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Engine Assembly: Installation

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  1. INSTALL ENGINE WIRE 
  2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  3. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  5. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U250E.

  7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE UNIT for E351.

  8. INSTALL STARTER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  9. INSTALL STARTER ASSEMBLY (for Automatic Transaxle)  (See INSTALLATION )
  10. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

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

      Fig 1: Locating Drive Shaft Bearing Bracket And Bolts
      G06008398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR 
    1. Temporarily install the front engine mounting insulator with the nut and through bolt.
    Fig 2: Locating Through Bolt And Nut
    G06008393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR 
    1. Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
    Fig 3: Locating Through Bolt And Nut
    G06008394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 
    1. Install the engine mounting insulator RH with the 3 bolts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      Fig 4: Locating Bolts And Engine Mounting Insulator Sub-Assembly RH
      G06008396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Temporarily install the engine mounting insulator LH with the 4 bolts.
    2. Tighten the 4 bolts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      HINT:

      Perform this procedure only when replacement of the engine mounting insulator is necessary.

      Fig 5: Locating Bolts And Engine Mounting Insulator LH
      G06008395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
      NOTE: Place the engine on wooden blocks or equivalent so that the engine is level.
    2. Remove the 2 bolts and 2 engine hangers.
    3. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulators RH and LH can be installed.
      Fig 6: Setting Engine Assembly With Transaxle On Engine Lifter
      G06008403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
      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.
    4. Install the engine mounting insulator RH with the bolt and 2 nuts.

      Torque: Nut A 

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

      Nut B 

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

      Bolt 

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

      Fig 7: Locating Engine Mounting Insulator RH With Bolt And Nuts
      G06008404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine mounting insulator LH with the through bolt and nut.

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

  16. TEMPORARILY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See INSTALLATION )
  17. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  (See INSTALLATION )
  18. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See INSTALLATION )
    Fig 8: Locating Through Bolt And Nut
    G06008390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR 
    1. Fully tighten the front engine mounting insulator with the nut and through bolt.

      Torque: 73 N*m (744 kgf*cm, 54 ft.*lbf) 

      Fig 9: Locating Nut And Through Bolt
      G06008406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR 
    1. Fully tighten the rear engine mounting insulator to the engine mounting bracket with the through bolt.

      Torque: 65 N*m (663 kgf*cm, 48 ft.*lbf) 

      Fig 10: Locating Through Bolt And Nut
      G06008394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U250E.

  22. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH  (See INSTALLATION )
  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  25. INSTALL STEERING KNUCKLE WITH AXLE HUB LH 
    1. Align the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.
  26. INSTALL STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure for the LH side.

    Fig 11: Identifying Matchmarks
    G06002846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
  28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  29. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  30. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  31. INSTALL TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  32. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  33. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  34. INSTALL FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure for the LH side.

  35. INSTALL FRONT AXLE SHAFT LH NUT  (See INSTALLATION )
  36. INSTALL FRONT AXLE SHAFT RH NUT 

    HINT:

    Perform the same procedure for the LH side.

  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  38. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  39. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See INSTALLATION )
  40. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See INSTALLATION )
  41. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  42. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Connect the transmission control cable to the control cable bracket.
      Fig 12: Locating Transmission Control Cable
      G06008385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the transmission control cable to the bracket with a new clip.
    3. Connect the transmission control cable assembly to the control shaft lever with the nut.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 13: Locating Transmission Control Cable Assembly Nut
      G06011483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Install the 2 transmission control cables to the control cable bracket with 2 new clips*1.
    2. Install the 2 transmission control cables to the transaxle with 2 new clips*2.
    Fig 14: Identifying Transmission Control Cables
    G06008411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REASSEMBLY for E351.

