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Engine Assembly: Installation

  1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION  )
  2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION  )
  3. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  4. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  8. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the bracket with the 3 bolts.

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

      Fig 1: Locating Bracket And Bolts
      G05387330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL REAR ENGINE MOUNTING INSULATOR SUB-ASSEMBLY 
    1. Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 2: Locating Rear Engine Mounting Insulator Bracket With Bolt
      G05387332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
    2. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator 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.
      Fig 3: Identifying Engine Lifter
      G05387328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  11. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH 
    1. Install the engine mounting insulator LH with the 4 bolts.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

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

      HINT:

      Install the through bolt by tightening the nut.

      Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

      Fig 4: Identifying Engine Mounting Insulator Bolts And Nut
      G05387327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH  (See INSTALLATION  )
  13. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY 
    1. Install the front crossmember with the 4 bolts.

      Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) 

      Fig 5: Identifying Front Crossmember Bolts
      G05388184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the front engine mounting insulator with the 2 bolts.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      HINT:

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

      Fig 6: Locating Front Engine Mounting Insulator Bolts
      G05387325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator front to the engine mounting bracket front with the bolt and nut.

      Torque: 145 N*m (1479 kgf*cm, 107 ft.*lbf) 

    Fig 7: Locating Engine Mounting Insulator Bolt And Nut
    G05387324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Support the front suspension crossmember with a transmission jack.
    2. While inserting SST into the reference holes on the front suspension crossmember RH and LH alternately, tighten 2 bolts A, 2 bolts B, and 2 nuts on the RH and LH sides to the respective specified torque in several steps.

      SST 09670-00020 

      Fig 8: Locating Front Suspension Crossmember Bolts And Nuts
      G05387338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 

      Bolt A 

      1. 145 N*m (1479 kgf*cm, 107 ft.*lbf) 

      Bolt B 

      1. 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Nut 

      1. 95 N*m (969 kgf*cm, 70 ft.*lbf) 
  15. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH 
    1. Install the front suspension member rear brace LH with the 3 bolts.

      Torque: 

      Bolt A 

      1. 145 N*m (1479 kgf*cm, 107 ft.*lbf) 

      Bolt B 

      1. 93 N*m (948 kgf*cm, 69 ft.*lbf) 
  16. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH 

    HINT:

    Perform the same procedure for the LH side.

    Fig 9: Locating Front Suspension Member Rear Brace LH Bolts
    G05387339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH 
    1. Install the front suspension member reinforcement LH with the 4 bolts.

      Torque: 96 N*m (979 kgf*cm, 71 ft.*lbf) 

      NOTE: Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D, and A.
  18. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH 

    HINT:

    Perform the same procedure for the LH side.

    Fig 10: Locating Front Suspension Member Reinforcement LH With Bolts
    G05387340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  22. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  23. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  24. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  25. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  26. INSTALL TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  27. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
  29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  30. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  31. INSTALL FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure for the LH side.

  32. INSTALL FRONT AXLE HUB NUT LH  (See INSTALLATION )
  33. INSTALL FRONT AXLE HUB NUT RH 

    HINT:

    Perform the same procedure for the LH side.

  34. CONNECT ENGINE WIRE 
    1. Install the ground cable with the bolt located near the starter.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    2. Connect the ground cable to the clamp located near the starter.
    3. Connect the ground cable connector.
    4. Connect the engine wire to the positive battery terminal with the nut.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

      Fig 11: Locating Positive Battery Terminal Nut
      G05387318Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 engine wire connectors and install the nut.
    6. Install the engine room relay block cover.
    7. Attach the clamp of the engine wire cover.
    8. Install the engine wire cover to with the bolt.
      Fig 12: Locating Engine Wire Connectors And Nut
      G05387317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. CONNECT ECM 
    1. Connect the connector to the engine control computer with the clamp and lock lever.
    Fig 13: Locating Engine Control Computer With Clamp And Lock Lever
    G05387343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See INSTALLATION )
  37. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See INSTALLATION )
  38. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  39. INSTALL STARTER ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  40. INSTALL STARTER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  41. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  42. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  43. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)  (See INSTALLATION )
  44. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 

    (See INSTALLATION )

  45. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle) 

    (See INSTALLATION )

