ENGINE ASSEMBLY 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.

Tech Tips

After replacing the engine assembly, perform the "Inspection After Repairs" Click here.

PROCEDURE


  1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  2. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    Click here

  3. INSTALL STARTER ASSEMBLY

    Click here

  4. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  5. INSTALL OUTLET WATER BY-PASS HOSE


    1. Connect the outlet water by-pass hose with the clip.

  6. INSTALL INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose A with the clip.

  7. INSTALL VENTILATION HOSE


    1. Connect the ventilation hose with the 2 clips.

  8. REMOVE ENGINE HANGER


    1. Remove the 2 bolts and the 2 engine hangers.

    2. Install the heated oxygen sensor wiring bracket with the bolt.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    3. Install the radio setting condenser with the bolt.

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

  9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine mounting insulator sub-assembly RH with the 3 bolts.

      Tech Tips

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

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

    2. Install the engine mounting insulator LH with the 5 bolts.

      Tech Tips

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

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

    3. Set the engine assembly with transaxle on the engine lifter.

    4. Operate the engine lifter and lift the engine assembly with transaxle into the position where the engine mounting insulators RH and LH can be installed.

      CAUTION:

      Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • Make sure that the engine is clear of all wiring and hoses.


      • While raising the engine into the vehicle, do not allow it to contact the vehicle.

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

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

    6. Install the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

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

    7. Provisionally install the front suspension crossmember onto the body with the 6 bolts.

      A005KN9E02
      Text in Illustration
      *a Datum Hole - -
      A005GO2 Front of the Vehicle - -

    8. 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.

      SST
      09670-00010
      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 in a vertical orientation.

      • If SST cannot be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.

  10. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT


    1. A005IU8E14
      Text in Illustration
      *1 Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the end of each of the 6 torque converter clutch setting bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Use SST to hold the crankshaft pulley in place.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    3. Install the 6 torque converter clutch setting bolts.

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

      Note

      First install the black-colored bolt, and then the remaining 5 silver-colored bolts.

  11. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  12. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  13. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. Install the drive shaft heat insulator sub-assembly with the bolt and nut.

      Torque:
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  16. CONNECT HEATED OXYGEN SENSOR CONNECTOR

    Click here

  17. INSTALL REAR CONSOLE BOX

    Click here

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

    Click here

  19. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  20. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  21. CONNECT ENGINE WIRE


    1. Install the transaxle earth wire of the engine room wire harness with the bolt.

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

    2. Connect the 2 connectors to the positive battery terminal.

    3. Engage the 3 clamps and connect the 2 connectors to the engine room relay block.

    4. A005H99

      Connect the engine wire harness connector to the ECM.

    5. Check that the engine wire is connected between the body and engine assembly with transaxle.

  22. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  23. CONNECT INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose A with the clamp.

  24. CONNECT OUTLET HEATER WATER HOSE A


    1. Connect the outlet heater water hose A with the clamp.

  25. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the booster vacuum tube.

  26. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube to the fuel pipe.

      CAUTION:

      Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

    2. Install the No. 1 fuel pipe clamp.

  27. INSTALL NO. 2 FUEL PIPE CLAMP


    1. Install the No. 2 fuel pipe clamp.

  28. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  29. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet.

  30. CONNECT RADIATOR RESERVOIR TANK HOSE


    1. Connect the radiator reservoir tank hose to the water filler.

  31. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the water filler.

  32. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. Connect the fuel vapor feed hose assembly with the 2 clips.

  33. INSTALL BATTERY CARRIER


    1. Install the battery carrier with the 5 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    2. Engage the 7 clamps to the battery carrier.

  34. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket with the 2 bolts.

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

    2. Connect the wire harness clamp to the air cleaner bracket.

  35. INSTALL AIR CLEANER ASSEMBLY


    1. Install the air cleaner case with the 2 bolts.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }
    2. A005J69

      Face the arrow shown in the illustration towards the front of the vehicle and install the air cleaner element.

    3. Install the air cleaner cap and air cleaner hose with the 2 clamps.

    4. Tighten the air cleaner hose clamp.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

    5. Engage the clamp and connect the No. 1 vacuum switching valve connector and hose.

    6. Engage the guide and 2 clips and connect the fuel vapor feed hose assembly.

    7. Engage the clamp and connect the intake mass air flow meter connector.

  36. INSTALL FAN AND GENERATOR V BELT

    Click here

  37. ADJUST FAN AND GENERATOR V BELT

    Click here

  38. INSPECT FAN AND GENERATOR V BELT

    Click here

  39. INSTALL BATTERY TRAY


    1. Install the battery tray to the battery carrier.

  40. INSTALL BATTERY


    1. Install the battery onto the vehicle with the battery clamp.

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

    2. Connect the cable to the battery terminal.

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

  41. INSTALL FRONT WHEELS

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

  42. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  43. ADD ENGINE OIL

  44. ADD ENGINE COOLANT

    Click here

  45. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  46. INSPECT FOR FUEL LEAK

    Click here

  47. INSPECT ENGINE OIL LEVEL

    Click here

  48. INSPECT FOR ENGINE OIL LEAK

  49. INSPECT FOR ENGINE COOLANT LEAK

    Click here

  50. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL

    Click here

  51. INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  52. INSPECT FOR EXHAUST GAS LEAK

  53. INSPECT IGNITION TIMING

    Click here

  54. INSPECT ENGINE IDLING SPEED

    Click here

  55. INSPECT CO/HC

    Click here

  56. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  57. INSTALL ENGINE UNDER COVER RH


    1. Install the engine under cover RH with the screw and 2 bolts.

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

  58. INSTALL ENGINE UNDER COVER LH


    1. Install the engine under cover LH with the 3 screws and 3 bolts.

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

  59. INSPECT ABS SENSOR SIGNAL

    Click here