Toyota Yaris: Engine Assembly / Installation

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Engine & Hybrid System / G16e-gts (engine Mechanical) / Engine Assembly / Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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HINT:

Perform "Inspection After Repair" after replacing the engine assembly.

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PROCEDURE

1. INSTALL ENGINE HANGER

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2. REMOVE ENGINE FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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4. INSTALL FLYWHEEL SUB-ASSEMBLY

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5. INSTALL COVER AND DISC CLUTCH SET

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6. INSTALL MANUAL TRANSAXLE ASSEMBLY

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7. INSTALL PROPELLER SHAFT HEAT INSULATOR

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8. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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9. INSTALL ENGINE WIRE

(a) Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.

(b) Install the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Install the 4 bolts.

Torque:

Bolt (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt (B) :

20 N·m {204 kgf·cm, 15 ft·lbf}

(d) Install the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

10. INSTALL GENERATOR WITH REGULATOR ASSEMBLY

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11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

12. INSTALL FAN AND GENERATOR V BELT

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13. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side cover to the cylinder block sub-assembly.

14. INSTALL STARTER ASSEMBLY

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15. INSTALL NO. 1 FUEL VAPOR FEED HOSE

(a) Engage the 2 clamps.

(b) Install the No. 1 fuel vapor feed hose to the purge valve (purge VSV).

16. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

*a

Temporarily Tighten

(b) Install the 2 bolts and nut in the order shown in the illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(c) Connect the air conditioner tube with the clamp.

17. INSTALL RESERVE TANK ASSEMBLY

(a) Install the 2 bplts and reserve tank assembly to the vehicle.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(b) Engage the clamp.

(c) Connect the No. 3 water by-pass hose to the reserve tank assembly and slide the clip to secure it.

18. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

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

(a) Temporarily install the engine mounting insulator LH to the vehicle.

*a

Temporarily Tighten

(b) Install the 5. bolts and nut in the order shown in the illustration.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

(c) Engage the clamp.

19. REMOVE ENGINE HANGER

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20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.

NOTICE:

  • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.
  • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

(b) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

  • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
  • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

(c) Connect the front suspension crossmember sub-assembly to the vehicle with the 8 bolts.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

(d) Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts in the order shown illustration.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(e) Install the engine mounting insulator LH to the engine mounting bracket LH with the 4 bolts in the order shown illustration.

Torque:

52 N·m {530 kgf·cm, 38 ft·lbf}

21. INSTALL NO. 1 CLUTCH HOSE

(a) Connect the No. 1 clutch hose to the clutch flexible hose bracket with a new clip.

*a

10 mm Union Nut Wrench

*b

Torque Wrench Fulcrum Length

(b) Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the No. 1 clutch hose.

Torque:

Specified tightening torque :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

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  • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

22. INSTALL NO. 1 AIR TUBE

(a) Install the No. 1 air tube with the 2 bolts.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

(b) Tighten the 2 hose clamp.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

23. INSTALL DRIVE SHAFT ASSEMBLY

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24. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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25. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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26. INSTALL COLUMN HOLE COVER SILENCER SHEET

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27. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

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28. CONNECT SUCTION HOSE SUB-ASSEMBLY

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29. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel pipe.

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(b) Install the No. 1 fuel pipe clamp to the fuel tube sub-assembly.

30. CONNECT INLET HEATER WATER HOSE

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31. CONNECT OUTLET HEATER WATER HOSE

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32. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the fuel tank to canister tube.

33. INSTALL NO. 2 WATER BY-PASS HOSE

(a) Connect the No. 2 water by-pass hose to the No. 4 water by-pass pipe and slide the clip to secure it.

34. INSTALL NO. 1 WATER BY-PASS HOSE

(a) Connect the No. 1 water by-pass hose to the No. 4 water by-pass pipe and slide the clip to secure it.

35. CONNECT UNION TO CONNECTOR TUBE HOSE

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36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install the transmission control cable assembly to the control cable bracket assembly with 2 new clips (B).

NOTICE:

Make sure that the paint marks on the transmission control cable assembly are aligned with the slits in the control cable bracket assembly before installing the clips.

*a

Paint Mark

(b) Connect the transmission control cable assembly to the manual transaxle assembly with the 2 clips (A).

37. INSTALL ECM

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38. INSTALL NO. 2 AIR TUBE

(a) Install the No. 2 air hose with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Tighten the hose 2 clamps.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

39. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.

40. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

41. CONNECT ENGINE WIRE

(a) Engage the 2 claws to the engine room relay block.

(b) Connect the 3 connectors to the engine room relay block.

(c) Install the 2 nut.

Torque:

Nut (A) :

10 N·m {102 kgf·cm, 7 ft·lbf}

Nut (B) :

7.6 N·m {77 kgf·cm, 67 in·lbf}

(d) Engage the clamp to connect the engine wire to the vehicle.

(e) Connect the engine wire to the vehicle with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

42. INSTALL JUNKTION BLOCK COVER

(a) Install the junktion block cover.

43. INSTALL NO. 1 RELAY BLOCK COVER

(a) Install the No. 1 relay block cover.

44. INSTALL AIR CLEANER BRACKET

(a) Install the air cleaner bracket with the 2 bolts.

Torque:

7.0 N·m {71 kgf·cm, 62 in·lbf}

(b) Engage the clamp to the air cleaner bracket.

45. INSTALL AIR CLEANER ASSEMBLY

(a) Install the air cleaner assembly and tighten the hose clamp.

Torque:

3.0 N·m {31 kgf·cm, 27 in·lbf}

(b) Connect the vacuum hose assembly and vacuum transmittinghose.

(c) Install the 2 clips.

(d) Connect the clamp.

(e) Connect the mass air flow meter connector.

(f) Engage the clamp to the air cleaner assembly.

(g) Connect the vacuum switching valve connector.

46. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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47. INSTALL NO. 1 FRONT VENTILATOR SEAL

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48. INSTALL WATER GUARD PLATE RH

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49. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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50. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Engage the 4 clamps to install the No. 1 engine cover sub-assembly.

NOTICE:

  • Securely engage the clamps.
  • If the clamps are forcibly engaged or struck with an object, they may be damaged.

51. INSTALL FRONT FENDER LINER LH

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52. INSTALL FRONT FENDER LINER RH

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53. CONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

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54. ADD ENGINE OIL

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55. ADD ENGINE COOLANT

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56. ADD MANUAL TRANSAXLE OIL

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57. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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58. WARM UP ENGINE

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59. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY

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60. INSPECT FOR ENGINE OIL LEAK

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61. INSPECT MANUAL TRANSAXLE OIL LEAK

62. INSPECT FOR COOLANT LEAK

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63. INSPECT FOR REFRIGERANT LEAK

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64. INSPECT FOR FUEL LEAK

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65. INSPECT FOR EXHAUST GAS LEAK

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66. CHECK ENGINE OIL LEVEL

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67. INSPECT RADIATOR RESERVE TANK ENGINE COOLANT LEVEL

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68. INSTALL CENTER NO. 4 ENGINE UNDER COVER

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69. INSTALL ENGINE UNDER COVER RH

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70. INSTALL ENGINE UNDER COVER LH

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71. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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72. INSTALL FRONT WHEELS

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73. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

74. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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75. PERFORM INITIALIZATION

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76. INSPECT IGNITION TIMING

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77. INSPECT ENGINE IDLE SPEED

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78. INSPECT CO/HC

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    Removal

    REMOVAL CAUTION / NOTICE / HINT The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the engine assembly removal/installation are shown below...

    Engine Unit

    ..

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