Installation

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Installation

2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

3. INSTALL RADIO SETTING CONDENSER

(a) Install the condenser with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

4. INSTALL KNOCK SENSOR Installation

5. INSTALL CAMSHAFT TIMING CONTROL VALVE ASSEMBLY Installation

6. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

7. INSTALL IGNITION COIL ASSEMBLY Installation

8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

9. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR Installation

10. INSTALL INTAKE MANIFOLD ASSEMBLY Installation

11. INSTALL NO. 1 WATER BY-PASS PIPE

(a) Install a new gasket and the water by-pass pipe with the bolt and 2 nuts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

12. INSTALL THERMOSTAT Installation

13. INSTALL WATER INLET Installation

14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Installation

15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

16. INSTALL NO. 2 MANIFOLD STAY Installation

17. INSTALL MANIFOLD STAY Installation

18. INSTALL OIL DIPSTICK GUIDE Installation

19. INSTALL OIL DIPSTICK Installation

20. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

21. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

(a) Clean the 8 bolts and 8 bolt holes.

(b) Apply adhesive to 2 or 3 threads of the 8 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque : 130 Nm (1,326 kgf-cm, 96 ft-lbf)

22. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) Installation

23. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation

24. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) Installation

25. INSTALL DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle)

(a) Clean the 8 bolts and 8 bolt holes.

(b) Apply adhesive to 2 or 3 threads of the 8 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Using SST, hold the crankshaft.

SST : 09213-54015

91651-60855

SST : 09330-00021

(d) Install the front spacer, drive plate and rear spacer onto the crankshaft.

(e) Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque : 98 Nm (1,000 kgf-cm, 72 ft-lbf)

26. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle) Installation

27. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Installation

28. INSTALL STARTER ASSEMBLY Installation

29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER

(a) Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.

(b) Install the through bolt which is used to secure the rear engine mounting insulator, into the rear engine mounting bracket.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(c) Install the bolt which is used to secure the front engine mounting bracket.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

32. INSTALL VANE PUMP ASSEMBLY

Installation

33. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.

(b) Temporarily install the suspension crossmember with the 2 bolts and 2 nuts.

(d) Install the engine mounting bracket RH with the 2 bolts and 2 nuts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

Torque : 113 Nm (1,152 kgf-cm, 83 ft-lbf for bolt A)

(e) Tighten the 2 bolts and 2 nuts.

Torque : 45 Nm (459 kgf-cm, 33 ft-lbf for bolt)

Torque : 133 Nm (1,356 kgf-cm, 98 ft-lbf for nut)

(f) Install the front suspension member brace rear RH and LH with the 8 bolts.

Torque : 133 Nm (1,356 kgf-cm, 98 ft-lbf for bolt A)

Torque : 80 Nm (816 kgf-cm, 59 ft-lbf for bolt B)

NOTICE:

When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.

(g) Connect the return tube.

(h) Connect the oil reservoir to No. 1 pump hose.

(i) Remove the No. 1 and No. 2 engine hangers.

34. INSTALL FRONT AXLE HUB SUB-ASSEMBLY Installation

35. INSTALL FRONT AXLE HUB HOLE SNAP RING Installation

36. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY LH Installation

37. CONNECT FRONT NO. 1 SUSPENSION ARM LOWER SUB-ASSEMBLY RH

HINT

Perform the same procedure for the LH side.

38. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation

39. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT

Perform the same procedure for the LH side.

40. INSTALL FRONT SPEED SENSOR LH Installation

41. INSTALL FRONT SPEED SENSOR RH

HINT

Perform the same procedure for the LH side.

42. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

43. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT

Perform the same procedure for the LH side.

44. INSTALL FRONT AXLE HUB NUT LH Installation

45. INSTALL FRONT AXLE HUB NUT RH Installation

46. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

47. INSTALL COLUMN HOLE COVER SILENCER SHEET

48. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

49. CONNECT ENGINE WIRE

(a) Install the ground cable with the bolt.

(b) Install the engine wire to the positive (+) battery terminal with the nut.

(d) Install the engine wire harness with the 2 claws.

(e) Connect the 2 connectors.

50. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation

51. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

52. INSTALL GENERATOR ASSEMBLY Installation

53. INSTALL V-RIBBED BELT Installation

54. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Installation

55. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Installation

56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Installation

57. CONNECT HEATER WATER OUTLET HOSE

(a) Connect the heater outlet hose to the air conditioner tube.

58. CONNECT HEATER WATER INLET HOSE

(a) Connect the heater inlet hose to the air conditioner tube.

59. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the union to connector tube to the booster vacuum tube.

60. CONNECT FUEL MAIN TUBE Installation

61. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 4 bolts.

Torque : 12.8 Nm (131 kgf-cm, 9 ft-lbf)

(b) Connect the clamp of the engine wire.

62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Connect the air cleaner case to the No. 1 air cleaner inlet.

(b) Install the air cleaner case with the 3 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(c) Connect the clamp of the engine wire.

63. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Installation

64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

65. INSTALL RADIATOR ASSEMBLY Installation

66. CONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)

67. CONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)

68. CONNECT RADIATOR HOSE OUTLET

69. CONNECT RADIATOR HOSE INLET

70. INSTALL BATTERY TRAY

71. INSTALL BATTERY

72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

73. ADD MANUAL TRANSAXLE OIL Installation

74. ADD AUTOMATIC TRANSAXLE FLUID Installation

75. ADD ENGINE COOLANT Testing and Inspection

76. INSPECT FOR FUEL LEAK Initial Inspection and Diagnostic Overview

77. INSPECT FOR COOLANT LEAK Initial Inspection and Diagnostic Overview

78. INSPECT FOR OIL LEAK

79. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

80. INSTALL FRONT FENDER APRON SEAL RH Installation

81. INSTALL ENGINE UNDER COVER LH

82. INSTALL ENGINE UNDER COVER RH

83. INSTALL FRONT WHEEL Installation

84. PERFORM INITIALIZATION

(a) Perform initialization Testing and Inspection.

NOTICE:

Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.