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Engine Unit: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install generator  .
      Fig 1: Locating & Installing Generator
      G01083799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the generator with the 2 bolts.
      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  .
    1. Install the vane pump with the 2 bolts.
      1. Torque: 43 N.m (440 kgf. cm, 32 ft. lbf) 
        2. Fig 2: Locating Vane Pump Bolts
        G01083800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the oil pressure switch connector.
  3. Install A/C compressor  .
    1. Install the compressor with the 3 bolts and nut.
      1. Torque: 24.5 N.m (250 kgf. cm, 18 ft. lbf) 
        2. Fig 3: Installing A/C Compressor
        G01083801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the magnetic clutch and lock sensor connector.
  4. Install drive belt (See  CHARGING SYSTEM  )  .
  5. A/T: Install drive plate 
    1. Apply adhesive to 2 or 3 threads of the bolt end.
      1. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 
        2. Fig 4: Displaying Adhesive Application
        G01083802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the pin of the front spacer with the pin hole of the crankshaft, and install the front spacer.
      Fig 5: Locating lock Pin & Pin Hole
      G01083803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the drive plate and rear spacer as shown in the illustration.
      Fig 6: Identifying Drive Plate & Rear Spacer
      G01083804Courtesy 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) 
  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  CLUTCH ASSEMBLY  )  .
    Fig 7: Locating & Tightening Bolts
    G01083805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. Install engine to transaxle  .
    1. Install the 6 upper bolts holding the transaxle to the engine.
      1. Torque: 46 N.m (470 kgf. cm, 34 ft. lbf) for bolt A 64 N.m (650 kgf. cm, 47 ft. lbf) for bolt B 
        2. Fig 8: Installing Engine To Transaxle
        G01083806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. A/T: Connect the connectors and clamps.
      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 engine mounting bracket.
        8. Fig 9: Locating A/T Connectors & Clamps
        G01083807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. M/T: Connect the connectors.
      1. Connect the vehicle speed sensor connector.
      2. Connect the back-up light switch connector.
        3. Fig 10: Locating M/T Connectors & Clamps
        G01083808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 4 lower bolts holding the engine to the transaxle.
      1. Torque: 44 N.m (450 kgf. cm, 32 ft. lbf) 
        2. Fig 11: Locating Lower Engine Holding Bolts
        G01083809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. A/T: Install torque converter clutch bolts  .
    1. Apply adhesive to 2 or 3 threads of the bolt end.
      1. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 
        2. Fig 12: Installing Converter Clutch Bolts
        G01083810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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  .
    Fig 13: Locating Bearing Brackets
    G01083811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Install the bearing bracket with the 3 bolts.

    1. Torque: 34 N.m (347 kgf. cm, 25 ft. lbf) 

  11. 4WD: Install stiffener plate 

    Install the stiffener plate with the 5 bolts.

    1. Torque: 34 N.m (347 kgf. cm, 25 ft. lbf) 
      2. Fig 14: Locating Stiffener Plate Bolts
      G01083812Courtesy 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.
      1. Torque: 88 N.m (898 kgf. cm, 65 ft. lbf) 
      Fig 15: Installing Bolt Holding Rear Engine Mounting Bracket
      G01083813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt holding the front engine mounting bracket to the mounting insulator.
      1. Torque: 56 N.m (571 kgf. cm, 41 ft. lbf) 
        2. Fig 16: Installing Bolt Holding Front Engine Mounting Bracket
        G01083814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      Fig 17: Displaying Engine Lifting
      G01083815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt and 2 nuts holding the RH engine mounting insulator to the timing chain cover.
      1. Torque: 52 N.m (530 kgf. cm, 38 ft. lbf) 
        2. Fig 18: Locating RH Engine Mounting Insulator
        G01083816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the bolt holding the LH engine mounting bracket to the mounting insulator.
      1. Torque: 56 N.m (571 kgf. cm, 41 ft. lbf) 
        2. Fig 19: Locating LH Engine Mounting Bracket
        G01083817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Support the suspension crossmember with a jack.
      Fig 20: Locating & Installing Bolts
      G01083818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the 6 bolts holding the suspension crossmember engine mounting member to the body.
      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 
  14. Install PS gear assembly  .

