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. SUSPEND ENGINE ASSEMBLY


    1. Using a sling device and a chain block, suspend the engine assembly.

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Remove the engine from the engine stand.

  3. INSTALL INNER OIL SEAL (w/ Stop and Start System)

    Click here

  4. INSTALL RING GEAR SUB-ASSEMBLY (w/ Stop and Start System)

    Click here

  5. INSTALL ONE-WAY CLUTCH ASSEMBLY (w/ Stop and Start System)

    Click here

  6. INSTALL FLYWHEEL SUB-ASSEMBLY (w/ Stop And Start System)

    Click here

  7. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  8. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

  9. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  10. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

    Click here

  11. INSTALL WATER BY-PASS HOSE ASSEMBLY (for CVT)


    1. Connect the water by-pass hose assembly with the clamp.

  12. INSTALL WATER HOSE SUB-ASSEMBLY (for Manual Transaxle)

    Tech Tips

    Use the same procedure for the water by-pass hose assembly.

  13. INSTALL WATER HOSE SUB-ASSEMBLY B (for CVT)


    1. Connect the water hose sub-assembly B with the clamp.

  14. INSTALL WATER HOSE SUB-ASSEMBLY B (for Manual Transaxle)

    Tech Tips

    Use the same procedure for the water hose subassembly B.

  15. INSTALL ENGINE WIRE


    1. Install the engine wire to the cylinder head cover with the 2 nuts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Install the 2 ground wires to the cylinder head with the 2 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  16. INSTALL GENERATOR ASSEMBLY

    Click here

  17. REMOVE ENGINE HANGER


    1. Remove the 2 bolts and 2 engine hangers.

  18. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  19. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  20. 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.

  21. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT


    1. Clean and degrease the 6 drive plate and torque converter setting bolts.

    2. A005IU8E28
      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

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

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

    4. Install the 6 torque converter set 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.

  22. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  23. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  24. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  25. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  26. INSTALL FRONT FLOOR CENTER BRACE


    1. Install the front floor center brace with the 2 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  27. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  28. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. Install the drive shaft heat insulator sub-assembly with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

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

    Click here

  30. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  31. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  32. CONNECT ENGINE WIRE


    1. Connect the connector to the negative battery terminal.

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

    3. Install the ground wire to the body with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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

    5. Install the engine room relay block cover.

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

  33. CONNECT ECM CONNECTOR (for LHD)


    1. A005GK6

      Connect the engine wire connector to the ECM.

    2. Engage the clamp and install the engine wire to the wire harness clamp bracket.

  34. CONNECT ECM CONNECTOR (for RHD)


    1. A005I1V

      Connect the engine wire connector to the ECM.

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

    Click here

  36. INSTALL CLUTCH HOSE (for Manual Transaxle)

    Click here

  37. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

    (See page MULTIDRIVE / CVT (K310) > TRANSMISSION CONTROL CABLE > INSTALLATION > INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY)

  38. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    Click here

  39. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  40. INSTALL EFI FUEL PIPE CLAMP

    Click here

  41. INSTALL WATER HOSE SUB-ASSEMBLY B


    1. Connect the water hose subassembly B with the clamp.

  42. INSTALL INLET HEATER WATER HOSE A


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

  43. CONNECT NO. 2 RADIATOR HOSE


    1. A005JE1E01
      Text in Illustration
      *a View A
      *b Upper Side

      Connect the No. 2 radiator hose with the clamp.

  44. CONNECT NO. 1 RADIATOR HOSE


    1. A005GMGE01
      Text in Illustration
      *a View A
      *b Upper Side
      *c Rear Side

      Connect the No. 1 radiator hose with the clamp.

  45. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the intake manifold.

  46. INSTALL AIR CLEANER AND HOSE ASSEMBLY


    1. Connect the air cleaner hose to the throttle body.

    2. Connect the No. 2 ventilation hose to the air cleaner hose.

    3. Connect the No. 1 fuel vapor feed hose and the No. 2 fuel vapor feed hose to the No. 1 vacuum switching valve assembly.

    4. Connect the No. 1 vacuum switching valve assembly connector and engage the clamp.

    5. Install the air cleaner case to the cylinder head cover with the 2 bolts.

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

    6. Connect the intake mass air flow meter connector and engage the clamp.

  47. INSTALL INLET NO. 1 AIR CLEANER


    1. Install the inlet No. 1 air cleaner to the cylinder head cover with the bolt.

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

  48. 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 3 clamps and connect the wire harness to the battery carrier.

  49. INSTALL BATTERY TRAY


    1. Install the battery tray to the battery carrier.

  50. INSTALL BATTERY


    1. Install the battery to the battery tray.

    2. Install the battery carrier clamp with the nut.

      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 }

  51. INSTALL FAN AND GENERATOR V BELT

    Click here

  52. INSTALL OUTER COWL TOP PANEL (for LHD)


    1. Install the outer cowl top panel with the 6 bolts.

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

  53. INSTALL OUTER COWL TOP PANEL (for RHD)

    Tech Tips

    Use the same procedure for the RH and LH sides.

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


    1. Install the cowl top to cowl brace with the 2 bolts.

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

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

    Tech Tips

    Use the same procedure for the RH and LH sides.

  56. INSTALL INNER COWL TOP REINFORCEMENT (for LHD)

    Click here

  57. INSTALL INNER LOWER COWL TOP REINFORCEMENT (for RHD)

    Click here

  58. INSTALL COWL TOP INSIDE CORNER PANEL LH (for LHD)

    Click here

  59. INSTALL COWL TOP INSIDE CORNER PANEL RH (for RHD)

    Click here

  60. INSTALL FRONT NO. 1 VENTILATOR SEAL


    1. Engage the clip and install the front No. 1 ventilator seal.

  61. INSTALL FRONT AIR SHUTTER SEAL RH

    Tech Tips

    Use the same procedure for the front No. 1 ventilator seal.

  62. INSTALL WINDSHIELD WIPER LINK ASSEMBLY

    Click here

  63. INSTALL FRONT WHEELS

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

  64. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  65. ADD ENGINE OIL

    Click here

  66. ADD ENGINE COOLANT

    Click here

  67. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  68. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  69. BLEED CLUTCH PIPE LINE (for Manual Transmission)

    Click here

  70. INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  71. INSPECT FOR FUEL LEAK

    Click here

  72. INSPECT ENGINE OIL LEVEL

    Click here

  73. INSPECT FOR ENGINE OIL LEAK

  74. INSPECT FOR ENGINE COOLANT LEAK

    Click here

  75. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL

    Click here

  76. INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK (for CVT)

  77. INSPECT MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

  78. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)

  79. INSPECT FOR EXHAUST GAS LEAK

  80. INSPECT IGNITION TIMING

    Click here

  81. INSPECT ENGINE IDLING SPEED

    Click here

  82. INSPECT CO/HC

    Click here

  83. INSTALL NO. 1 ENGINE COVER


    1. Engage the 3 clamps and install the No. 1 engine cover to the cylinder head cover.

  84. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  85. 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 }

  86. 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 }

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

    Click here

  88. CHECK SPEED SENSOR SIGNAL (w/ VSC)

    Click here