LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2003 >> RAV4 Base, AWD, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Unit (Removal & Installation) >> Installation

Engine Unit (Removal & Installation): Installation

  1. INSTALL GENERATOR 
    1. Install the generator with the 2 bolts.
      Fig 1: Installing Generator
      G02854133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 

      52 N.m (530 kgf.cm, 38 ft.lbf) for bolt A 

      21 N.m (214 kgf.cm, 16 ft.lbf) for bolt B 

    2. Connect the A/C wire.
    3. Connect the generator connector.
    4. Connect the generator wire with the nut, and install the cover.
      1. Torque: 9.7 N.m (100 kgf.cm, 85 in..lbf) 
  2. INSTALL PS VANE PUMP 
    Fig 2: Installing PS Vane Pump
    G02854134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the vane pump with the 2 bolts.
      1. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) 
    2. Connect the oil pressure switch connector.
  3. INSTALL A/C COMPRESSOR 
    Fig 3: Installing A/C Compressor
    G02854135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the compressor with the 3 bolts and nut.
      1. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 
    2. Connect the magnetic clutch and lock sensor connector.
  4. INSTALL DRIVE BELT (See  REMOVAL & INSTALLATION  ) 
  5. A/T: 

    INSTALL DRIVE PLATE 

    1. Apply adhesive to 2 or 3 threads of the bolt end.
      Fig 4: Applying Adhesive To Bolt End Threads
      G02854136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: 

      Part No. 08833-00070, THREE BOND 1324 or equivalent 

    2. Align the pin of the front spacer with the pin hole of the crankshaft, and install the front spacer.
      Fig 5: Aligning Front Spacer Pin With Crankshaft Pin Hole
      G02854137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the drive plate and rear spacer as shown in the illustration.
      Fig 6: Installing Drive Plate & Rear Spacer
      G02854138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
      1. Torque: 98 N.m (100 kgf.cm, 72 ft.lbf) 
      Fig 7: Installing & Tightening Bolts In Sequence
      G02854139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. M/T: 

    INSTALL FLYWHEEL (See procedure in step   5 ) 

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

    INSTALL CLUTCH DISC AND COVER (See  REMOVAL & INSTALLATION  ) 

  8. INSTALL ENGINE TO TRANSAXLE 
    Fig 8: Installing Upper Bolts Holding Transaxle To Engine
    G02854140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the 6 upper bolts holding the transaxle to the engine.
      1. Torque: 
      2. 46 N.m (470 kgf.cm, 34 ft.lbf) for bolt A 
      3. 64 N.m (650 kgf.cm, 47 ft.lbf) for bolt B 
    2. A/T:
    3. Connect the connectors and clamps.
      Fig 9: Connecting Connectors & Clamps (A/T)
      G02854141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the park/neutral position switch connector.
      2. Connect the solenoid wire connector.
      3. Connect the input turbine speed sensor connector.
      4. Connect the counter gear speed sensor connector.
      5. Connect the vehicle speed sensor.
      6. Connect the wire clamp from the bracket.
      7. Connect the wire clamp to the mounting bracket.
    4. M/T:

      Connect the connectors.

      Fig 10: Connecting Connectors (M/T)
      G02854142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the vehicle speed sensor connector.
      2. Connect the back-up light switch connector.
    5. Install the 4 lower bolts holding the engine to the transaxle.
      Fig 11: Installing Lower Bolts Holding Engine To Transaxle
      G02854143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 
  9. A/T: 

    INSTALL TORQUE CONVERTER CLUTCH BOLTS 

    1. Apply adhesive to 2 or 3 threads of the bolt end.
      Fig 12: Applying Adhesive To Bolt End Threads (A/T)
      G02854144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Adhesive: 

      Part No. 08833-00070, THREE BOND 1324 or equivalent 

    2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
      1. Torque: 41 N.m (418 kgf.cm, 30 ft.lbf) 
      NOTE: First tighten the green colored bolt, install the other bolts.
  10. 2WD: 

    INSTALL CENTER BEARING BRACKET 

    Install the bearing bracket with the 3 bolts.

    Fig 13: Installing Center Bearing Bracket (2WD)
    G02854145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Torque: 34 N.m (347 kgf.cm, 25 ft.lbf) 
  11. 4WD: 

    INSTALL STIFFENER PLATE 

    Install the stiffener plate with the 5 bolts.