  45. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the union to connector tube hose.
    Fig 15: Locating Connector Tube Hose
    G06008383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. 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.
    Fig 16: Identifying Claw And No. 1 Fuel Pipe Clamp
    G06008381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose with the clamp.
    Fig 17: Locating Inlet Heater Water Hose With Clamp
    G06008414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose with the clamp.
    Fig 18: Locating Outlet Heater Water Hose With Clamp
    G06008379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL BREATHER HOSE (for Automatic Transaxle) 
    1. Install the breather hose.
    Fig 19: Locating Breather Hose
    G06008416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. CONNECT OIL COOLER HOSE (for Automatic Transaxle) 
    1. Connect the 2 oil cooler hoses with the clamps.
    Fig 20: Locating Oil Cooler Hoses With Clamps
    G06008377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose with the clamp.
    Fig 21: Locating No. 1 Radiator Hose With Clamp
    G06008418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose with the clamp.
  53. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY  (See INSTALLATION )
  54. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  55. INSTALL V-RIBBED BELT  (See ON-VEHICLE INSPECTION )
  56. INSTALL THROTTLE BODY ASSEMBLY  (See INSTALLATION )
    Fig 22: Locating No. 2 Radiator Hose With Clamp
    G06008375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL WIRE HARNESS 
    1. Install the ground cable to the transmission with the bolt and clamp (for Manual Transaxle).

      Torque: 13 N*m (130 kgf*cm, 10 ft.*lbf) 

      Fig 23: Locating Bolt And Ground Cable
      G06008371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the earth wire to the transmission with the bolt and clamp (for Automatic Transaxle).

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

      Fig 24: Locating Earth Wire Bolt
      G06008421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the wire harness with the 2 nuts.

      Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

    4. Connect the 3 connectors
      Fig 25: Locating Wire Harness With Nuts
      G06008422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connector to the ECM with the clamp and lock lever.
    Fig 26: Locating ECM With Clamp And Lock Lever
    G05387343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 4 bolts.

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

    2. Connect the 2 wire harness clamps.
  59. INSTALL BATTERY 
    1. Install the battery tray, battery and battery insulator.
      Fig 27: Locating Bolts And Battery Carrier
      G06008368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the battery clamp with the bolt and nut.

      Torque: Bolt 

      6.5 N*m (66 kgf*cm, 58 in.*lbf) 

      Nut 

      3.5 N*m (36 kgf*cm, 31 in.*lbf) 

    3. Connect the battery cables.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 28: Locating Battery Clamp With Bolt And Nut
      G06008425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL AIR CLEANER CASE 
    1. Install the air cleaner case with the 3 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

    2. Install the engine wire clamp to the air cleaner case.
    3. Install the air cleaner filter element.
  61. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See INSTALLATION )
    Fig 29: Locating Air Cleaner Case And Bolts
    G06008426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
    1. Install the radiator reserve tank assembly with the 3 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

  63. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for E351.

    Fig 30: Locating Radiator Reserve Tank Assembly And Bolts
    G06008427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for E351.

  65. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U250E.

  66. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U250E.

  67. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U250E.

  68. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U250E.

  69. ADD ENGINE COOLANT  (See COOLANT )
  70. WARM UP ENGINE 
  71. FILL BRAKE FLUID RESERVOIR (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  72. BLEED CLUTCH LINE (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  73. INSPECT FLUID LEVEL (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  74. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  75. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  76. INSPECT FOR OIL LEAK 
  77. INSPECT FOR EXHAUST GAS LEAK 
  78. INSTALL ENGINE UNDER COVER LH 
  79. INSTALL ENGINE UNDER COVER RH 
  80. INSTALL FRONT WHEELS 

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

  81. INSPECT IGNITION TIMING  (See ENGINE )
  82. INSPECT ENGINE IDLING SPEED  (See ON-VEHICLE INSPECTION )
  83. INSPECT CO/HC  (See ON-VEHICLE INSPECTION )
  84. ADJUST FRONT WHEEL ALIGNMENT 

    HINT:

    See FRONT WHEEL ALIGNMENT .

  85. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Install the No. 1 engine cover sub-assembly with the 2 nuts.
  86. CHECK ABS SPEED SENSOR SIGNAL 

    HINT:

    Fig 31: Locating Nuts And No. 1 Engine Cover Sub-Assembly
    G06008364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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