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Engine Assembly: Installation

WARNING: This page is about a different car, the 2006 Scion tC. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (See  INSTALLATION  ) 
  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
  3. INSTALL RADIO SETTING CONDENSER 
    1. Install the condenser with the bolt.

      Torque: 10 N.m (102 kgf.cm, 7 ft. lbf) 

  4. INSTALL KNOCK SENSOR (See  INSTALLATION  ) 
  5. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY (See  INSTALLATION  ) 
  6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (See  INSTALLATION  ) 
  7. INSTALL IGNITION COIL ASSEMBLY (See  INSTALLATION  ) 
  8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See  INSTALLATION   ) 
  9. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (See  INSTALLATION  ) 
  10. INSTALL INTAKE MANIFOLD ASSEMBLY (See  INSTALLATION  ) 
    Fig 1: Installing Condenser With Bolt
    G04221665Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Install a new gasket and the water by-pass pipe with the bolt and 2 nuts.

      Torque: 9.0 N.m (92 kgf.cm, 80 in. lbf) 

  12. INSTALL THERMOSTAT (See  INSTALLATION  ) 
  13. INSTALL WATER INLET (See  INSTALLATION  ) 
  14. INSTALL EXHAUST MANIFOLD CONVERTER SUBASSEMBLY (See  INSTALLATION   ) 
  15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See  INSTALLATION   ) 
  16. INSTALL NO. 2 MANIFOLD STAY (See  INSTALLATION   ) 
  17. INSTALL MANIFOLD STAY (See  INSTALLATION   ) 
  18. INSTALL OIL DIPSTICK GUIDE (See  INSTALLATION   ) 
  19. INSTALL OIL DIPSTICK (See  INSTALLATION   ) 
  20. INSTALL DRIVE SHAFT BEARING BRACKET 
    Fig 2: Installing New Gasket And Water By-Pass Pipe With Bolt And 2 Nuts
    G04221666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque: 64 N.m (653 kgf.cm, 47 ft. lbf) 

  21. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Clean the 8 bolts and 8 bolt holes.
    2. Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive: 

      Part No. 08833-00070, THREE BOND or equivalent 

      Fig 3: Installing Drive Shaft Bearing Bracket With 3 Bolts
      G04221667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST, hold the crankshaft.

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

      Fig 4: Holding Crankshaft Using SST
      G04221668Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque: 130 N.m (1,326 kgf.cm, 96 ft. lbf) 

  22. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) (See  INSTALLATION  ) 
  23. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) (See  INSTALLATION  ) 
  24. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) (See  INSTALLATION  ) 
    Fig 5: Tightening Drive Plate Bolts Sequence
    G04221669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Clean the 8 bolts and 8 bolt holes.
    2. Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive: 

      Part No. 08833-00070, THREE BOND or equivalent 

    3. Using SST, hold the crankshaft.

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

    4. Install the front spacer, drive plate and rear spacer onto the crankshaft.
      Fig 6: Holding Crankshaft Using SST
      G04221670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque: 98 N.m (1,000 kgf.cm, 72 ft. lbf) 

  26. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle) (See  INSTALLATION  ) 
  27. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (See  INSTALLATION  ) 
  28. INSTALL STARTER ASSEMBLY (See  INSTALLATION  ) 
  29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See  INSTALLATION  ) 
    Fig 7: Tightening Drive Plate Bolts Sequence
    G04221671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See  INSTALLATION  ) 
  31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER 
    1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
    2. Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.

      Torque: 87 N.m (887 kgf.cm, 64 ft. lbf) 

      Fig 8: Installing Through Bolt Securing Rear Engine Mounting Insulator
      G04221672Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt which is used to secure the front engine mounting bracket.

      Torque: 52 N.m (530 kgf.cm, 38 ft. lbf) 

  32. INSTALL VANE PUMP ASSEMBLY 
  33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
      Fig 9: Installing Bolt Used To Securing Front Engine Mounting Bracket
      G04221673Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.
      Fig 10: Installing Suspension Crossmember With 2 Bolts And 2 Nuts
      G04221674Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator LH with the through bolt and nut.

      Torque: 87 N.m (887 kgf.cm, 64 ft. lbf) 

      Fig 11: Installing Engine Mounting Insulator LH With Through Bolt And Nut
      G04221675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine mounting insulator RH with the 2 bolts and 2 nuts.

      Torque: 52 N.m (530 kgf.cm, 38 ft. lbf) 

      113 N.m (1,152 kgf.cm, 83 ft. lbf) for bolt A 

      Fig 12: Installing Engine Mounting Insulator RH With 2 Bolts And 2 Nuts
      G04221676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Tighten the 2 bolts and 2 nuts.

      Torque: 45 N.m (459 kgf.cm, 33 ft. lbf) for bolt 

      133 N.m (1,356 kgf.cm, 98 ft. lbf) for nut 

      Fig 13: Tightening Front Suspension Member 2 Bolts And 2 Nuts
      G04221677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the front suspension member brace rear RH and LH with the 8 bolts.