    Fig 14: Installing Stiffener Plate (4WD)
    G02854146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Torque: 34 N.m (347 kgf.cm, 25 ft.lbf) 
    Fig 15: Installing Bolt Holding The Rear Engine Mounting Bracket To Mounting Insulator
    G02854147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL ENGINE AND TRANSAXLE ASSEMBLY TO FRONT SUSPENSION CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER 
    1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
    2. Install the bolt holding the rear engine mounting bracket to the mounting insulator.
      Fig 16: Installing Bolt Holding Front Engine Mounting Bracket To Mounting Insulator
      G02854148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 88 N.m (898 kgf.cm, 65 ft.lbf) 
    3. Install the bolt holding the front engine mounting bracket to the mounting insulator.
      Fig 17: Lifting Engine Into Engine Compartment
      G02854149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 56 N.m (571 kgf.cm, 41 ft.lbf) 
  13. INSTALL ENGINE, TRANSAXLE, FRONT SUSPENSION CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER ASSEMBLY IN VEHICLE 
    1. Attach the engine sling device to the engine hangers.
    2. Lift the engine into the engine compartment.
    3. Install the bolt and 2 nuts holding the RH engine mounting insulator to the timing chain cover.
      Fig 18: Installing RH Engine Mounting Insulator To Timing Chain Cover Holding Bolt & Nuts
      G02854150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 
    4. Install the bolt holding the LH engine mounting bracket to the mounting insulator.
      Fig 19: Installing LH Engine Mounting Bracket To Mounting Insulator Holding Bolt
      G02854151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 56 N.m (571 kgf.cm, 41 ft.lbf) 
    5. Support the suspension crossmember with a jack.
    6. Install the 6 bolts holding the suspension crossmember engine mounting member to the body.
      Fig 20: Installing Suspension Crossmember Engine Mounting Member To Body Holding Bolt
      G02854152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 

      39 N.m (400 kgf.cm, 28 ft.lbf) for bolt A 

      113 N.m (1,150 kgf.cm, 82 ft.lbf) for bolt B 

      157 N.m (1,600 kgf.cm, 115 ft.lbf) for bolt C 

    7. INSTALL PS GEAR ASSEMBLY 
      Fig 21: Installing PS Gear Assembly
      G02854153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the PS gear assembly with the 2 bolts.

      1. Torque: 137 N.m (1,400 kgf.cm, 101 ft.lbf) 
    8. REMOVE NO. 1 AND NO. 2 ENGINE HANGERS 
    9. CONNECT STABILIZER BAR LINKS 
      Fig 22: Connecting Stabilizer Bar Links
      G02854154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the LH and RH stabilizer links with the 2 nuts.

      1. Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 
    10. INSTALL FRONT EXHAUST PIPE 

      Install 2 new gaskets and the exhaust pipe, with the 2 compression rings and 4 bolts.

      Fig 23: Installing Front Exhaust Pipe
      G02854155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 
      2. 43 N.m (439 kgf.cm, 32 ft.lbf) for bolt A 
      3. 49 N.m (500 kgf.cm, 36 ft.lbf) for bolt B 
    11. INSTALL LH AND RH FRONT DRIVE SHAFTS (See  REMOVAL & INSTALLATION  ) 
    12. 4WD: 

      INSTALL PROPELLER SHAFT (See  INSTALLATION  ) 

    13. CONNECT GROUND CABLE TO TRANSAXLE 
      1. Torque: 19 N.m (195 kgf.cm, 14 ft.lbf) 
    14. A/T: 

      CONNECT OIL COOLER HOSES 

      Fig 24: Connecting Oil Cooler Hoses (A/T)
      G02854156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    15. A/T: 

      CONNECT SHIFT CONTROL CABLE TO TRANSAXLE 

      Fig 25: Connecting Shift Control Cable To Transaxle (A/T)
      G02854157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the control cable with the nut.
        1. Torque: 15 N.m (150 kgf.cm, 11 ft.lbf) 
      2. Connect the control cable with the clip.
      3. Connect the control cable to the cable clamp.
    16. M/T: 

