Tighten the 8 bolts uniformly in several steps in the order shown in the illustration.

      Torque:
      122.5 N*m  { 1249 kgf*cm, 90 ft.*lbf }

      Note

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

  9. INSTALL CLUTCH DISC ASSEMBLY

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  10. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  11. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  12. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  13. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. INSTALL GENERATOR ASSEMBLY

    Click here

  16. INSTALL VANE PUMP ASSEMBLY


    1. Temporarily install the vane pump assembly with the 2 bolts and nut.

    2. B0024YBE03

      Install the vane pump pulley to the vane pump assembly shaft.

    3. Using SST, hold the pulley and install the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  17. CONNECT COMPRESSOR ASSEMBLY WITH MAGNET CLUTCH (w/ Air Conditioning System)


    1. Connect the compressor assembly with magnet clutch to the No. 1 compressor mounting bracket with the 4 bolts.

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

  18. CONNECT FUEL HOSE


    1. Connect the 2 fuel hoses to the injection pump assembly, and slide the 2 clamps to secure the hose.

  19. CONNECT HEATER WATER HOSE ASSEMBLY


    1. Install the bolt, connect the heater water hose assembly to the engine assembly, and slide the 2 clamps to secure the 2 hoses.

      Torque:
      18.1 N*m  { 185 kgf*cm, 13 ft.*lbf }

  20. INSTALL BATTERY TRAY

  21. INSTALL BATTERY

  22. INSTALL BATTERY HOLD DOWN CLAMP


    1. Install the battery clamp sub-assembly to the battery with the 2 nuts.

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

  23. CONNECT WIRE HARNESS


    1. Connect the engine room main wire to the battery positive cable with the nut.

      Torque:
      7.1 N*m  { 72 kgf*cm, 63 in.*lbf }

    2. Attach the clamp and connect the No. 2 engine wire with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    3. Connect the 2 connectors to the engine room relay block sub-assembly.

    4. Connect the wire to wire to the engine room relay block sub-assembly with the nut.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    5. Attach the 2 clips and install the No. 1 relay block side cover to the engine room relay block sub-assembly.

    6. Attach the 3 clips and install the No. 1 relay block upper cover to the engine room relay block sub-assembly.

  24. INSTALL INTAKE PIPE

    Click here

  25. INSTALL AIR CLEANER CASE ASSEMBLY


    1. Install the air cleaner case assembly with the 3 bolts.

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

  26. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  27. INSTALL AIR CLEANER CAP AND HOSE


    1. Install the air cleaner cap and hose.

    2. Attach the 4 clips.

    3. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    4. Connect the connector to the intake air temperature sensor and attach the 5 wire harness clamps.

  28. CONNECT ENGINE WIRE


    1. Pass the engine wire into the cabin.

    2. Attach the grommet to the body.

      Tech Tips

      Make sure the direction of the grommet is as shown in the illustration.

      B0026LMN01

    3. Attach the 2 wire harness clamps to connect the engine wire to the wire harness bracket.

    4. Attach the 2 clamps and connect the 3 connectors to the instrument panel wire.

    5. Install the ECM.

      Click here

  29. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  30. INSTALL RADIATOR ASSEMBLY

    Click here

  31. INSTALL FAN AND GENERATOR V BELT

    Click here

  32. INSTALL COOLER COMPRESSOR V BELT (w/ Air Conditioning System)

    Click here

  33. INSTALL VANE PUMP V BELT

    Click here

  34. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood sub-assembly to the 2 hood hinge assemblies with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. Connect the washer nozzle hose to the hood sub-assembly.

  35. ADD POWER STEERING FLUID

  36. ADD MANUAL TRANSMISSION OIL

    Click here

  37. ADD ENGINE OIL

    Click here

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  39. BLEED AIR FROM FUEL SYSTEM

    Click here

  40. ADD ENGINE COOLANT

    Click here

  41. BLEED AIR FROM POWER STEERING SYSTEM

    Click here

  42. INSPECT POWER STEERING FLUID LEVEL

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  43. INSPECT FOR COOLANT LEAK

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  44. INSPECT FOR OIL LEAK

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  45. INSPECT FOR EXHAUST GAS LEAK

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  46. INSPECT FOR FUEL LEAK

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  47. CHECK ENGINE IDLE SPEED AND MAXIMUM SPEED

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  48. INSPECT ENGINE OIL LEVEL

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  49. INSTALL NO. 2 ENGINE UNDER COVER

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  50. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Torque:
    for M6 bolt
    11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }
    for M8 bolt
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }