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Home >> Toyota >> 2017 >> 86 Base, Automatic Trans >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (Service Information) >> Engine Assembly >> Installation [03/2017 - ] >> Procedure

Installation [03/2017 - ]: Procedure

  1. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the 2 front engine mounting brackets with the 4 bolts.

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

  2. REMOVE ENGINE STAND 
    1. Attach an engine sling device and hang the engine with a chain block.
      NOTE:

      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.

    2. Remove the engine stand from the engine.
  3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    See step  2

  4. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) 

    See step  3

  5. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission) 

    Refer to PROCEDURE - Step 1

  6. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) 

    Refer to PROCEDURE - Step 2

  7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) 

    See step  6

  8. INSTALL ENGINE ASSEMBLY 
    GTY385920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Confirm that 2 knock pins are on the transmission contact surface of the engine block before transmission installation.
    2. Keeping the engine assembly and the transmission assembly in a horizontal position, align the knock pins with each hole on the transmission assembly and install the bolt.

      Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) 

  9. REMOVE ENGINE HANGER 

    See step  36

  10. CONNECT FUEL HOSE 
    1. Connect the fuel tube and No. 2 fuel tube to the fuel pipe (Refer to PRECAUTION [06/2016 - ] ).
    2. Connect the No. 2 fuel vapor feed hose to the fuel pipe.
  11. INSTALL DRIVE PLATE SETTING HEXAGON BOLT (for Automatic Transmission) 

    Refer to PROCEDURE - Step 14

  12. INSTALL FLYWHEEL HOUSING UNDER COVER 

    Refer to PROCEDURE - Step 15

  13. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember sub-assembly with new 2 nuts.

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

  14. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission) 
    1. Install the 3 bolts and 2 nuts.

      Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) 

  15. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) 
    1. Install the 3 bolts and 2 nuts.

      Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) 

  16. INSTALL FRONT STABILIZER BAR (for Automatic Transmission) 

    Refer to INSTALLATION [03/2017 - ]

  17. INSTALL REAR ENGINE UNDER COVER LH (w/ Floor Under Cover) 
    1. Install the rear engine under cover LH with the 3 bolts and 8 clips.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  18. INSTALL GROUNDED CABLE 
    1. Install the 2 grounded cables with the 2 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  19. CONNECT RADIATOR OUTLET HOSE 
    1. Install the clamp and connect the radiator outlet hose.
  20. CONNECT NO. 3 TRANSMISSION OIL COOLER HOSE (for Automatic Transmission) 
    1. Connect the No. 3 transmission oil cooler hose.
  21. INSTALL STARTER ASSEMBLY 
  22. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 3

  23. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the suction hose sub-assembly.
    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the O-ring onto the suction hose sub-assembly.
    4. Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.

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

    5. Remove the vinyl tape from the suction hose sub-assembly.
    6. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction hose sub-assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    7. Connect the O-ring to the suction hose sub-assembly.
    8. Connect the suction hose sub-assembly.
    9. Rotate the hook connector in the direction indicated by the arrow in the illustration.
    10. Insert the pipe joint into the cooler expansion valve securely and tighten the bolt.
      GTY739041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

    11. Install the suction hose sub-assembly with the nut.

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

  24. INSTALL NO. 1 TRANSMISSION OIL COOLER HOSE (for Automatic Transmission) 
    1. Connect the No. 1 transmission oil cooler hose.
  25. CONNECT HEATER WATER HOSE 
    1. Install the 2 hose clamps and connect 2 heater water hoses.
  26. INSTALL EXHAUST MANIFOLD 

    Refer to INSTALLATION [06/2016 - ]

  27. CONNECT VACUUM TUBE CONNECTOR HOSE (for Manual Transmission) 
    1. Connect the vacuum tube connector hose with the bolt.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Connect the vacuum tube connector hose.
  28. CONNECT VACUUM TUBE CONNECTOR HOSE (for Automatic Transmission) 
    1. Connect the vacuum tube connector hose with the 2 bolts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

    2. Connect the vacuum tube connector hose.
  29. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for Automatic Transmission) 

    Refer to PROCEDURE - Step 6

  30. CONNECT ENGINE WIRE 
    1. Connect the generator connector and connect the clamp.
    2. Connect the generator wire with the nut.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

    3. Install the terminal cap.
    4. Connect the 3 wire harness clamps.
    5. Connect the wire harness clamp to the No. 2 engine hanger.
    6. Connect the connector.
    7. Connect the connector (B).
      GTY706616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the wire harness connector (A) and securely lock the connector.
    9. Install the wire harness clamp bracket to the No. 2 engine hanger with the 2 bolts.

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

    10. for Automatic Transmission:
      1. Install the wire harness clamp bracket with the bolt.

        Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      2. Connect the 3 wire harness clamps.
      3. Slide the connector in the direction shown in the diagram, and connect the wire harness.
        GTY391370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Connect the wire harness connector (A) and securely lock the connector.
      5. Connect the connector (B).
  31. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 1

  32. INSTALL WATER FILLER SUB-ASSEMBLY 
    1. Install the 2 clamps and connect the water filler sub-assembly.
    2. Install the water filler sub-assembly with 2 bolts.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  33. INSTALL RADIATOR RESERVE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 16

  34. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 
    1. Install the stay with bolt to the body.

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

    2. Install the air cleaner assembly with hose with the 3 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

    3. Install the hose clamp.

      Torque: 2.0 N*m (20 kgf*cm, 18 in.*lbf) 

    4. Connect the clamp and wire harness to the air cleaner cap.
    5. Connect the mass air flow meter connector.
    6. Connect the No. 2 ventilation hose.
    7. Install the 2 bolts and the chamber duct with chamber.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

    8. Connect the hose.
  35. INSTALL FRONT SUSPENSION UPPER TO COWL BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  36. INSTALL FRONT SUSPENSION UPPER TO COWL BRACE SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 2

  37. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 3

  39. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  40. CHARGE WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  41. CHECK FOR ENGINE COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  42. CHECK FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 5

  43. CHECK FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  44. CHECK FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 6

  45. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  46. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY 

    Refer to PROCEDURE - Step 6

  47. INSPECT IGNITION TIMING 

    See step  7

  48. INSPECT ENGINE IDLE SPEED 

    See step  8

  49. INSPECT CO/HC 

    See step  10

  50. INSPECT ENGINE COOLANT LEVEL 

    Refer to PROCEDURE - Step 2

  51. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 2

  52. SET HOOD SUB-ASSEMBLY 
    1. Change the front hood stay position from B to A, and store the front hood stay.
      GTY708109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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