Engine Unit: Installation

INSTALL GENERATOR
1. Install the generator with the 2 bolts.
  Torque:
  
  52 N.m (530 kgf.cm, 38 ft.lbf) for bolt A
  
  21 N.m (214 kgf.cm, 15 ft.lbf) for bolt B
2. Connect the A/C wire.
3. Connect the generator connector.
4. Connect the generator wire with the nut, and install the cover.
  Torque: 9.7 N.m (99 kgf.cm, 86 in.lbf)
  
  Fig 1: Installing Generator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PS VANE PUMP
1. Install the vane pump with the 2 bolts.
  Torque: 43 N.m (439 kgf.cm, 32 ft.lbf)
2. Connect the oil pressure switch connector.
  
  Fig 2: Installing PS Vane Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL A/C COMPRESSOR
1. Install the compressor with the 3 bolts and nut.
  Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf)
2. Connect the magnetic clutch and lock sensor connector.
Fig 3: Installing A/C Compressor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRIVE BELT (See CHARGING SYSTEM )
A/T: INSTALL DRIVE PLATE
1. Apply adhesive to 2 or 3 threads of the bolt end.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
  
  Fig 4: Applying Adhesive To Threads Of Bolt End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Align the pin of the front spacer with the pin hole of the crankshaft, and install the front spacer.
  
  Fig 5: Aligning Pin Of Front Spacer With Pin Hole In Crack
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the drive plate and rear spacer as shown.
  
  Fig 6: Installing Drive Plate And Rear Spacer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
  Torque: 98 N.m (1,000 kgf.cm, 72 ft.lbf)
  
  Fig 7: Tightening Drive Plate Bolts In Several Passes In Sequence Shown
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
M/T: INSTALL FLYWHEEL (See procedure in step 5 )
Torque: 130 N.m (1,326 kgf.cm, 96 ft.lbf)
MT: INSTALL CLUTCH DISC AND COVER (See INSTALLATION )
INSTALL ENGINE TO TRANSAXLE
1. Install the 6 upper bolts holding the transaxle to the engine.
  Torque:
  
  46 N.m (469 kgf.cm, 34 ft.lbf) for bolt A
  
  64 N.m (653 kgf.cm, 47 ft.lbf) for bolt B
  
  Fig 8: Installing Upper Bolts Holding Transaxle To Engine
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. A/T: Connect the connectors and clamps.
  1. Connect the park/neutral position switch connector.
  2. Connect the solenoid wire connector.
  3. Connect the input turbine speed sensor connector.
  4. Connect the counter gear speed sensor connector.
  5. Connect the vehicle speed sensor.
  6. Connect the wire clamp from the bracket.
  7. Connect the wire clamp to the mounting bracket.
    
    Fig 9: Connecting Wiring Harness Connectors & Clamps (A/T)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. M/T: Connect the connectors.
  1. Connect the vehicle speed sensor connector.
  2. Connect the back-up light switch connector.
    
    Fig 10: Connecting Wiring Harness Connectors (M/T)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 4 lower bolts holding the engine to the transaxle.
  Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
  
  Fig 11: Installing Lower Bolts Holding Transaxle To Engine
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
A/T: INSTALL TORQUE CONVERTER CLUTCH BOLTS
1. Apply adhesive to 2 or 3 threads of the bolt end.
  Adhesive:
  
  Part No. 08833-00070, THREE BOND 1324 or equivalent
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
  Torque: 41 N.m (418 kgf.cm, 30 ft.lbf)
  
  HINT:
  
  First tighten the green colored bolt, install the other bolts.
  
  Fig 12: Installing Torque Converter Clutch Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2WD: INSTALL CENTER BEARING BRACKET
Install the bearing bracket with the 3 bolts.

Torque: 34 N.m (347 kgf.cm, 25 ft.lbf)

Fig 13: Installing Center Bearing Bracket (2WD)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4WD: INSTALL STIFFENER PLATE
Install the stiffener plate with the 5 bolts.

Torque: 34 N.m (347 kgf.cm, 25 ft.lbf)

Fig 14: Installing Stiffener Plate (4WD)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE AND TRANSAXLE ASSEMBLY TO FRONT SUSPENSION CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER
1. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
2. Install the bolt holding the rear engine mounting bracket to the mounting insulator.
  Torque: 88 N.m (898 kgf.cm, 65 ft.lbf)
  
  Fig 15: Installing Bolt Holding Rear Engine Mounting Bracket To Mounting Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bolt holding the front engine mounting bracket to the mounting insulator.
  Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)
  
  Fig 16: Installing Bolt Holding Front Engine Mounting Bracket To Mounting Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ENGINE, TRANSAXLE, FRONT SUSPENSION CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER ASSEMBLY IN VEHICLE
1. Attach the engine sling device to the engine hangers.
2. Lift the engine into the engine compartment.
  
  Fig 17: Lifting Engine Into Engine Compartment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bolt and 2 nuts holding the RH engine mounting insulator to the timing chain cover.
  Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
  
  Fig 18: Installing RH Engine Mounting Insulator To Timing Chain Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the bolt holding the LH engine mounting bracket to the mounting insulator.
  Torque: 56 N.m (571 kgf.cm, 41 ft.lbf)
  
  Fig 19: Installing LH Engine Mounting Bracket To Mounting Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Support the suspension crossmember with a jack.
6. Install the 6 bolts holding the suspension crossmember engine mounting member to the body.
  Torque:
  
  39 N.m (398 kgf.cm, 29 ft.lbf) for bolt A
  
  113 N.m (1,153 kgf.cm, 83 ft.lbf) for bolt B
  
  157 N.m (1,601 kgf.cm, 116 ft.lbf) for bolt C
  
  Fig 20: Installing Front Suspension Crossmember
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PS GEAR ASSEMBLY
Install the PS gear assembly with the 2 bolts.

