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Engine Assembly: Installation

WARNING: This page is about a different variant/trim than selected.
  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:

  7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSTALLATION 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 (for 2WD) 
    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 (2WD)
      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 Front Engine Mounting Insulator Bolt And Nut
    G06008393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 2WD) 
    1. Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
    Fig 3: Locating Rear Engine Mounting Insulator And Bolt (2WD)
    G06008394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 4WD) 
    1. Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
    Fig 4: Locating Rear Engine Mounting Insulator Bolt (4WD)
    G06041069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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 5: Locating Engine Mounting Insulator Sub-Assembly RH And Bolts
      G06008396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. 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 6: Locating Engine Mounting Insulator LH And Bolts
      G06008395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. 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.
      Fig 7: Identifying Engine Assembly With Transaxle On Engine Lifter
      G06041062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      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 8: 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) 

      Fig 9: Locating Engine Mounting Insulator LH With Bolt And Nut
      G06008390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY 

    HINT:

  18. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    HINT:

  19. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY 

    HINT:

  20. 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 10: Locating Front Engine Mounting Insulator Bolt And Nut
      G06008393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 2WD) 
    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 11: Locating Rear Engine Mounting Insulator And Bolt (2WD)
      G06008394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 4WD) 
    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 12: Locating Rear Engine Mounting Insulator Bolt (4WD)
      G06041069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) 

    HINT:

  24. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH  (See INSTALLATION )
  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  26. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT:

  27. INSTALL STEERING KNUCKLE WITH AXLE HUB LH 
    1. Align the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.
  28. INSTALL STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure for the LH side.

    Fig 13: Identifying Matchmarks Location
    G06002846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See INSTALLATION )
  30. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

  33. INSTALL TIE ROD END SUB-ASSEMBLY LH 

    HINT:

  34. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

  39. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)  (See INSTALLATION )
  40. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)  (See INSTALLATION )
  41. INSTALL FRONT EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  42. INSTALL CENTER EXHAUST PIPE ASSEMBLY  (See INSTALLATION )
  43. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See INSTALLATION )
  44. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    HINT:

  45. INSTALL COLUMN HOLE COVER SILENCER SHEET  (See INSTALLATION )
  46. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. U250E Automatic Transaxle:
      1. Connect the transmission control cable to the control cable bracket.
        Fig 14: Locating Control Cable Bracket
        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 15: Locating Transmission Control Cable Assembly And Nut (Automatic Transaxle)
        G06011483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. U140F Automatic Transaxle:
      1. Connect the transmission control cable to the control cable bracket.
        Fig 16: Locating Control Cable Bracket
        G06041059Courtesy 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 17: Locating Control Cable Assembly Nuts
        G06041058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. 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 18: Identifying Control Cable Bracket
      G06008411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REASSEMBLY for E351.

  49. CONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Connect the union to connector tube hose.
    Fig 19: Locating Connector Tube Hose
    G06008383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. 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 20: Identifying No. 1 Fuel Pipe Clamp
      G06008381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose with the clamp.
    Fig 21: Locating Inlet Heater Water Hose Clamp
    G06008414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose with the clamp.
    Fig 22: Locating Outlet Heater Water Hose
    G06008379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL BREATHER HOSE (for Automatic Transaxle) 
    1. Install the breather hose.
    Fig 23: Locating Breather Hose Clamp (Automatic Transaxle)
    G06008416Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. CONNECT OIL COOLER HOSE (for Automatic Transaxle) 
    1. Connect the 2 oil cooler hoses with the clamps.
    Fig 24: Locating Oil Cooler Hose Clamp (Automatic Transaxle)
    G06041049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSTALL NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose with the clamp.
    Fig 25: Locating No. 1 Radiator Hose Clamp
    G06008418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose with the clamp.
      Fig 26: Locating No. 2 Radiator Hose Clamp
      G06008375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY  (See INSTALLATION )
  58. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  59. INSTALL V-RIBBED BELT  (See INSTALLATION  )
  60. INSTALL THROTTLE BODY ASSEMBLY  (See INSTALLATION )
  61. 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 27: Locating Ground Cable And Clamp (Manual Transaxle)
      G06008371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ground wire to the transmission with the bolt and clamp (for Automatic Transaxle).

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

      Fig 28: Locating Ground Cable And Clamp (Automatic Transaxle)
      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 29: 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 30: Connecting Connector To ECM With Clamp And Lock Lever
    G05387343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSTALL BATTERY CARRIER 
    1. Install the battery carrier with the 4 bolts.

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

      Fig 31: Identifying Wire Harness Clamps And Battery Carrier Bolts
      G06008368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 wire harness clamps.
  63. INSTALL BATTERY 
    1. Install the battery tray, battery and battery insulator.
    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) 

      Fig 32: Locating Battery Clamp And Bolt With Nut
      G06008425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. 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) 

      Fig 33: Locating Air Cleaner Case And Bolts
      G06008426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire clamp to the air cleaner case.
    3. Install the air cleaner filter element.
  65. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See INSTALLATION )
  66. 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) 

      Fig 34: Locating Radiator Reserve Tank Assembly And Bolts
      G06008427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for E351.

  68. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for E351.

  69. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

  70. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

  71. ADD TRANSFER OIL (for 4WD) 
  72. INSPECT TRANSFER OIL (for 4WD)  (See TRANSFER OIL )
  73. ADJUST TRANSFER OIL  (See TRANSFER OIL )
  74. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT:

  75. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT:

  76. ADD ENGINE COOLANT  (See COOLANT )
  77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

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

  78. WARM UP ENGINE 
  79. FILL BRAKE FLUID RESERVOIR (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  80. BLEED CLUTCH LINE (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  81. INSPECT FLUID LEVEL (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

  82. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  83. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  84. INSPECT FOR OIL LEAK 
  85. INSPECT FOR EXHAUST GAS LEAK 
  86. INSTALL ENGINE UNDER COVER LH 
  87. INSTALL ENGINE UNDER COVER RH 
  88. INSTALL FRONT WHEELS 

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

  89. INSPECT IGNITION TIMING  (See ENGINE )
  90. INSPECT ENGINE IDLING SPEED  (See ON-VEHICLE INSPECTION )
  91. INSPECT CO/HC  (See ON-VEHICLE INSPECTION )
  92. ADJUST FRONT WHEEL ALIGNMENT 

    HINT:

    See FRONT WHEEL ALIGNMENT .

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

    HINT:

    Fig 35: Locating No. 1 Engine Cover Sub-Assembly And Nuts
    G06008364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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