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Engine Assembly: Installation: Installation

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL ENGINE WIRE 
  2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  See step  2
  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  See step  3
  4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)  . Refer to INSTALLATION - Step 1
  5. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)  . Refer to INSTALLATION - Step 2
  6. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)  . Refer to INSTALLATION - Step 3
  7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT: 

    Refer to INSTALLATION for C59.

  8. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT: 

    Refer to INSTALLATION for U341E.

  9. INSTALL STARTER ASSEMBLY  . Refer to INSTALLATION - Step 1
  10. INSTALL FLYWHEEL HOUSING SIDE COVER 
  11. INSTALL FRONT ENGINE MOUNTING INSULATOR 
    1. Install the front engine mounting insulator with the nut and bolt.
      Fig 1: Identifying Front Engine Mounting Insulator With Nut And Bolt
      GTY169588Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  12. INSTALL REAR ENGINE MOUNTING INSULATOR 
    1. Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
      Fig 2: Identifying Engine Mounting Bracket With Bolt
      GTY194439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  13. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Temporarily install the engine mounting insulator LH with the 4 bolts.
      Fig 3: Identifying Engine Mounting Insulator LH And Bolts
      GTY169710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

  14. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH with the 3 bolts.
      Fig 4: Identifying Engine Mounting Insulator RH And Bolts
      GTY194551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

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

    2. Install the radiator reserve tank with the 3 bolts.
      Fig 5: Identifying Radiator Reserve Tank And Bolts
      GTY177458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the relay block assembly.
      Fig 6: Identifying Relay Block Assembly And Clamp
      GTY169830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      WARNING:

      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.
    3. Install the engine mounting insulator LH with the through bolt and nut.
      Fig 7: Identifying Engine Mounting Insulator Nuts (LH)
      GTY194435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Install the engine mounting insulator RH with the bolt and 2 nuts.
      Fig 8: Identifying Engine Mounting Insulator RH With Bolt And Nuts
      GTY170825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Nut A 

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

      Nut B 

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

      Bolt 

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

  16. TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 6
  17. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 7
  18. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 8
  19. REMOVE ENGINE HANGER 
    1. Remove the 2 bolts and 2 engine hangers.
    2. Install the wire harness bracket with the bolt.
      Fig 9: Identifying Wire Harness Bracket And Bolt
      GTY169084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)  . Refer to INSTALLATION - Step 13
  21. INSTALL FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)  . Refer to INSTALLATION - Step 14
  22. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH  . Refer to INSTALLATION - Step 1
  23. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH  . Refer to INSTALLATION - Step 2
  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  . Refer to INSTALLATION - Step 3
  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  . Refer to INSTALLATION - Step 4
  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.
      Fig 10: Aligning Shaft Splines In Drive Shaft To Steering Knuckle With Axle Hub
      GTY182757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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  . Refer to INSTALLATION - Step 3
  29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure for the LH side.

  30. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  . Refer to INSTALLATION - Step 13
  31. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure for the LH side.

  32. CONNECT TIE ROD END SUB-ASSEMBLY LH  . Refer to INSTALLATION - Step 11
  33. CONNECT TIE ROD END SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure for the LH side.

  34. INSTALL FRONT SPEED SENSOR LH  . Refer to INSTALLATION - Step 12
  35. INSTALL FRONT SPEED SENSOR RH 

    HINT: 

    Perform the same procedure for the LH side.

  36. INSTALL FRONT AXLE SHAFT LH NUT  . Refer to INSTALLATION - Step 15
  37. INSTALL FRONT AXLE SHAFT RH NUT 

    HINT: 

    Perform the same procedure for the LH side.