Torque: 137 N.m (1,397 kgf.cm, 101 ft.lbf)

Fig 21: Installing PS Gear Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 AND NO. 2 ENGINE HANGERS
CONNECT STABILIZER BAR LINKS
Connect the LH and RH stabilizer links with the 2 nuts.

Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)

Fig 22: Connecting LH & RH Stabilizer Links
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT EXHAUST PIPE
Install 2 new gaskets and the exhaust pipe, with the 2 compression rings and 4 bolts.

Torque:

43 N.m (439 kgf.cm, 32 ft.lbf) for bolt A

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

Fig 23: Installing Front Exhaust Pipe
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LH AND RH FRONT DRIVE SHAFTS (See INSTALLATION )
4WD: INSTALL PROPELLER SHAFT (See INSTALLATION )
CONNECT GROUND CABLE TO TRANSAXLE
Torque: 19 N.m (195 kgf.cm, 14 ft.lbf)
A/T: CONNECT OIL COOLER HOSES

Fig 24: Connecting Oil Cooler Hoses (A/T)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
A/T: CONNECT SHIFT CONTROL CABLE TO TRANSAXLE
1. Connect the control cable with the nut.
  Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
2. Connect the control cable with the clip.
3. Connect the control cable to the cable clamp.
  
  Fig 25: Connecting Control Cable (A/T)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
M/T: INSTALL CLUTCH RELEASE CYLINDER AND TUBE
1. Install the release cylinder with the 5 bolts.
  Torque:
  
  25 N.m (255 kgf.cm, 18 ft.lbf) for bolt A
  
  12 N.m (122 kgf.cm, 9 ft.lbf) for bolt B
  
  5.0 N.m (51 kgf.cm, 44 in.lbf) for bolt C
  
  Fig 26: Installing Clutch Release Cylinder & Tube (M/T)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the heat insulator with the 2 bolts.
  Torque: 12 N.m (122 kgf.cm, 9 ft.lbf)
INSTALL STARTER
1. Install the starter.
2. Connect the starter cable with the nut.
  Torque: 8.8 N.m (90 kgf.cm, 78 in.lbf)
3. Install the starter with the 2 bolts.
  Torque: 37 N.m (377 kgf.cm, 27 ft.lbf)
4. Connect the connector.
  
  Fig 27: Installing Starter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the hose to the dipstick guide.
M/T: CONNECT SHIFT CONTROL CABLES TO TRANSAXLE
1. Connect the 2 control cables with the 2 clips.
2. Install the 2 washers and 2 clips.
  
  Fig 28: Connecting Shift Control Cables To Transaxle (M/T)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT TUBES, HOSES, CONNECTOR, CABLE AND WIRE
1. Install 2 new O-rings, and connect the discharge and liquid tubes to the compressor (see REMOVAL ).
  
  Fig 29: Connecting Discharge & Liquid Tubes To A/C Compressor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the accelerator cable.
3. Connect the ground wire to the cylinder head.
4. Install a new gasket, and connect the suction hose and pressure feed tube to the PS vane pump.
  
  Fig 30: Installing Suction Hose And Pressure Feed Tube To PS Vane Pump
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Connect the upper radiator hose.
6. Connect the lower radiator hose.
7. Connect the fuel tube connector (see SFI ).
8. Connect the 2 heater hoses.
9. Connect the connector to the fusible link block.
  
  Fig 31: Connecting Harness Connector To Fusible Link Block
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT ENGINE WIRE TO CABIN
1. Push in engine wire through the cabin.
2. Connect the 6 engine wire connectors to the ECM and instrument panel wire.
3. Install the glove compartment door with the 2 screws.
INSTALL ENGINE ROOM J/B
1. Connect the engine wire clamp.
2. Connect the connector.
3. Push into the engine wire connector.
4. Install the engine room J/B, and tighten the bolt until it fails to catch.
5. Install the engine room J/B cover.
  
  Fig 32: Installing Engine Room Junction/Box
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR CLEANER ASSEMBLY
1. Connect the air cleaner hose to the throttle body, and install the air cleaner assembly with the 3 bolts.
2. Connect the MAF meter connector.
3. Connect the 2 EVAP hoses to the VSV.
4. Connect the VSV connector for EVAP.
5. Connect the CCV hose to the air cleaner.
6. Connect the PCV hose to the cylinder head cover.
  
  Fig 33: Installing Air Cleaner Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BATTERY AND TRAY
1. Install the battery bracket with the 5 bolts.
2. Install the battery tray and battery with the hold-down clamp.
  
  Fig 34: Installing Battery Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cowl top ventilation louver (see INSTALLATION ).
INSTALL RADIATOR RESERVOIR TANK
INSTALL HOOD (See HOOD )
FILL WITH ENGINE COOLANT
FILL WITH ENGINE OIL
FILL WITH TRANSFER OIL
FILL WITH TRANSAXLE OIL
START ENGINE AND CHECK FOR LEAKS
BLEED POWER STEERING SYSTEM (See BLEEDING )
PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
RECHECK ENGINE COOLANT AND OIL LEVELS
INSTALL ENGINE UNDER COVERS