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Engine Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL ENGINE HANGERS  (See INSTALLATION )
  2. REMOVE ENGINE STAND 
  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY  (See ENGINE ASSEMBLY )
  4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY  (See DISASSEMBLY )
    Fig 1: Locating Engine Hangers Bolts
    G05997905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

    Fig 2: Locating Engine Mounting Bracket RH Bolts
    G06030177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR 
    1. Temporarily install the front engine mounting insulator with the nut.
    Fig 3: Locating Front Engine Mounting Insulator Nut
    G06112149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Temporarily install the engine mounting insulator LH with the nut.
    Fig 4: Locating Engine Mounting Insulator LH Nut
    G06112150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Temporarily install the engine mounting insulator RH with the nut.
  9. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine assembly with transaxle with the 9 nuts.
      Fig 5: Locating Engine Mounting Insulator RH Nut
      G06112151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 6: Locating Engine Assembly With Transaxle Nuts
      G05640512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: A 

      52 N*m (531 kgf*cm, 39 ft.*lbf) 

      B 

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

    2. Tighten the 3 nuts.
      Fig 7: Locating Front Frame Assembly Nuts
      G06112159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: A 

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

      B 

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

    3. Install the 5 hole plugs.
    Fig 8: Locating Hole Plugs
    G05640491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 

  11. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH  (See REASSEMBLY )
  12. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  13. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  14. INSTALL STARTER ASSEMBLY  (See INSTALLATION )
  15. INSTALL COMPRESSOR AND MAGNETIC CLUTCH  (See INSTALLATION )
    Fig 9: Locating Drive Shaft Bearing Bracket Bolts
    G06030182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  17. INSTALL V-RIBBED BELT  (See INSTALLATION )
  18. INSTALL ENGINE WIRE 
  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Remove engine hangers (See INSTALLATION ).
    3. Install the engine assembly to the vehicle.
    4. Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.

      Torque: Bolt A 

      85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt B 

      32 N*m (327 kgf*cm, 24 ft.*lbf) 

      Nut C 

      32 N*m (327 kgf*cm, 24 ft.*lbf) 

      Fig 10: Locating Frame Side Rail Plates Bolts And Nuts (RH And LH)
      G06112162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the front suspension member rear braces RH and LH with the 6 bolts and 2 nuts.

      Torque: Bolt A 

      85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt B 

      32 N*m (327 kgf*cm, 24 ft.*lbf) 

      Nut C 

      32 N*m (327 kgf*cm, 24 ft.*lbf) 

      Fig 11: Locating Front Suspension Member Rear Braces Bolts And Nuts (RH And LH)
      G06112163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft pulley.

      SST 09213-54015, 09330-00021, 91551 -80650 

      Fig 12: Holding Crankshaft Pulley Using SST
      G06030119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply a few drops of adhesive to the 2 or 3 end threads of the 6 drive plate and torque converter clutch setting bolts.

      Adhesive: 

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent 

      Fig 13: Applying Drops Of Adhesive To End Threads Of Drive Plate And Torque Converter Clutch Setting Bolts
      G05997874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 6 drive plate and torque converter clutch setting bolts.

      Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) 

      NOTE: Install the black colored bolt first, and then the 5 silver colored bolts.
      Fig 14: Locating Torque Converter Clutch Setting Bolt
      G06030200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover.
  22. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See INSTALLATION )
  23. INSTALL FRONT AXLE ASSEMBLY LH  (See INSTALLATION )
  24. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Use the same procedure described for the LH side.

    Fig 15: Locating Flywheel Housing Under Cover
    G06030201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. INSTALL NO. 1 FRONT LOWER SUSPENSION ARM LH  (See INSTALLATION )
  26. INSTALL NO. 1 FRONT LOWER SUSPENSION ARM RH 

    HINT:

    Use the same procedure described for the LH side.

  27. CONNECT TIE ROD ASSEMBLY LH  (See INSTALLATION )
  28. CONNECT TIE ROD ASSEMBLY RH 

    HINT:

    Use the same procedure described for the LH side.