    Install the PS gear assembly with the 2 bolts.

    1. Torque: 137 N.m (1,400 kgf. cm, 101 ft. lbf) 
      2. Fig 21: Installing PS Gear Assembly
      G01083819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  15. Remove No. 1 and No. 2 engine hangers  .
  16. Connect stabilizer bar links  .

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

    1. Torque: 44 N.m (450 kgf. cm, 32 ft. lbf) 
      2. Fig 22: Connecting RH & LH Stabilizer Links
      G01083820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

  17. Install front exhaust pipe  .
    Fig 23: Installing Front Exhaust Pipe
    G01083821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    1. Torque: 43 N.m (439 kgf. cm, 32 ft. lbf) for bolt A, 49 N.m (500 kgf. cm, 36 ft. lbf) for bolt B 

  18. Install LH and RH front drive shafts (See  REASSEMBLY  )  .
  19. 4WD: Install propeller shaft (See  INSTALLATION  )  .
  20. Connect ground cable to transaxle  .
    1. Torque: 19 N.m (195 kgf. cm, 14 ft. lbf) 
  21. A/T: Connect oil cooler hoses  .
    Fig 24: Connecting Oil Cooler Hoses
    G01083822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. A/T: Connect shift control cable to transaxle  .
    1. Connect the control cable with the nut.
      1. Torque: 15 N.m (150 kgf. cm, 11 ft. lbf) 
        2. Fig 25: Connecting Shift Control Cable
        G01083823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the control cable with the clip.
    3. Connect the control cable to the cable clamp.
  23. M/T: Install clutch release cylinder and tube  .
    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 
        Fig 26: Installing Clutch Release Cylinder
        G01083824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the heat insulator with the 2 bolts.
      1. Torque: 12 N.m (120 kgf. cm, 44 ft. lbf) 
  24. Install starter  .
      Fig 27: Locating & Installing Starter
      G01083825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      1. Torque: 37 N.m (378 kgf. cm, 28 ft. lbf) 
    4. Connect the connector.
    5. Connect the hose to the dipstick guide.
  25. 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.
      3. Fig 28: Identifying & Locating Shift Control Cables
      G01083826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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. Connect the accelerator cable.
    3. Connect the ground wire to the cylinder head.
      Fig 29: Locating O-Rings
      G01083827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new gasket, and connect the suction hose and pressure feed tube to the PS vane pump.
      Fig 30: Installing New Gasket
      G01083828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the upper radiator hose.
    6. Connect the lower radiator hose.
    7. Connect the fuel tube connector.
    8. Connect the 2 heater hoses.
    9. Connect the connector to the fusible link block.
      Fig 31: Connecting Connector To Fusible Link Block
      G01083829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. 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. Install the glove compartment door with the 2 screws.
  28. Install engine room J/B  .
      Fig 32: Installing Engine Room J/B
      G01083830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  29. Install air cleaner assembly  .
      Fig 33: Installing Air Cleaner Assembly
      G01083831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  30. Install battery and tray  .
    1. Install the battery bracket with the 5 bolts.
      Fig 34: Installing Battery & Tray
      G01083832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the battery tray and battery with the hold-down clamp.
    3. Install the cowl top ventilation louver (See INSTALLATION ).
  31. Install radiator reservoir tank  .
  32. Install hood  .
  33. Fill with engine coolant  .
  34. Fill with engine oil  .
  35. Fill with transfer oil  .
  36. Fill with transaxle oil  .
  37. Start engine and check for leaks  .
  38. Bleed power steering system (See  POWER STEERING FLUID  )  .
  39. Perform road test  .

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

  40. Recheck engine coolant and oil levels  .
  41. Install engine under covers  .
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