LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Corolla XLE, 1.8 L >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2ZR-FE) >> Engine Assembly >> Installation

Engine Assembly: Installation

  1. INSTALL ENGINE WIRE 
  2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See REAR CRANKSHAFT OIL SEAL )
  4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  5. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  6. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See INSTALLATION )
  7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSTALLATION for C59.

  8. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U341E.

  9. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  10. INSTALL FLYWHEEL HOUSING SIDE COVER 
  11. INSTALL FRONT ENGINE MOUNTING INSULATOR 
    1. Install the front engine mounting insulator with the nut and bolt.

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

      Fig 1: Identifying Front Engine Mounting Insulator With Nut And Bolt
      G06008798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL REAR ENGINE MOUNTING INSULATOR 
    1. Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

      Torque: except TMC made 

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

      for TMC made 

      87 N*m (887 kgf*cm, 64 ft.*lbf) 

      Fig 2: Identifying Engine Mounting Bracket With Bolt
      G06008799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 3: Identifying Engine Mounting Insulator LH
      G06008800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH with the 3 bolts.

      HINT:

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

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

      Fig 4: Identifying Engine Mounting Insulator RH
      G06008803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the radiator reserve tank with the 3 bolts.

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

      Fig 5: Identifying Radiator Reserve Tank Bolts
      G06008802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the relay block assembly.
  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
    2. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.
      CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
      Fig 6: Identifying Clamp And Relay Block Assembly
      G06008801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
    3. Install the engine mounting insulator LH with the through bolt and nut.

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

      Fig 7: Identifying Engine Mounting Insulator Nuts (LH)
      G06008797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  16. TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See INSTALLATION )
    Fig 8: Identifying Engine Mounting Insulator RH With Bolt And Nuts
    G06008813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  (See INSTALLATION )
  18. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See INSTALLATION )
  19. REMOVE ENGINE HANGER 
    1. Remove the 2 bolts and 2 engine hangers.
    2. Install the wire harness bracket with the bolt.

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

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)  (See INSTALLATION )
  21. INSTALL FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)  (See INSTALLATION )
  22. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH  (See INSTALLATION )
    Fig 9: Identifying Wire Harness Bracket
    G06008804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH  (See INSTALLATION )
  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  26. INSTALL STEERING KNUCKLE WITH AXLE HUB LH 
    1. Align the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.
  27. INSTALL STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure for the LH side.

  28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
  29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 
    Fig 10: Identifying Matchmarks Location
    G06002846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

  32. CONNECT TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  33. CONNECT TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

  38. INSTALL FRONT 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 WIRE HARNESS 
    1. Install the earth wire to the engine compartment with the bolt and clamp (for Manual Transaxle).

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

      Fig 11: Identifying Bolt And Clamp (Manual Transaxle)
      G06008793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the earth wire to the engine compartment with the bolt and clamp (for Automatic Transaxle).

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

      Fig 12: Identifying Wire Harnesses And Connectors
      G06008794Courtesy 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 and 2 wire harness clamps to the engine room junction block.
      Fig 13: Identifying Wire Harness With Nuts
      G06008818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the connector to the ECU with the lock lever and connect the clamp.
    Fig 14: Identifying Wire Harness With Clamp
    G05387343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Install the clutch release cylinder assembly with the 4 bolts and clutch tube bracket.

      Torque: Bolt A 

      12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Bolt B 

      12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Bolt C 

      8.0 N*m (82 kgf*cm, 71 in.*lbf) 

      Fig 15: Locating Clutch Release Cylinder Assembly With Bolts And Clutch Tube Bracket
      G06008820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)  (See INSPECTION )
  45. INSTALL FAN BELT ADJUSTING BAR 
    1. Install the bolt and fan belt adjusting bar.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

  46. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  47. INSTALL V-RIBBED BELT  (See INSTALLATION )
  48. ADJUST V-RIBBED BELT  (See INSTALLATION )
  49. INSPECT V-RIBBED BELT  (See ON-VEHICLE INSPECTION )
  50. CONNECT 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 on 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 No. 1 Fuel Pipe Clamp
    G05387476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose with the clamp.
    Fig 17: Locating Inlet Heater Water Hose With Clamp
    G06008785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose with the clamp.
    Fig 18: Identifying Outlet Heater Water Hose With Clamp
    G06008784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. CONNECT OIL COOLER HOSE (for Automatic Transaxle) 
    1. Connect the 2 oil cooler hoses with the clamps.
    Fig 19: Locating Oil Cooler Hoses With Clamps
    G06008783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the union to connector tube hose.
    Fig 20: Locating Connector Tube Hose Clamp
    G06008782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Connect the fuel vapor feed hose assembly.
    Fig 21: Locating Fuel Vapor Feed Hose Clamp
    G06008781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Install the transmission control cable to the control cable bracket with 2 new clips.
    2. Install the transmission control cable to the transaxle with the 2 clips.
    Fig 22: Locating Transmission Control Cable Assembly (Manual Transaxle)
    G06008779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Secure the control cable onto the control cable bracket with a new clip.
    2. Connect the control cable onto the control shaft lever with the nut.

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

    3. Connect the control cable to the cable support.
    4. Connect the clamp of the control cable with the bolt.

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

      Fig 23: Locating Transmission Control Cable Assembly (Automatic Transaxle)
      G06008780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose with the clamp.
    Fig 24: Locating No. 2 Radiator Hose Clamp
    G06008778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose with the clamp.
    2. Connect the clamp.
  60. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 4 bolts.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 25: Locating No. 1 Radiator Hose Clamp
      G06008830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the radiator pipe with the 2 bolts.

      Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf) 

      Fig 26: Identifying Battery Carrier Bolts
      G06008776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 wire harness clamps.
  61. INSTALL BATTERY 
    1. Install the battery clamp with the bolt and nut.

      Torque: for bolt 

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

      for nut 

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

    2. Connect the battery cables.

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

      Fig 27: Identifying Wire Harness Clamps
      G06008775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. 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 wire harness clamp to the air cleaner case.
    3. Install the air cleaner filter element.
  63. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSPECTION )
  64. ADD TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for C59.

    Fig 28: Locating Bolts With Air Cleaner Case
    G06008774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSPECT AND ADJUST TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for C59.

  66. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

    See INSTALLATION for U341E.

  67. INSPECT TRANSAXLE FLUID LEVEL (for Automatic Transaxle) 

    HINT:

    See ON-VEHICLE INSPECTION for U341E.

  68. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK (for Automatic Transaxle) 
  69. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT:

    See ADJUSTMENT for U341E.

  70. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT:

    See ADJUSTMENT for U341E.

  71. ADD ENGINE COOLANT  (See REPLACEMENT )
  72. ADD ENGINE OIL  (See REPLACEMENT )
  73. INSPECT ENGINE OIL LEVEL  (See ON-VEHICLE INSPECTION )
  74. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  75. INSPECT FOR ENGINE COOLANT LEAK  (See ON-VEHICLE INSPECTION )
  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 ON-VEHICLE INSPECTION )
  82. INSPECT ENGINE IDLE 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. 2 CYLINDER HEAD COVER 
    1. Engage the 4 clips to install the No. 2 cylinder head cover.
    NOTE:
    • Be sure to engage the clips securely.
    • Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
  86. CHECK ABS SPEED SENSOR SIGNAL 
    Fig 29: Identifying No. 2 Cylinder Head Cover Bolts
    G06008773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    See TEST MODE PROCEDURE for ABS.

    See TEST MODE PROCEDURE for VSC.

scientia non olet · About LEMON Manuals