  29. INSTALL FRONT SPEED SENSOR LH  (See INSTALLATION )
  30. INSTALL FRONT SPEED SENSOR RH 

    HINT:

    Use the same procedure described for the LH side.

  31. INSTALL FRONT AXLE HUB NUT LH  (See INSTALLATION )
  32. INSTALL FRONT AXLE HUB NUT RH 

    HINT:

    Use the same procedure described for the LH side.

  33. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  34. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Use the same procedure described for the LH side.

  35. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  36. CONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See INSTALLATION )
  37. CONNECT SUCTION HOSE SUB-ASSEMBLY  (See INSTALLATION )
  38. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the 2 union to check valve hoses.
    Fig 16: Locating Union To Check Valve Hoses
    G06112138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL ENGINE MOVING CONTROL ROD 
    1. Temporarily install the engine moving control rod with the 4 bolts.
      Fig 17: Locating Engine Moving Control Rod Bolts
      G06030160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Temporarily install the No. 2 engine mounting stay with the 2 bolts.
    3. Tighten the 6 bolts.

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

    Fig 18: Locating No. 2 Engine Mounting Stay RH Bolts
    G06030159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. CONNECT ENGINE WIRE 
    1. Connect the 4 ECM connectors, 2 junction block connectors and clamp.
      Fig 19: Locating ECM Connectors, Junction Block Connectors With Clamp
      G06112134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire with the 2 nuts and clamp.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      Fig 20: Locating Engine Wire Nuts With Clamp
      G06112135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the ground cable with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

      Fig 21: Locating Ground Cable Bolt
      G06030207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the ground cable with the 2 bolts.

      Torque: A 

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

      B 

      12 N*m (122 kgf*cm, 9 ft.*lbf) 

      Fig 22: Locating Ground Cable Bolts
      G06112174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the positive (+) cable with the nut and 2 clamps.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      Fig 23: Locating Positive (+) Cable Nut With Clamps
      G06030157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the ground cable with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    7. Connect the engine wire clamp.
      Fig 24: Locating Ground Cables Bolt
      G06112130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the engine wire clamp.
      Fig 25: Identifying Engine Wire Clamp
      G06112129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the engine wire to the engine room relay block.
      Fig 26: Connecting Engine Wire To Engine Room Relay Block
      G06112178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Install the nut, and connect the engine wire connector.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

      Fig 27: Locating Nut And Engine Wire Connector
      G06112127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Install the No. 1 relay block cover.
  41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install a new clip to the control cable bracket.
      Fig 28: Identifying No. 1 Relay Block Cover
      G06112126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the control cable to the control cable bracket.
      NOTE:
      • Make sure that the A claws on the clip are securely fit into the bracket holes.
      • Make sure that the cable is securely installed inside the B claws of the clip.
      Fig 29: Identifying Control Cable With Claw
      G05010223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the transmission control cable to the control shaft lever with the nut.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      NOTE: Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.
      Fig 30: Locating Control Shaft Lever Nut
      G06112182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. CONNECT OUTLET OIL COOLER HOSE 
    1. Connect the outlet oil cooler hose.
  43. CONNECT INLET OIL COOLER HOSE 
    1. Connect the inlet oil cooler hose.
    Fig 31: Locating Inlet Oil Cooler Hose And Outlet Oil Cooler Hose
    G06112124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Push in the fuel tube connector to the fuel pipe until the fuel tube makes a "click" sound.
      NOTE:
      • Check for damage or dirt and foreign objects on the connected part of the pipe.
      • Check if the pipe and the connector are securely connected by trying to pull them apart.
      Fig 32: Pushing Fuel Tube Connector To Fuel Pipe
      G04961676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 fuel pipe clamp.
    Fig 33: Locating No. 1 Fuel Pipe Clamp
    G06030149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose.
    Fig 34: Locating Outlet Heater Water Hose
    G06030148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose.
    Fig 35: Locating Inlet Heater Water Hose
    G06030147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose.
    Fig 36: Locating No. 1 Radiator Hose
    G06112119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose.
    Fig 37: Locating No. 2 Radiator Hose
    G06112120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL RESERVOIR BRACKET 
    1. Install the reservoir bracket with the 2 bolts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    Fig 38: Locating Reservoir Bracket Bolts
    G06112118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Install the brake master cylinder reservoir assembly with the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    2. Connect the level warning switch connector.
    Fig 39: Locating Level Warning Switch Connector And Brake Master Cylinder Reservoir Assembly Bolt
    G06112117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. INSTALL NO. 1 INLET AIR CLEANER 
    1. Install the No. 1 inlet air cleaner with the bolt.

