Engine Unit: Installation

HINT:

• The mounting bolts are tightened in 2 progressive steps (steps  b and  e).
• If any one of the mounting bolts is broken or deformed, replace it.

1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

   Fig 1: Applying Adhesive To Threads Of Mounting Bolt End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the front spacer, drive plate and rear spacer on the crankshaft.
3. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown in Fig 2.

   Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

   If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.

   Fig 2: Installing And Uniformly Tightening Mounting Bolts In Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Mark the mounting bolt with paint.
5. Retighten the mounting bolts by 90° in the numerical order shown in Fig 2.
6. Check that the painted mark is now at a 90° angle to (e).

Fig 3: Checking Painted Mark Is At 90°

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1. Check the torque converter clutch installation. (See REMOVAL )
2. Attach the transmission to the engine.
3. Install the ground strap and 10 bolts.

   Torque: 

   37 N.m (380 kgf.cm, 27 ft.lbf) for 14 mm head 

   72 N.m (730 kgf.cm, 53 ft.lbf) for 17 mm head 

Fig 4: Installing Transmission To Engine

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1. Apply adhesive to 2 or 3 threads of the bolt end.

   Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 

   Fig 5: Applying Adhesive Threads Of Bolt End

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.

   Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) 

   HINT:

   First install the black colored bolt, install the other bolts.

3. Install the flywheel housing under cover with the 2 bolts.

   Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

   Fig 6: Installing Flywheel Housing Under Cover With Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the dipstick guide.
2. Apply soapy water to the O-ring.
3. Connect the dipstick guide end to the dipstick tube of the oil pan.
4. Install the dipstick guide with the bolt.
5. Install the dipstick.

Connect the connectors and wire:

• Connect the VSV connector.
• Connect the PNP switch connector.
• Connect the solenoid connector.
• Connect the direct clutch speed sensor connector.
• Connect the engine wire to 3 wire clamps.

1. Attach the engine chain hoist to the engine hangers.
2. Slowly lower the engine and transmission assembly into the engine compartment.
   Fig 7: Lowering Engine And Transmission Assembly Into Engine Compartment

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
4. Keep the engine level.
   Fig 8: Keeping Engine Level

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5. Install the rear engine mounting member with the 4 bolts and 4 nuts.

   Torque: 

   25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolts 

   13.5 N.m (135 kgf.cm, 10 ft.lbf) for nuts 

   NOTE: Be careful of installation direction.
   Fig 9: Installing Rear Engine Mounting Member With Bolts And Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.

   Torque: 68 N.m (700 kgf.cm, 50 ft.lbf) 

   Fig 10: Installing Nuts Holding Engine Mounting Brackets To Front Suspension Cross Member

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the 2 hole plugs.
8. Remove the engine chain hoist.
9. Install the No.1 V-bank cover bracket to the No.2 engine hanger with the nut.

1. Connect the sliding yoke to the steering intermediate shaft.
2. Install the PS gear housing with the 4 bolts.

   Torque: 65 N.m (660 kgf.cm, 48 ft.lbf) 

   Fig 11: Installing PS Gear Housing Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 PS oil tube with the bolt.
4. Install the bolt holding the sliding yoke to the steering intermediate shaft.

   Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 

Fig 12: Installing Bolt Holding Sliding Yoke To Steering Intermediate Shaft

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Install the control rod with the 2 clips.

Fig 13: Installing Transmission Control Rod With Clips

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1. Install the A/C compressor, compressor stay and wire bracket with the 3 bolts and nut.

   Torque: 

   49 N.m (500 kgf.cm, 36 ft.lbf) for bolt 

   29 N.m (300 kgf.cm, 21 ft.lbf) for nut 

   Fig 14: Installing A/C Compressor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the A/C compressor connector.
3. Install the wire clamp.

1. Install the PS pump with the 2 bolts and nut. Alternately tighten the bolts and nut.

   Torque: 

   39.2 N.m (400 kgf.cm, 29 ft.lbf) for bolts 

   43.1 N.m (440 kgf.cm, 32 ft.lbf) for nut 

   Fig 15: Installing PS Pump

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the PS oil pressure switch connector.
3. Install the RH engine under cover with the 2 screws.

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

Install a new gasket and the TWC with 3 new nuts. Install the 2 TWC.

Torque: 62 N.m (630 kgf.cm, 46 ft.lbf) 

Fig 16: Installing TWC

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Install the 2 oxygen sensors to the front exhaust pipe.

Torque: 44 N.m (450 kgf.cm, 32 ft.lbf) 

HINT:

• Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
• After installing the oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it.

1. Install the engine wire grommet to the ECM box.
2. Connect these connectors:
   • Connect the 3 engine ECM connectors.
   • Connect the 4 wire harness connectors.
   • Connect the 2 junction connectors.
3. Install these parts:
   • Install the ECM hood.
   • Install the ECM cover.

• Connect the generator wire to generator.
• Connect the wire for generator wire to wire clamp on generator.
• Connect the ground cable to stay on generator.
• Connect the PS oil hose to No. 1 oil pan.
• Connect the 2 PS air hoses to hose clamp on No. 3 RH timing belt cover.
• Connect the hose clamp for PS air hose.
• Connect the PS air hose to upper intake manifold.
• Connect the starter cable to battery.
• Connect the ground strap to body.
• Connect the 2 heater hoses.
• Connect the fuel inlet hose (rear fuel pipe) to fuel main tube.

Install the brace with the 6 bolts.

Torque: 58 N.m (590 kgf.cm, 43 ft.lbf) 

Fig 17: Installing Front Suspension Member Brace Bolts

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Check for abnormal noise, shock, slippage, correct shift points and smooth operation.