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Engine Assembly: Installation

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  1. INSTALL DRIVE PLATE SUB-ASSEMBLY 
    1. Clean the 8 bolts and 8 bolt holes.
    2. Apply adhesive to 2 or 3 threads of the 8 bolts.

      Adhesive: Toyota Genuine Adhesive 1342, Three Bond 1342 or Equivalent 

    3. Using SST, hold the crankshaft.

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

      Fig 1: Holding Crankshaft Using SST
      G04484857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front spacer.

      HINT:

      Align the pin of the front spacer with the pin hole of the crankshaft.

      Fig 2: Identifying Front Spacer
      G04484858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the drive plate and rear spacer onto the crankshaft.
      Fig 3: Identifying Drive Plate And Rear Spacer Onto Crankshaft
      G04484859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the figure below.

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

      Fig 4: Tightening Drive Plate Bolts In Sequence
      G04484860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY 
    1. Install the torque converter clutch for U241E (2WD), (see appropriate step(s) under INSTALLATION ).
    2. Install the torque converter clutch for U140F (4WD), (see appropriate step(s) under INSTALLATION ).
  3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Install the automatic transaxle for U241E (2WD), (see appropriate step(s) under INSTALLATION ).
    2. Install the automatic transaxle for U140F (4WD), (see appropriate step(s) under INSTALLATION ).
  4. INSTALL STARTER ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  5. INSTALL TRANSFER ASSEMBLY (for 4WD) (see appropriate step(s) under  INSTALLATION  ) 
  6. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD) 
    1. Install the bracket with the 3 bolts.

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

      Fig 5: Identifying Drive Shaft Bearing Bracket Bolts (2WD)
      G04484861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL DRIVE SHAFT BEARING BRACKET (for 4WD) 
    1. Install the bracket with the 3 bolts.

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

      Fig 6: Identifying Drive Shaft Bearing Bracket Bolts (4WD)
      G04484862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL ENGINE HANGER 
    1. Install the No. 1 and No. 2 engine hangers.

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

      Part No. 

      ENGINE HANGER PART NO. REFERENCE

      ITEM Part No.
      No. 1 engine hanger 12281-28010
      No. 2 engine hanger 12282-28010
      Bolt 91512-61020
      Fig 7: Identifying Engine Hangers
      G04484863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the sling device and the engine with the chain block.
  9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Lift the engine assembly (with transaxle) with the chain block.
      Fig 8: Attaching Sling Device To Engine Hangers And Chain Block
      G04484864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lower the engine out of the vehicle slowly and carefully.
      NOTE: Make sure the engine is clear of all wiring, hoses and cables.
      Fig 9: Removal/Installation Of Engine Assembly With Transaxle
      G04484865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH with the 4 bolts.

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

      Fig 10: Identifying Engine Mounting Insulator Bolts(LH)
      G04484866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 11: Identifying Through Bolt
      G04484867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH with the 2 bolts and 2 nuts.

      Torque: 

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

      95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A 

      52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B 

      Fig 12: Identifying Engine Mounting Insulator RH Bolts And Nuts
      G04484868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE ENGINE HANGER 
    1. Remove the No. 1 and No. 2 engine hangers.
      Fig 13: Identifying Engine Hanger
      G04484869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL ENGINE MOUNTING INSULATOR RR 
    1. Install the engine mounting insulator RR with the 2 nuts and 2 bolts.

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

      Fig 14: Identifying Engine Mounting Insulator Nuts And Bolts (RR)
      G04484870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.

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

      Fig 15: Identifying Through Bolt
      G04484871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL ENGINE MOUNTING INSULATOR FR 
    1. Install the engine mounting insulator FR with the 2 bolts.

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

      Fig 16: Identifying Engine Mounting Insulator Bolts FR
      G04484872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the through bolt and nut which is used to secure the front engine mounting bracket FR.

      HINT:

      Install the through bolt by tightening the nut.

      Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf) 

  15. INSTALL PROPELLER SHAFT ASSEMBLY (for 4WD) 
    1. Install the propeller shaft (see appropriate step(s) under PROPELLER SHAFT ).
  16. INSTALL FRONT DRIVE SHAFT ASSEMBLY 
    1. Install the front drive shaft RH (for 2WD) (see appropriate step(s) under INSTALLATION ).
    2. Install the front drive shaft RH (for 4WD) (see appropriate step(s) under INSTALLATION ).
      Fig 17: Identifying Through Bolt And Nut
      G04484873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT EXHAUST PIPE (see appropriate step(s) under  INSTALLATION  ) 
  18. 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) 

      Fig 18: Identifying Ground Cable Bolt
      G04484874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the ground cable to the clamp located near the starter.
    3. Connect the engine wire to the positive (+) battery terminal with the nut.