  38. INSTALL FRONT EXHAUST PIPE ASSEMBLY  . Refer to INSTALLATION - Step 1
  39. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  . Refer to INSTALLATION - Step 5
  40. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  . Refer to INSTALLATION - Step 3
  41. INSTALL COLUMN HOLE COVER SILENCER SHEET  . Refer to INSTALLATION - Step 8
  42. INSTALL WIRE HARNESS 
    1. Install the earth wire to the engine compartment with the bolt and clamp (for Manual Transaxle).
      Fig 11: Identifying Bolt And Clamp (Manual Transaxle)
      GTY183050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the earth wire to the engine compartment with the bolt and clamp (for Automatic Transaxle).
      Fig 12: Identifying Bolt And Clamp (Automatic Transaxle)
      GTY183169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the wire harness with the 2 nuts.
      Fig 13: Locating Engine Room Junction Block And Clamps
      GTY235663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
    5. Connect the connector to the ECU with the lock lever and connect the clamp.
      Fig 14: Locating Engine Control Computer With Clamp And Lock Lever
      GTY189602Courtesy 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.
      Fig 15: Locating Clutch Release Cylinder Assembly Bolts (For Manual Transaxle)
      GTY194725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 

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

      Bolt B 

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

      Bolt C 

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

  44. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)  . Refer to INSTALLATION - Step 2
  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  . Refer to INSTALLATION - Step 1
  47. INSTALL V-RIBBED BELT  See step  1
  48. ADJUST V-RIBBED BELT  See step  2
  49. INSPECT V-RIBBED BELT  See step  1
  50. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube connector and fuel pipe.
      WARNING:

      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
      GTY171622Courtesy 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
      GTY194437Courtesy 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
      GTY194438Courtesy 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
      GTY213321Courtesy 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
      GTY183898Courtesy 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
      GTY182106Courtesy 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.
      Fig 22: Locating Transmission Control Cable Assembly (Manual Transaxle)
      GTY176087Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission control cable to the transaxle with the 2 clips.
  57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Secure the control cable onto the control cable bracket with a new clip.
      Fig 23: Locating Transmission Control Cable Assembly (Automatic Transaxle)
      GTY193796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

  58. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose with the clamp.
      Fig 24: Locating No. 2 Radiator Hose With Clamp
      GTY189769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose with the clamp.
      Fig 25: Locating No. 1 Radiator Hose With Clamp
      GTY172195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

    2. Connect the radiator pipe with the 2 bolts.
      Fig 26: Identifying Battery Carrier Bolts
      GTY170383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the 2 wire harness clamps.
      Fig 27: Identifying Wire Harness Clamps
      GTY173265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL BATTERY 
    1. Install the battery clamp with the bolt and nut.

      for bolt 

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

      for nut 

      Torque: 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) 

  62. INSTALL AIR CLEANER CASE 
    1. Install the air cleaner case with the 3 bolts.
      Fig 28: View Of Air Cleaner Case And Bolts
      GTY182726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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  . Refer to INSTALLATION - Step 2
  64. ADD TRANSAXLE OIL (for Manual Transaxle) 

    HINT: 

    Refer to REPLACEMENT for C59.

  65. INSPECT AND ADJUST TRANSAXLE OIL (for Manual Transaxle) 

    HINT: 

    Refer to REPLACEMENT for C59.

  66. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 
  67. INSPECT TRANSAXLE FLUID LEVEL (for Automatic Transaxle) 

    HINT: 

    Refer to ON-VEHICLE INSPECTION for U341E.

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

    HINT: 

    Refer to ADJUSTMENT for U341E.

  70. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle) 

    HINT: 

    Refer to ADJUSTMENT for U341E.

  71. ADD ENGINE COOLANT  . Refer to REPLACEMENT - Step 2
  72. ADD ENGINE OIL  . Refer to REPLACEMENT - Step 4
  73. INSPECT ENGINE OIL LEVEL  . Refer to ON-VEHICLE INSPECTION - Step 1
  74. INSPECT FOR FUEL LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  75. INSPECT FOR ENGINE COOLANT LEAK  . Refer to ON-VEHICLE INSPECTION - Step 1
  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 step  8
  82. INSPECT ENGINE IDLE SPEED  See step  9
  83. INSPECT CO/HC  See step  11
  84. ADJUST FRONT WHEEL ALIGNMENT 

    HINT: 

    Refer to ADJUSTMENT .

  85. INSTALL NO. 2 CYLINDER HEAD COVER 
    1. Engage the 4 clips to install the No. 2 cylinder head cover.
      Fig 29: Identifying No. 2 Cylinder Head Cover And Clips
      GTY168589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 SPEED SENSOR SIGNAL 

    HINT: 

    Refer to TEST MODE PROCEDURE w/o VSC.

    Refer to TEST MODE PROCEDURE w/ VSC.

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