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Engine Unit: Installation

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

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

      Fig 1: Applying Adhesive To 2 Or 3 Threads Of Bolt End
      G06042358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install and uniformly tighten the new 6 bolts in several passes, in the sequence shown.

      Torque: 84 N.m (857 kgf.cm, 62 ft.lbf) 

    3. Retighten the flywheel bolts by 90° in the numerical order shown.
    Fig 2: Identifying Flywheel Bolts Tightening Sequence
    G06042354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL DAMPER DISC 
    1. Insert SST in the damper disc, then insert them in the flywheel.

      SST 09301-00110

      HINT:

      Take care not to insert damper disc in the wrong direction.

    2. Set the damper spring on the damper disc.
    3. Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top.
      Fig 3: Inserting SST In Damper Disc
      G06042360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 16 N.m (163 kgf.cm, 12 ft.lbf) 

      HINT:

      • Following the order in the illustration, tighten the bolts at a time evenly.
      • Move SST up and down, right and left lightly, after checking that the disc in the center, tighten the bolts.
      Fig 4: Identifying Flywheel Bolts Tightening Sequence
      G06042354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL TRANSAXLE TO ENGINE 
    1. Attach the transaxle to the engine, and install the 6 bolts.

      Torque: 33 N.m (337 kgf.cm, 24 ft.lbf) 

    2. Install the dust cover.
    3. Install the LH engine mounting bracket.

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

  4. SET ENGINE JACK 
    NOTE: Using a chain, hold the engine tightly.
  5. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE 
    1. Raise the engine into the engine compartment.
    2. Keep the engine level, and align RH and LH mountings with the insulator.
      Fig 5: Raising Engine Into Engine Compartment
      G06042350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the LH mounting bracket to the insulator with the nut.

      Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) 

    4. Connect the RH mounting bracket to the insulator with the 2 bolts and 2 nuts.

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

      Fig 6: Locating RH Mounting Bracket Bolts And Nuts
      G06042351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL SUSPENSION MEMBER 

    Connect the suspension member with the 4 bolts.

    Torque: 

    Bolt A: 113 N.m (1,152 kgf.cm, 83 ft.lbf) 

    Bolt B: 157 N.m (1,601 kgf.cm, 116 ft.lbf) 

    Fig 7: Identifying Suspension Member Bolts
    G06042349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL TORQUE ROD 
    1. Install the torque rod through bolt and nut.

      Torque: 100 N.m (1,020 kgf.cm, 74 ft.lbf) 

    2. Install the 2 bolts.

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

  8. INSTALL DRIVE SHAFTS (See  INSTALLATION  ) 
    Fig 8: Installing Torque Rod Through Bolt And Nut
    G06042348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. CONNECT BALL JOINT TO LOWER ARM 

    Torque: 142 N.m (1,448 kgf.cm, 105 ft.lbf) 

  10. CONNECT STABILIZER BAR LINK 

    Torque: 74 N.m (755 kgf.cm, 55 ft.lbf) 

  11. CONNECT TIE ROD END TO STEERING KNUCKLE (See  FRONT AXLE HUB & WHEEL BEARING  ) 
    Fig 9: Locating Ball Joint Bolts And Nuts
    G06042347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL EXHAUST PIPE 
    1. Install the 2 gaskets to the exhaust pipe and connect the 2 O-rings.
    2. Install the 2 springs and 3 bolts.

      Torque: 

      Front exhaust pipe: 62 N.m (630 kgf.cm, 46 ft.lbf) 

      Tailpipe: 32 N.m (326 kgf.cm, 24 ft.lbf) 

    3. Connect the hose to the actuator.
    4. Connect the heated oxygen sensor.
    Fig 10: Locating Heated Oxygen Sensor
    G06042367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL A/C COMPRESSER 
    1. Connect the A/C compresser to the engine with the 4 bolts.

      Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

    2. Connect the A/C compresser connector.
    14. Fig 11: Identifying A/C Compresser Bolts
    G06042345Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. CONNECT INTERMEDIATE EXTENSION STEERING ASSEMBLY (See  COMPONENTS  ) 
  15. INSTALL DRIVE BELT (See  DRIVE BELT ROUTING  ) 
  16. CONNECT FUEL TUBE 
  17. INSTALL J/B NO. 1 TO RH FENDER APRON 
    Fig 12: Identifying Fuel Tube
    G06042344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. CONNECT ENGINE WIRE TO CABIN 
    1. Pull in the engine wire to the cowl panel and connect the grommet.
    2. Connect the ECM connectors.
    3. Install the ECM (See ENGINE CONTROL MODULE ).
    Fig 13: Identifying Cowl Panel Grommet
    G06042343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. INSTALL BRAKE RESERVOIR TANK 
    1. Install the reservoir tank with the 2 bolts.
    2. Connect the brake fluid level sensor connector.
  20. CONNECT SHIFT LEVER CABLE TO TRANSAXLE 
  21. CONNECT HEATER HOSE TO CYLINDER BLOCK 
  22. CONNECT 2 RADIATOR HOSES TO RADIATOR 
  23. INSTALL ENGINE COOLANT RESERVOIR TANK 
  24. INSTALL AIR INLET 
  25. CONNECT CONNECTORS, CLAMPS AND HOSES 
    1. Connect the Ground strap from LH fender apron.
    2. Connect the Ground strap from RH fender apron.
    3. Connect the VSV hose for purge line.
    4. Connect the VSV connector for purge line.
    5. Connect the 2 power steering connectors.
    6. Connect the Heated oxygen sensor connector.
    7. Connect the Engine wire clamps.
    Fig 14: Locating Connectors, Clamps And Hoses
    G06042233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL AIR CLEANER ASSEMBLY 
    1. Install the air cleaner assembly with the 2 bolts.
    2. Tighten the 2 hose clamps.
    3. Connect the EVAP hose to the air cleaner case.
    4. Connect the MAF meter connector.
  27. INSTALL HEATER UNIT WATER PUMP (See  HEATER WATER PUMP  ) 
    Fig 15: Identifying Air Cleaner Assembly
    G06042230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL CONVERTER AND INVERTER ASSEMBLY (See  CONVERTER AND INVERTER ASSEMBLY  ) 
  29. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY (See  INSTALLATION  ) 
  30. FILL WITH ENGINE COOLANT 
  31. FILL WITH HV COOLANT 
  32. INSTALL ENGINE UNDER COVERS 
  33. CONNECT BATTERY NEGATIVE (-) TERMINAL AND HV BATTERY SERVICE PLUG (See  SERVICE PRECAUTIONS  ) 
  34. ROAD TEST VEHICLE 

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

  35. RECHECK ENGINE COOLANT AND HV TRANSAXLE COOLANT 
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