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

      Fig 19: Connecting Engine Wire To Positive Battery Terminal
      G04484875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the ground cable connector.
      Fig 20: Identifying Ground Cable Connector
      G04484876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 2 engine wire connectors and install the nut.
      Fig 21: Identifying Engine Wire Connectors And Nut
      G04484877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 22: Identifying Engine Wire Cover With Bolt
      G04484878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL ECM (see appropriate step(s) under  INSTALLATION  ) 
  20. INSTALL COOLER COMPRESSOR ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  21. INSTALL GENERATOR ASSEMBLY (see  INSTALLATION  ) 
  22. INSTALL FAN AND GENERATOR V BELT (see appropriate step(s) under  INSTALLATION  ) 
  23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH (see appropriate step(s) under  INSTALLATION  ) 
  24. INSTALL TRANSAXLE CONTROL CABLE ASSEMBLY 
    1. Install the transaxle control cable for U241E, (see appropriate step(s) under REPLACEMENT ).
    2. Install the transaxle control cable for U140F, (see appropriate step(s) under REPLACEMENT ).
  25. INSTALL INTAKE MANIFOLD INSULATOR (see appropriate step(s) under  INSTALLATION  ) 
  26. INSTALL INTAKE MANIFOLD (see appropriate step(s) under  INSTALLATION  ) 
  27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  28. CONNECT NO. 2 VENTILATION HOSE (see appropriate step(s) under  INSTALLATION  ) 
  29. INSTALL THROTTLE BODY ASSEMBLY (see appropriate step(s) under  INSTALLATION  ) 
  30. CONNECT FUEL TUBE (see appropriate step(s) under  INSTALLATION  ) 
  31. CONNECT HEATER WATER OUTLET HOSE 
    1. Connect the heater water outlet hose to the air conditioner tube.
      Fig 23: Identifying Heater Water Outlet Hose
      G04484879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. CONNECT HEATER WATER INLET HOSE 
    1. Connect the heater water inlet hose to the air conditioner tube.
      Fig 24: Identifying Heater Water Inlet Hose
      G04484880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the 2 union to connector tube hoses to the booster vacuum tube.
      Fig 25: Connecting Union To Connector Tube Hose
      G04484881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. INSTALL BATTERY CARRIER BRACKET 
    1. Install the battery carrier bracket with the nut and 2 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 26: Identifying Battery Carrier Bracket
      G04484882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL BATTERY BRACKET REINFORCEMENT 
    1. Install the battery bracket reinforcement with the 2 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 27: Identifying Battery Bracket Reinforcement With Bolts
      G04484883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. INSTALL FRONT BATTERY CARRIER 
    1. Install the front battery carrier with the 4 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    2. Connect the 2 clamps of the engine wire.
  37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Connect the air cleaner case to the No. 1 air cleaner inlet.
      Fig 28: Identifying Front Battery Carrier With Bolts
      G04484884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the air cleaner case with the 3 bolts.

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

      Fig 29: Identifying Air Cleaner Case With Bolts
      G04484885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  39. INSTALL AIR CLEANER CAP (see appropriate step(s) under  INSTALLATION  ) 
  40. INSTALL PURGE VSV (see appropriate step(s) under  INSTALLATION  ) 
  41. INSTALL RADIATOR RESERVOIR 
    1. Install the reservoir with the 2 bolts.

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

      Fig 30: Identifying Reservoir With Bolts
      G04484886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. INSTALL RADIATOR ASSEMBLY 
    1. Install the radiator (see appropriate step(s) under INSTALLATION ).
  43. INSTALL BATTERY TRAY 
  44. INSTALL BATTERY 
    1. Install the battery.
    2. Install the battery clamp with the bolt and nut.

      Torque: 

      8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt 

      5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut 

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  46. ADD AUTOMATIC TRANSAXLE FLUID 
    1. Add automatic transaxle fluid for U241E (2WD), (see ON-VEHICLE INSPECTION ).
    2. Add automatic transaxle fluid for U140F (4WD), (see ON-VEHICLE INSPECTION ).
  47. CHECK FOR FUEL LEAKS (see  INSTALLATION  ) 
  48. ADD ENGINE COOLANT (see appropriate step(s) under  COOLANT  ) 
  49. CHECK FOR ENGINE COOLANT LEAKS 
    1. Check for engine coolant leaks (see appropriate step(s) under COOLING SYSTEM ).
  50. CHECK FOR AUTOMATIC TRANSAXLE FLUID LEAKS 
  51. ADJUST SHIFT LEVER POSITION 
    1. Adjust the shift lever position for U241E (2WD), (see ADJUSTMENT ).
    2. Adjust the shift lever position for U140F (4WD), (see ADJUSTMENT ).
  52. INSTALL NO. 1 ENGINE COVER (see appropriate step(s) under  INSTALLATION  ) 
  53. INSTALL FRONT FENDER APRON RH 
  54. INSTALL NO. 2 ENGINE UNDER COVER 
  55. INSTALL NO. 1 ENGINE UNDER COVER 
  56. INSTALL FRONT WHEEL 
  57. INSTALL RADIATOR SUPPORT OPENING COVER 
  58. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood (see INSTALLATION ).
    2. Adjust the hood (see ADJUSTMENT ).
  59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust the front wheel alignment (see FRONT WHEEL ALIGNMENT ).
  60. PERFORM REGISTRATION 
    1. When replacing the engine assembly, perform vehicle stability control system recognition in ECM (see REGISTRATION ).
  61. RESET MEMORY (for Automatic Transaxle) 
    1. When replacing the engine assembly, perform the RESET MEMORY procedure (A/T initialization):

      For U241E (2WD), (see INITIALIZATION ).

      For U140F (4WD), (see INITIALIZATION ).

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