ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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.

PROCEDURE

  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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

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

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  2. INSTALL ENGINE MOUNTING INSULATOR LH

    Tip:

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    1. Install the engine mounting insulator LH with the 4 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tip:

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    1. A295905N01

      Install the rear engine mounting insulator with the 2 bolts and 2 nuts in the order shown in the illustration.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  4. INSTALL ENGINE HANGER

    Click here

  5. 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 while it is suspended, as doing so is dangerous.

    1. Install a sling device and chain block to the engine and hang the engine.

    2. Remove the engine from the engine stand.

  6. FIX ENGINE ASSEMBLY

    Click here

  7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    1. A297509N01

      Using SST, hold the crankshaft pulley.

      09213-58014

      91551-80840

      09330-00021

    2. A215653C01

      *1

      Drive Plate and Ring Gear Sub-assembly

      *2

      Rear Drive Plate Spacer

      *3

      Front Drive Plate Spacer

      (Reversible)

      *a

      Engine Side

      *b

      Transaxle Side

      Install the front drive plate spacer, drive plate and ring gear sub-assembly and rear drive plate spacer to the crankshaft.

      Tip:

      • The front drive plate spacer is reversible.

      • As the rear drive plate spacer and drive plate and ring gear sub-assembly are not reversible, be sure to install them so that they are facing in the direction shown in the illustration.

    3. A057108C43

      *1

      Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the end of each of the 8 bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. A297522N01

      Install and uniformly tighten the 8 bolts in several steps, in the sequence shown in the illustration.

      92 N*m

      938 kgf*cm

      68 ft.*lbf

      Note:

      Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.

  8. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  9. INSTALL STIFFENER PLATE LH

    1. A297523N01

      Temporarily install the stiffener plate LH with the 4 bolts.

    2. While holding the stiffener plate LH against the automatic transaxle assembly, tighten bolt A, and then tighten bolts B, C and D.

      46 N*m

      469 kgf*cm

      34 ft.*lbf

  10. INSTALL STIFFENER PLATE RH

    1. A297524N01

      Temporarily install the stiffener plate RH with the 4 bolts.

    2. While holding the stiffener plate RH against the automatic transaxle assembly, tighten bolt A, and then tighten bolts B, C and D.

      46 N*m

      469 kgf*cm

      34 ft.*lbf

  11. INSTALL OIL PAN INSULATOR

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

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  12. INSTALL ENGINE MOUNTING BRACKET LH

    Tip:

    Perform this procedure only when replacement of the engine mounting bracket LH is necessary.

    1. Install the engine mounting bracket LH with the 4 bolts.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  13. INSTALL REAR ENGINE MOUNTING BRACKET

    1. Temporarily install the rear engine mounting bracket with the 4 bolts.

    2. A297541N01

      Tighten the 4 bolts of the rear engine mounting bracket in the order shown in the illustration.

      45 N*m

      459 kgf*cm

      33 ft.*lbf

  14. INSTALL FRONT ENGINE MOUNTING BRACKET

    1. A299157N01

      Temporarily install the front engine mounting bracket with the 4 bolts.

    2. Tighten the 4 bolts of the front engine mounting bracket in the order shown in the illustration.

      64 N*m

      653 kgf*cm

      47 ft.*lbf

  15. INSTALL ENGINE WIRE

    Click here

  16. INSTALL STARTER ASSEMBLY

    Click here

  17. INSTALL NO. 1 AIR TUBE

    1. Install the No. 1 air tube with the 2 bolts and tighten the clamp.

      for bolt

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      for clamp

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      Before installation, remove any oil residue from the inside of the No. 1 air tube and air hose.

  18. INSTALL ENGINE WITH TRANSAXLE

    1. Temporarily install the front engine mounting insulator with the through bolt and nut.

    2. A295909C01

      *1

      Alignment Mark

      *2

      Protrusion

      Temporarily install the front suspension member sub-assembly with the through bolt.

      Tip:

      When installing the front suspension member sub-assembly, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

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

      Tip:

      Place the engine on wooden blocks or equivalent so that the engine is level.

    4. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator LH and engine mounting insulator sub-assembly RH 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.

      • Align the matchmarks on the intermediate shaft and pinion.

    5. Temporarily install the 2 bolts to the front suspension member sub-assembly.

    6. Temporarily install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts.

    7. Connect the engine mounting insulator LH with the bolt and nut.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

      Tip:

      While holding the bolt in place, tighten the nut.