      INSTALL CLUTCH RELEASE CYLINDER AND TUBE 

      Fig 26: Connecting Clutch Release Cylinder & Tube (M/T)
      G02854158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the release cylinder with the 5 bolts.
        1. Torque: 

        25 N.m (255 kgf.cm, 18 ft.lbf) for bolt A 

        12 N.m (120 kgf.cm, 9 ft.lbf) for bolt B 

        5 N.m (51 kgf.cm, 44 in..lbf) for bolt C 

      2. Install the heat insulator with the 2 bolts.
        1. Torque: 12 N.m (120 kgf.cm, 44 ft.lbf) 
    17. INSTALL STARTER 
      1. Install the starter.
      2. Connect the starter cable with the nut.
        1. Torque: 8.8 N.m (86 kgf.cm, 78 in..lbf) 
      3. Install the starter with the 2 bolts.
        Fig 27: Installing Starter
        G02854159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        1. Torque: 37 N.m (378 kgf.cm, 28 ft.lbf) 
      4. Connect the connector.
      5. Connect the hose to the dipstick guide.
    18. M/T: 

      CONNECT SHIFT CONTROL CABLES TO TRANSAXLE 

      1. Connect the 2 control cables with the 2 clips.
      2. Install the 2 washers and 2 clips.
        Fig 28: Connecting Shift Control Cables To Transaxle (M/T)
        G02854160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    19. DISCONNECT TUBES, HOSES, CONNECTOR, CABLE AND WIRE 
      1. Install 2 new O-rings, and connect the discharge and liquid tubes to the compressor (See REMOVAL ).
        2. Fig 29: Connecting Discharge & Liquid Tubes To Compressor
        G02854161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the accelerator cable.
      3. Connect the ground wire to the cylinder head.
      4. Install a new gasket, and connect the suction hose and pressure feed tube to the PS vane pump.
        5. Fig 30: Connecting Suction Hose & Pressure Feed Tube To PS Vane Pump
        G02854162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Connect the upper radiator hose.
      6. Connect the lower radiator hose.
      7. Connect the fuel tube connector (See SERVICE PRECAUTIONS ).
      8. Connect the 2 heater hoses.
      9. Connect the connector to the fusible link block.
    20. CONNECT ENGINE WIRE TO CABIN 
      1. Push in engine wire through the cabin.
      2. Connect the 6 engine wire connectors to the ECM and instrument panel wire.
        3. Fig 31: Connecting Wire Connectors To ECM & Instrument Panel Wire
        G02854163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Install the glove compartment door with the 2 screws.
    21. INSTALL ENGINE ROOM J/B 
      1. Connect the engine wire clamp.
      2. Connect the connector.
      3. Push into the engine wire connector.
      4. Install the engine room J/B, and tighten the bolt until it fails to catch.
      5. Install the engine room J/B cover.
        Fig 32: Installing Engine Room J/B
        G02854164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    22. INSTALL AIR CLEANER ASSEMBLY 
      1. Connect the air cleaner hose to the throttle body, and install the air cleaner assembly with the 3 bolts.
      2. Connect the MAF meter connector.
      3. Connect the 2 EVAP hoses to the VSV.
      4. Connect the VSV connector for EVAP.
      5. Connect the CCV hose to the air cleaner.
      6. Connect the PCV hose to the cylinder head cover.
      Fig 33: Installing Air Cleaner Assembly
      G02854165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL BATTERY AND TRAY 
    1. Install the battery bracket with the 5 bolts.
    2. Install the battery tray and battery with the hold-down clamp.
    3. Install the cowl top ventilation louver (See INSTALLATION ) .
      Fig 34: Installing Battery And Tray
      G02854166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL RADIATOR RESERVOIR TANK 
  16. INSTALL HOOD (See  ADJUSTMENT  ) 
  17. FILL WITH ENGINE COOLANT 
  18. FILL WITH ENGINE OIL 
  19. FILL WITH TRANSFER OIL 
  20. FILL WITH TRANSAXLE OIL 
  21. START ENGINE AND CHECK FOR LEAKS 
  22. BLEED POWER STEERING SYSTEM (See  BLEEDING  ) 
  23. PERFORM ROAD TEST 

    Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 

  24. RECHECK ENGINE COOLANT AND OIL LEVELS 
  25. INSTALL ENGINE UNDER COVERS 
scientia non olet · About LEMON Manuals