Tercel 1995-1996

Engine

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Removal & Installation



3E-E Engine

Specific to:

Toyota Tercel 1995


NOTE
Each fuel and vacuum line must be tagged or labeled individually during disassembly for correct installation.

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Drain the cooling system and save the coolant for reuse.
  4.  
  5. Drain the engine oil and the transmission oil.
  6.  
  7. With the help of an assistant, remove the hood (mark hood hinges for correct installation) from the car. Be careful not to damage the paint finish.
  8.  
  9. Remove the air cleaner assembly from the carburetor.
  10.  
  11. Disconnect the upper radiator hose from the engine and remove the overflow hose.
  12.  
  13. Remove the coolant hose at the cylinder head rear coolant pipe and remove the coolant hose at the thermostat housing.
    NOTE
    On the 3E-E engine, the fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  14.  
  15. Remove the fuel hoses from the fuel pump.
  16.  
  17. Loosen the adjuster(s) and remove the alternator belt, the power steering and/or air conditioning drive belts depending on equipment.
  18.  
  19. Label and remove all wiring running to the motor. Be careful when unhooking wiring connectors; many have locking devices which must be released.
  20.  
  21. Label and disconnect vacuum hoses. Make sure your labels contain accurate information for reconnecting both ends of the hose. Make sure the labels will stay put on the hoses.
  22.  
  23. Disconnect the wiring at the transaxle.
  24.  
  25. Disconnect the speedometer cable at the transaxle.
  26.  
  27. Safely elevate and support the vehicle on jackstands.
  28.  
  29. Disconnect the exhaust pipe from the manifold. Be ready to deal with rusty hardware.
  30.  
  31. Disconnect the air hose at the converter pipe, if so equipped.
  32.  
  33. Loosen and remove the transaxle cooler lines at the radiator.
  34.  
  35. Remove the left and right undercovers (splash shields) under the car.
  36.  
  37. If so equipped, remove the power steering pump from its mounts and lay it aside. Leave the hoses attached. The pump may be hung on a piece of stiff wire to be kept out of the way.
  38.  
  39. If so equipped, remove the air conditioning compressor from its mounts and position out of the way. DO NOT loosen any hoses or fittings simply move the compressor out of the way. It may be hung from a piece of stiff wire to be kept out of the way.
  40.  
  41. Disconnect the cable and bracket from the transaxle.
  42.  
  43. Disconnect the steering knuckles at the lower control arms.
  44.  
  45. Have an assistant step on the brake pedal while you loosen the nuts and bolts holding the driveshafts to the transaxle. Let the disconnected shafts hang down clear of the transaxle. Remove the driveshaft assembly to the rear differential on 4-Wheel Drive vehicles.
  46.  
  47. Remove the flywheel cover. If equipped with an automatic transmission, remove the flexplate-to-torque converter bolts.
  48.  
  49. Disconnect the front and rear mounts at the crossmember by first removing the two bolt covers and removing the two bolts at each mount. Remove the center crossmember under the engine.
  50.  
  51. Remove the clip and washer holding the shift cable; disconnect the cable at the outer shift lever or outer selector lever.
  52.  
  53. Lower the vehicle to the ground. Remove the radiator and fan assembly.
  54.  
  55. Install the engine hoist to the lifting bracket on the engine. Keep the wiring harness in front of the chain. Draw tension on the hoist enough to support the engine but no more. Double check the hoist attachments before proceeding.
  56.  
  57. Remove the through-bolt to the right side engine mount.
  58.  
  59. Remove the left side transaxle mount bolt and remove the mount.
  60.  
  61. Lift the engine and transaxle assembly out of the engine compartment, proceeding slowly and watching for any interference. Pay particular attention to not damaging the right side engine mount, the power steering housing and the neutral safety switch. Make sure wiring, hoses and cables are clear of the engine.
  62.  
  63. Support the engine assembly on a suitable stand; do not allow it to remain on the hoist for any length of time.
  64.  
  65. To install lower the engine and transaxle into the car, paying attention to clearance and proper position. Raise and lower the vehicle as necessary to perform each service operation.
  66.  
  67. Install the left side transaxle mount and its bolt.
  68.  
  69. Install and tighten the right side through-bolt for the motor mount.
  70.  
  71. When the engine is securely mounted within the car, the lifting devices may be removed. Replace the radiator and fan assembly.
  72.  
  73. Safely elevate and support the vehicle on jackstands. Install the center crossmember and connect the shift cable.
  74.  
  75. Connect the front and rear mountings for the crossmember and reinstall the bolt covers.
  76.  
  77. Install the flywheel-to-torque converter bolts. Tighten them to the final specification in steps.
  78.  
  79. Replace the flywheel cover.
  80.  
  81. Connect the driveshafts to the transaxle. Install the driveshaft assembly to the rear differential on 4-Wheel Drive vehicles.
  82.  
  83. Reconnect the steering knuckles to the lower control arms.
  84.  
  85. Reattach the cable and bracket to the transaxle.
  86.  
  87. Depending on equipment, reinstall the power steering pump and/or the air conditioning compressor. Tighten the mounting bolts enough to hold the unit in place but no more; the belts will be installed later.
  88.  
  89. Install the left and right splash shields (undercovers).
  90.  
  91. Reconnect the transmission cooler lines to the radiator and connect the air hose at the converter pipe.
  92.  
  93. Connect the exhaust pipe to the manifold.
  94.  
  95. Lower the vehicle to the ground; reconnect the speedometer cable at the transaxle.
  96.  
  97. Paying close attention to proper routing and labeling, connect the wiring and vacuum hoses to the engine.
  98.  
  99. Install the drive belts (alternator, power steering and air conditioning) and make sure the belts are properly seated on the pulleys. Adjust the belts to the correct tension and tighten the bolts.
  100.  
  101. Connect the fuel hoses at the fuel pump. Use new clamps if necessary.
  102.  
  103. Attach the coolant hoses: at the thermostat housing, at the cylinder head rear pipe, at the overflow, and at the outlet for the upper hose. Insure that the hoses are firmly over the ports; use new clamps wherever needed.
  104.  
  105. Install the air cleaner assembly onto the carburetor.
  106.  
  107. Have an assistant help reinstall the hood. Make sure its is properly adjusted and secure.
  108.  
  109. Refill the transmission with the proper fluid.
  110.  
  111. Refill the engine oil to the proper level.
  112.  
  113. Refill the engine coolant with the proper amount of fluid.
  114.  
  115. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  116.  
  117. Check all fluid levels. Bleed systems as necessary. Make all necessary adjustments. Start the engine. Check for any fluid leaks, road test the vehicle for proper operation.
  118.  