      Torque: 7.0 N*m (72 kgf*cm, 62 in.*lbf) 

    Fig 40: Locating No. 1 Inlet Air Cleaner Bolt
    G06112116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL AIR CLEANER BRACKET 
    1. Install the air cleaner bracket with the 2 bolts.

      Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) 

    Fig 41: Locating Air Cleaner Bracket Bolts
    G06112115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly with the 3 bolts and 2 clamps.

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

  54. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Install the air cleaner filter element sub-assembly.
  55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY  (See INSTALLATION )
    Fig 42: Locating Air Cleaner Case Sub-Assembly Bolts With Clamps
    G06112114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL NO. 2 INLET AIR CLEANER 
    1. Install the No. 2 inlet air cleaner with the 2 bolts.

      Torque: 7.0 N*m (72 kgf*cm, 62 in.*lbf) 

    2. Connect the 2 clamps and vacuum hose.
  57. INSTALL BATTERY 
    1. Install the battery tray and battery.
      Fig 43: Locating No. 2 Inlet Air Cleaner Bolts And Vacuum Hose With Clamp
      G06112113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the battery clamp with the bolt and nut.

      Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 

    3. Install the positive (+) battery terminal with the nut.

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

  58. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY  (See INSTALLATION )
  59. INSTALL EJECTOR TUBE  (See INSTALLATION )
  60. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
    Fig 44: Locating Positive (+) Battery Terminal And Nut
    G06112112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  62. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  63. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  64. INSTALL FRONT WHEELS 

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

  65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  66. ADD ENGINE OIL  (See REPLACEMENT )
  67. ADD ENGINE COOLANT  (See COOLANT )
  68. ADD AUTOMATIC TRANSAXLE FLUID 

    HINT:

    See DISASSEMBLY .

  69. CHARGE WITH REFRIGERANT  (See REPLACEMENT )
  70. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  71. INSPECT FOR OIL LEAK 
  72. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  73. INSPECT FOR EXHAUST GAS LEAK 
  74. INSPECT FOR REFRIGERANT LEAK  (See REPLACEMENT )
  75. INSPECT AND ADJUST SHIFT LEVER POSITION 

    HINT:

    See INSPECTION .

  76. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    HINT:

    See FRONT WHEEL ALIGNMENT .

  77. INSPECT IGNITION TIMING  (See ENGINE )
  78. INSPECT ENGINE IDLE SPEED  (See DRIVE BELT )
  79. INSPECT CO/HC  (See DRIVE BELT )
  80. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 bolts and clip.
    Fig 45: Locating Front Fender Apron Seal RH Bolts And Clip
    G06112110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 bolts and clip.
  82. INSTALL FRONT FENDER LINER LH  (See INSTALLATION )
  83. INSTALL FRONT FENDER LINER RH  (See INSTALLATION )
  84. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH  (See INSTALLATION )
    Fig 46: Locating Front Fender Apron Seal LH Bolts And Clip
    G06112109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH  (See CAMSHAFT )
  86. INSTALL FLOOR UNDER COVER LH 
  87. INSTALL NO. 2 ENGINE UNDER COVER 
  88. INSTALL NO. 1 ENGINE UNDER COVER 
  89. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Fit the 3 retainers and install the No. 1 engine cover sub-assembly.
    Fig 47: Locating No. 1 Engine Cover
    G06030140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the cool air intake duct seal with the 11 clips.
  91. CHECK ABS SPEED SENSOR SIGNAL 

    HINT:

    See TEST MODE PROCEDURE .

    Fig 48: Locating Cool Air Intake Duct Seal Clips
    G06112108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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