    8. A297529N01

      Connect the engine mounting insulator sub-assembly RH with the 2 bolts and 2 nuts.

      for bolt and nut A

      95 N*m

      969 kgf*cm

      70 ft.*lbf

      for nut B

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    9. A273397E01

      Tighten the 8 bolts.

      for bolt A

      137 N*m

      1397 kgf*cm

      101 ft.*lbf

      for bolt B

      93 N*m

      948 kgf*cm

      69 ft.*lbf

    10. A297527N01

      Install the front crossmember sub-assembly with the 6 bolts.

      for bolt A

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

      for bolt B

      95 N*m

      969 kgf*cm

      70 ft.*lbf

    11. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.

    12. Tighten the through bolt of the rear engine mounting insulator.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

      Tip:

      Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the engine mounting insulator.

    13. Tighten the through bolt and nut of the front engine mounting insulator.

      145 N*m

      1479 kgf*cm

      107 ft.*lbf

  19. INSTALL FUEL HOSE PROTECTOR

    1. Install the fuel hose protector to the cylinder head sub-assembly.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

  20. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A295896

      Install the front suspension member reinforcement LH with the 4 bolts.

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

  21. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  22. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    1. Turn the crankshaft to gain access to the installation locations of the 6 torque converter assembly setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

      44 N*m

      449 kgf*cm

      32 ft.*lbf

      Note:

      Install the black bolt first, and then the 5 silver bolts.

    2. Install the oil pan insulator and temporarily install the 2 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click hereClick here

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click hereClick here

  25. INSTALL FRONT AXLE ASSEMBLY LH

    Click hereClick here

  26. INSTALL FRONT AXLE ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  27. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click hereClick here

  28. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click hereClick here

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  31. CONNECT FRONT SPEED SENSOR LH

    Click hereClick hereClick here

  32. CONNECT FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  33. INSTALL FRONT AXLE SHAFT NUT LH

    Click hereClick hereClick here

  34. INSTALL FRONT AXLE SHAFT NUT RH

    Tip:

    Perform the same procedure as for the LH side.

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

    Click hereClick here

  36. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  37. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  38. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. Connect the transmission control cable assembly with the nut and a new clip.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  39. CONNECT SUCTION HOSE SUB-ASSEMBLY

    1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil

      ND-OIL 8 or equivalent

    2. Install the O-ring to the suction hose sub-assembly.

    3. Connect the suction hose sub-assembly to the cooler compressor assembly and install the bolt.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    4. Connect the connector to the cooler compressor assembly.

  40. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil

      ND-OIL 8 or equivalent

    2. Install the O-ring to the discharge hose sub-assembly.

    3. Connect the discharge hose sub-assembly to the cooler compressor assembly and install the bolt.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

  41. INSTALL RADIATOR RESERVOIR ASSEMBLY

    1. Install the radiator reservoir assembly with the 2 bolts.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. Connect the water by-pass hose to the radiator reservoir assembly, and slide the clamp to secure the hose.

  42. CONNECT NO. 2 WATER BY-PASS HOSE

    1. Connect the No. 2 water by-pass hose to the No. 4 water by-pass pipe and slide the clamp to secure the hose.

  43. CONNECT NO. 2 RADIATOR HOSE

    1. Connect the No. 2 radiator hose to the water inlet housing and slide the clamp to secure the hose.

  44. INSTALL INTERCOOLER AIR HOSE

    Click hereClick here

  45. CONNECT RADIATOR HOSE SUB-ASSEMBLY

    1. Connect the radiator hose sub-assembly to the cylinder head sub-assembly and slide the clamp to secure the hose.

  46. CONNECT OUTLET HEATER WATER HOSE

    1. Connect the outlet heater water hose to the No. 3 water by-pass pipe and slide the clamp to secure the hose.

  47. CONNECT INLET HEATER WATER HOSE

    1. Connect the inlet heater water hose to the cylinder head sub-assembly and slide the clamp to secure the hose.

  48. CONNECT HOSES AND CONNECTORS

    1. Connect the vacuum pump hose to the vacuum pump assembly and slide the clip to secure the hose.

    2. Install the injector driver assembly with the 2 nuts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    3. Connect the 4 injector driver connector and attach the 2 wire harness clamps.

    4. Attach the 3 wire harness clamps to the 3 wire harness clamp brackets.

    5. Connect the shift position switch connector and attach the 2 wire harness clamps.

    6. Install the ground cable with the bolt to the automatic transaxle.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

    7. Connect the transaxle ECM connector and attach the 2 wire harness clamps.

    8. Install the bolt to wire harness clamp bracket.

      7.7 N*m

      79 kgf*cm

      68 in.*lbf

    9. Connect the starter wire with the nut.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    10. Install the bolt and attach the engine wire cover clamp and engine wire harness clamp.