5e-FE Engine

Specific to:

Toyota Tercel 1996

  1. Disconnect the negative battery cable from the battery. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Remove the hood from the vehicle.
  4.  
  5. Remove the undercovers from the vehicle.
  6.  
  7. Drain the cooling system and remove the radiator.
  8.  
  9. If equipped with automatic transaxle, disconnect and plug the transaxle fluid lines and disconnect the accelerator cable.
  10.  
  11. Disconnect the throttle cable.
  12.  
  13. Drain the transaxle fluid and the engine oil.
  14.  
  15. Remove the air cleaner assembly and bracket.
  16.  
  17. Remove the charcoal canister.
    CAUTION
    To avoid personal injury, properly release the fuel pressure on any fuel injected model before disconnecting any fuel lines.

  18.  
  19. Disconnect the fuel return and inlet hoses.
  20.  
  21. Disconnect the speedometer cable.
  22.  
  23. Disconnect the idle up air hoses from the power steering air control valve.
  24.  
  25. Disconnect and label the oxygen sensor wire, the oil pressure switch wire, the coolant fan switch wire, the water temperature gauge wire, the back-up light switch and neutral safety switch wires.
  26.  
  27. Disconnect and tag any remaining wiring harnesses connected to the engine. Remove the wire harness from the engine.
  28.  
  29. Disconnect and tag the PCV hoses and any other vacuum hoses that prevent the removal of the engine.
  30.  
  31. Disconnect and tag the starter wires.
  32.  
  33. If equipped with cruise control, remove the actuator assembly.
  34.  
  35. Disconnect and tag the heater hoses.
  36.  
  37. If equipped with manual transaxle, remove the clutch release cylinder.
  38.  
  39. Remove the clips and washers, then disconnect the transaxle control cables.
  40.  
  41. If equipped with power steering, remove the power steering pump and position it aside. Do not disconnect the power steering hoses.
  42.  
  43. If equipped with air conditioning, remove the air conditioning compressor and position it aside. Leave the refrigerant lines connected.
  44.  
  45. Disconnect the front exhaust pipe.
  46.  
  47. Remove the halfshafts.
  48.  
  49. Support the engine/transaxle assembly properly.
  50.  
  51. Connect a suitable lifting device to the engine lifting hooks.
  52.  
  53. If equipped with manual transaxle, remove the rear mounting through-bolt and the rear mounting assembly. If equipped with automatic transaxle, remove the front mounting through-bolt and front mounting assembly.
  54.  
  55. Remove the right and left side mounting bolts and brackets.
  56.  
  57. Carefully lift the engine/transaxle assembly out of the vehicle.
  58.  
  59. Disconnect the starter from the engine/transaxle by removing the starter stay bracket and then the two bolts to the starter.
  60.  
  61. For automatic transaxles, disconnect the torque converter clutch mounting bolts.
  62.  
  63. Separate the engine from the transaxle by removing the bolts.
  64.  