  46. CONNECT CHECK VALVE TO CONNECTOR TUBE HOSE 
    1. Connect the check valve to connector tube hose.
    Fig 14: Locating Check Valve To Connector Tube Hose
    G05386987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. INSTALL FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube connector and 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. Engage the claw and install the No. 1 fuel pipe clamp.
    3. Install the No. 2 fuel pipe clamp.
    Fig 15: Locating No. 1 Fuel Pipe Clamp
    G05387313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. CONNECT HEATER INLET WATER HOSE  (See INSTALLATION )
  49. CONNECT HEATER OUTLET WATER HOSE  (See INSTALLATION )
  50. CONNECT NO. 2 OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) 
  51. CONNECT NO. 1 OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) 
  52. INSTALL COMPRESSOR ASSEMBLY  (See INSTALLATION )
  53. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  54. CONNECT SUCTION HOSE SUB-ASSEMBLY  (See INSTALLATION )
  55. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  56. INSTALL FAN AND GENERATOR V BELT  (See ON-VEHICLE INSPECTION  )
  57. INSTALL THROTTLE BODY ASSEMBLY  (See INSTALLATION )
  58. INSTALL NO. 2 BATTERY CARRIER  (See INSTALLATION )
  59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY  (See INSTALLATION )
  60. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See INSTALLATION )
  61. INSTALL RADIATOR RESERVE TANK ASSEMBLY  (See INSTALLATION  )
  62. INSTALL FRONT EXHAUST PIPE ASSEMBLY 
    1. Using vernier calipers, measure the free length of the compression spring.

      Minimum length: 41.5 mm (1.634 in.) 

      If the length is not as specified, replace the compression spring.

    2. Install the new exhaust pipe gasket to the exhaust manifold converter.
    3. Install the front exhaust pipe with the 2 compression springs and 2 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 16: Measuring Free Length Of Compression Spring
      G05387695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL CENTER EXHAUST PIPE ASSEMBLY 
    1. Install the new gasket onto the front exhaust pipe.
    2. Install the center exhaust pipe with the 2 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  64. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)  (See INSTALLATION )
  65. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)  (See ON-VEHICLE INSPECTION )
  66. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) 
  67. INSPECT AND ADJUST MANUAL TRANSAXLE OIL (for Manual Transaxle)  (See ON-VEHICLE INSPECTION )
  68. INSTALL BATTERY  (See INSTALLATION )
  69. ADD ENGINE COOLANT  (See REPLACEMENT )
  70. CHARGE REFRIGERANT  (See REPLACEMENT )
  71. WARM UP ENGINE  (See REPLACEMENT )
  72. ADD CLUTCH FLUID (for Manual Transaxle) 
  73. BLEED CLUTCH LINE (for Manual Transaxle)  (See BLEEDING )
  74. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transaxle) 
  75. INSPECT CLUTCH FLUID LEVEL IN RESERVOIR (for Manual Transaxle) 
  76. INSPECT FOR FUEL LEAK  (See FUEL SYSTEM )
  77. INSPECT FOR ENGINE COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  78. INSPECT REFRIGERANT LEAK  (See REPLACEMENT )
  79. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK (for Automatic Transaxle) 
  80. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle)  (See ON-VEHICLE INSPECTION )
  81. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle)  (See INSTALLATION )
  82. INSPECT EXHAUST GAS LEAK 
  83. INSTALL REAR ENGINE UNDER COVER LH 
  84. INSTALL REAR ENGINE UNDER COVER RH 
  85. INSTALL NO. 2 ENGINE UNDER COVER 
  86. INSTALL NO. 1 ENGINE UNDER COVER 
  87. INSTALL CENTER TRANSMISSION UNDER COVER ASSEMBLY 
  88. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  89. INSTALL HOOD  (See INSTALLATION  )
  90. INSPECT HOOD  (See ADJUSTMENT )
  91. ADJUST HOOD  (See ADJUSTMENT )
  92. INSPECT ENGINE IDLING SPEED  (See ON-VEHICLE INSPECTION  )
  93. INSPECT CO/HC  (See ON-VEHICLE INSPECTION  )
  94. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY  (See INSTALLATION )
  95. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust the front wheel alignment (see ADJUSTMENT ).
  96. INSPECT ABS SPEED SENSOR SIGNAL 
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