      7.7 N*m

      79 kgf*cm

      68 in.*lbf

    11. Attach the 2 claws and connect the engine wire to the engine room No. 1 relay block with the nut.

      13 N*m

      133 kgf*cm

      10 ft.*lbf

    12. Connect the 3 connectors to the engine room No. 1 relay block.

    13. Install the engine room relay block and junction block cover.

  49. INSTALL ECM

    Click here

  50. INSTALL AIR CLEANER BRACKET

    1. Install the air cleaner bracket with the 3 bolts.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

    2. Connect the 2 fuel hoses to the air cleaner bracket.

    3. Attach the 3 wire harness clamps.

    4. Connect the glow plug relay and level warning switch connector.

  51. INSTALL FUEL FILTER ASSEMBLY

    1. Install the fuel filter assembly to the air cleaner bracket with the bolt.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

    2. Connect the 2 fuel hoses to the fuel filter assembly and slide the clamp secure the hoses.

  52. INSTALL AIR CLEANER SUPPORT

    1. Install the air cleaner support with the 2 nuts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  53. INSTALL AIR CLEANER CASE

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

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  54. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    1. Install the air cleaner cap sub-assembly and attach the 3 clips.

    2. Connect the mass air flow meter connector and wire harness clamp.

    3. Connect the air cleaner hose and tighten the hose clamp.

    4. Connect the PCV hose.

  56. INSTALL NO. 3 AIR HOSE

    Click here

  57. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  58. INSTALL RADIATOR ASSEMBLY

    Click hereClick here

  59. INSTALL BATTERY BRACKET REINFORCEMENT

    1. Install the battery bracket reinforcement with the 2 bolts.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  60. INSTALL FRONT BATTERY BRACKET

    1. Install the front battery bracket with the 4 bolts.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

    2. Attach the 2 wire harness clamps.

  61. INSTALL BATTERY TRAY

  62. INSTALL BATTERY

  63. INSTALL BATTERY INSULATOR

  64. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    1. Attach the hook of the battery clamp sub-assembly to the front battery bracket.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Attach the 2 wire harness clamps.

    4. Adjust the battery clamp position.

    5. Tighten the nut and bolt.

      for bolt

      17 N*m

      173 kgf*cm

      13 ft.*lbf

      for nut

      4.9 N*m

      50 kgf*cm

      43 in.*lbf

  65. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  66. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click hereClick here

  67. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  68. INSTALL FRONT BUMPER COVER

    Click hereClick here

  69. ADD ENGINE OIL

    Click here

  70. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click hereClick hereClick hereClick here

  72. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  73. ADD ENGINE COOLANT

    Click here

  74. BLEED AIR FROM FUEL SYSTEM

    Click here

  75. CHARGE REFRIGERANT

    Click hereClick here

  76. WARM UP ENGINE

    Click hereClick here

  77. INSPECT FOR REFRIGERANT LEAK

    Click hereClick here

  78. PERFORM REGISTRATION

    1. Perform registration of the injector compensation codes.

      Click here

    2. Perform registration of the pilot quantity learning.

      Click here

  79. PERFORM INITIALIZATION

    1. Perform initialization of the crank time compensation reset function.

      Click here

  80. PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING

    Click here

  81. INSPECT FOR OIL LEAK

    Click here

  82. INSPECT FOR COOLANT LEAK

    Click here

  83. INSPECT FOR FUEL LEAK

    Click here

  84. INSPECT FOR EXHAUST GAS LEAK

    Click here

  85. ADJUSTMENT AUTOMATIC TRANSAXLE FLUID

    Click hereClick here

  86. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  87. INSTALL REAR ENGINE UNDER COVER LH

    1. Install the rear engine under cover LH with the 2 clips.

  88. INSTALL FRONT FLOOR COVER RH

    1. Install the front floor cover RH with the 3 nuts and 3 clips.

  89. INSTALL NO. 2 ENGINE UNDER COVER

    1. Install the No. 2 engine under cover with the bolt and clip.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  90. INSTALL FRONT FLOOR COVER

    Click here

  91. INSTALL NO. 1 ENGINE UNDER COVER

    1. Install the No. 1 engine under cover with the 10 clips.

    2. Install the 4 bolts and 2 screws.

  92. INSTALL NO. 1 ENGINE COVER

    1. Attach the 4 clips to install the No. 1 engine cover.

  93. CHECK IDLE SPEED

    Click here

  94. CHECK MAXIMUM ENGINE SPEED

    Click here

  95. ADJUST FRONT WHEEL ALIGNMENT

    Click hereClick here

  96. CHECK ABS SPEED SENSOR SIGNAL

    Click hereClick hereClick here