To install:

  1. Attach the transaxle to the engine and install the bolts. On automatic transaxles, install the torque converter clutch and mounting bolts. Install the gray bolt first, then install the other five bolts. Torque the bolts to 20 ft. lbs. (27 Nm).
  2.  
  3. Install the starter with the two bolts and torque the bolts to 29 ft. lbs. (39 Nm).
  4.  
  5. Attach an engine sling to the engine hangers and lower the engine and transaxle assembly in the vehicle.
  6.  
  7. Tilt the transaxle downward, lower the engine and clear the left side mounting.
  8.  
  9. Keep the engine level and align the right side and left side mountings with the body bracket.
  10.  
  11. Attach the right side mounting insulator to the mounting bracket and the body and temporarily install the through-bolt, two bolts and nut.
  12.  
  13. Install the left side mounting bracket to the transaxle and mounting insulator with the 5 bolts and torque the bolts. Torque the bracket to transaxle bolts with the head marked (NT) to 47 ft. lbs. (64 Nm), and the bracket to insulator bolts with the bolt head marked (7T) to 35 ft. lbs. (48 Nm).
  14.  
  15. Connect the ground strap. Torque the ground strap to 35 ft. lbs. (49 Nm).
  16.  
  17. Install the rear mounting bracket to the transaxle with the 3 bolts (M/T) or 2 bolts (A/T) and torque to 35 ft. lbs. (48 Nm).
  18.  
  19. Install and torque the rear insulator through-bolt to 47 ft. lbs. (64 Nm).
  20.  
  21. Install the halfshafts.
  22.  
  23. Remove the engine sling from the engine.
  24.  
  25. Install the two bolts, nut and through-bolt of the right side mounting insulator. Torque the 2 bolts and nut to 47 ft. lbs. (64 Nm) and the through-bolt to 54 ft. lbs. (73 Nm).
  26.  
  27. Connect the front exhaust pipe.
  28.  
  29. If equipped with air conditioning, install the air conditioning compressor.
  30.  
  31. If equipped with power steering, install the power steering pump to the engine.
  32.  
  33. Install the transaxle control cables with the washers and clips.
  34.  
  35. If equipped with manual transaxle, install the clutch release cylinder. Torque the bolts to 9 ft. lbs. (12 Nm).
  36.  
  37. Connect the idle up air hoses to the power steering air control valve.
  38.  
  39. Connect the speedometer cable to the transaxle.
  40.  
  41. Connect the heater hoses.
  42.  
  43. If equipped with cruise control, connect the actuator assembly.
  44.  
  45. Connect the starter wires and nut.
  46.  
  47. Connect vacuum hoses to the engine.
  48.  
  49. Connect the oxygen sensor wire, oil pressure switch, coolant fan switch wire, water temp. gauge wire, back-up light switch, and the neutral safety switch wires.
  50.  
  51. Connect any other wiring to the engine.
  52.  
  53. Connect the fuel line hoses.
  54.  
  55. Connect the charcoal canister.
  56.  
  57. Install the air cleaner assembly and bracket.
  58.  
  59. Install the radiator. Connect the coolant hoses and on vehicles equipped with A/T, connect the cooling lines.
  60.  
  61. Refill all fluids to specifications.
  62.  
  63. Install the engine undercovers.
  64.  
  65. Install the hood.
  66.  
  67. Connect the negative battery cable to the battery.
  68.  
  69. Start the engine and check for leaks.
  70.  

 
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