      Torque: 133 N.m (1,356 kgf.cm, 98 ft. lbf) for bolt A 

      80 N.m (816 kgf.cm, 59 ft. lbf) for bolt B 

      NOTE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.
      Fig 14: Installing Front Suspension Member Brace Rear RH And LH With 8 Bolts
      G04221678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Connect the return tube.
      Fig 15: Connecting Return Tube
      G04221679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the oil reservoir to No. 1 pump hose.
      Fig 16: Connecting Oil Reservoir To No. 1 Pump Hose
      G04221680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the No. 1 and No. 2 engine hangers.
  34. INSTALL FRONT AXLE HUB SUB-ASSEMBLY (See  INSTALLATION  ) 
  35. INSTALL FRONT AXLE HUB HOLE SNAP RING (See  INSTALLATION  ) 
  36. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH (See  INSTALLATION  ) 
  37. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY RH (See  INSTALLATION  ) 
    Fig 17: Removing No. 1 And No. 2 Engine Hangers
    G04221681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL TIE ROD END SUB-ASSEMBLY LH (See  INSTALLATION  ) 
  39. INSTALL TIE ROD END SUB-ASSEMBLY RH (See  INSTALLATION  ) 
  40. INSTALL FRONT SPEED SENSOR LH (See  INSTALLATION  ) 
  41. INSTALL FRONT SPEED SENSOR RH (See  INSTALLATION  ) 
  42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See  INSTALLATION  ) 
  43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH (See  INSTALLATION  ) 
  44. INSTALL FRONT AXLE HUB NUT LH (See  INSTALLATION  ) 
  45. INSTALL FRONT AXLE HUB NUT RH (See  INSTALLATION  ) 
  46. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (See  INSTALLATION  ) 
  47. INSTALL COLUMN HOLE COVER SILENCER SHEET 
  48. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See  INSTALLATION  ) 
  49. CONNECT ENGINE WIRE 
    1. Install the ground cable with the bolt.
      Fig 18: Installing Ground Cable With Bolt
      G04221682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire to the battery positive terminal with the nut.
      Fig 19: Installing Engine Wire To Battery Positive Terminal With Nut
      G04221683Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 clamps of the engine wire.
      Fig 20: Installing 2 Clamps Of Engine Wire
      G04221684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the engine wire harness with the 2 claws.
    5. Connect the 2 connectors.
  50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See  INSTALLATION  ) 
  51. INSTALL COOLER COMPRESSOR ASSEMBLY (See  INSTALLATION  ) 
  52. INSTALL GENERATOR ASSEMBLY (See  INSTALLATION  ) 
  53. INSTALL FAN AND GENERATOR V BELT (See  INSTALLATION  ) 
  54. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) (See  INSTALLATION  ) 
  55. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) (See  INSTALLATION  ) 
  56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) (See  INSTALLATION  ) 
    Fig 21: Installing Engine Wire Harness With 2 Claws
    G04221685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. CONNECT HEATER WATER OUTLET HOSE 
    1. Connect the heater outlet hose to the air conditioner tube.
    Fig 22: Connecting Heater Outlet Hose To Air Conditioner Tube
    G04221686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT HEATER WATER INLET HOSE 
    1. Connect the heater inlet hose to the air conditioner tube.
    Fig 23: Connecting Heater Inlet Hose To Air Conditioner Tube
    G04221687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the union to connector tube to the booster vacuum tube.
  60. CONNECT FUEL MAIN TUBE (See  INSTALLATION  ) 
    Fig 24: Connecting Union To Connector Tube To Booster Vacuum Tube
    G04221688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 4 bolts.

      Torque: 12.8 N.m (131 kgf.cm, 9 ft. lbf) 

    2. Connect the clamp of the engine wire.
    Fig 25: Installing Battery Carrier With 4 Bolts
    G04221689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Connect the air cleaner case to the No. 1 air cleaner inlet.
    2. Install the air cleaner case with the 3 bolts.

      Torque: 5.0 N.m (51 kgf.cm, 44 in. lbf) 

    3. Connect the clamp of the engine wire.
    Fig 26: Installing Air Cleaner Case
    G04221690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL AIR CLEANER FILTER ELEMENT SUBASSEMBLY (See  INSTALLATION  ) 
  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See  INSTALLATION  ) 
  65. INSTALL RADIATOR ASSEMBLY (See  INSTALLATION  ) 
  66. CONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) 
  67. CONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) 
  68. CONNECT RADIATOR HOSE OUTLET 
  69. CONNECT RADIATOR HOSE INLET 
  70. INSTALL BATTERY TRAY 
  71. INSTALL BATTERY 
  72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  73. ADD MANUAL TRANSAXLE OIL (See  INSTALLATION  ) 
  74. ADD AUTOMATIC TRANSAXLE FLUID (See  INSTALLATION  ) 
  75. ADD ENGINE COOLANT (See  COOLANT  ) 
  76. CHECK FOR FUEL LEAKAGE (See  ON-VEHICLE INSPECTION  ) 
  77. CHECK FOR ENGINE COOLANT LEAKS 
    1. Check for the engine coolant leaks (See COOLANT ).
  78. CHECK FOR MANUAL TRANSAXLE OIL LEAKS 
  79. CHECK FOR AUTOMATIC TRANSAXLE FLUID LEAKS 
  80. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See  INSTALLATION   ) 
  81. INSTALL FRONT FENDER APRON SEAL RH (See  INSTALLATION  ) 
  82. INSTALL ENGINE UNDER COVER LH 
  83. INSTALL ENGINE UNDER COVER RH 
  84. INSTALL FRONT WHEEL (See  INSTALLATION  ) 
  85. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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