Installation

2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

NOTICE:
When the manual transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the manual transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

1. REMOVE ENGINE STAND

2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Installation

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

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

5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation

6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Installation

7. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

HINT
Installation.

8. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

HINT
Installation.

9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

HINT
Installation.

10. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

11. INSTALL REAR ENGINE MOUNTING BRACKET (for Manual Transaxle)

(a) Install the rear engine mounting bracket with the 3 bolts.

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

12. INSTALL NO. 2 REAR ENGINE MOUNTING BRACKET (for Manual Transaxle)

(a) Install the No. 2 rear engine mounting bracket with the 2 bolts.

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

13. INSTALL DRIVE SHAFT BEARING BRACKET (for Automatic Transaxle)

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

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

14. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the front engine mounting insulator with the nut.

15. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

(a) for Manual Transaxle:

(1) Temporarily install the engine mounting insulator LH with the 3 bolts.

(b) for Automatic Transaxle:

(1) Temporarily install the engine mounting insulator LH with the nut.

16. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

(a) Temporarily install the engine mounting insulator RH with the nut.

17. TEMPORARILY INSTALL ENGINE LATERAL CONTROL ROD (for Manual Transaxle)

(a) Temporarily install the engine lateral control rod with the through bolt and nut.

18. INSTALL FRONT FRAME ASSEMBLY

(a) Install the front frame assembly with the 9 nuts.

A - Torque : 52 Nm (531 kgf-cm, 38 ft-lbf)

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

(b) Install the 5 hole plugs.

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

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

C - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(d) for Automatic Transaxle:

(1) Tighten the 3 nuts.

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

B - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(e) for Manual Transaxle:

(1) Install the engine lateral control rod with the 2 nuts.

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

(2) Install the 2 hole plugs.

(3) Tighten the 3 through bolts and nut.

Torque : 89 Nm (908 kgf-cm, 65 ft-lbf)

19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Reassembly

20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

22. INSTALL V-RIBBED BELT TENSIONER SUB-ASSEMBLY (for Vane Pump)

(a) Install the V-ribbed belt tensioner sub-assembly with the 3 bolts.

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

23. INSTALL PUMP BRACKET

(a) Install the pump bracket with the 3 bolts.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

24. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump assembly with the 2 bolts.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

25. INSTALL STARTER ASSEMBLY Installation

26. INSTALL GENERATOR ASSEMBLY Installation

27. INSTALL COMPRESSOR AND PULLEY (for TMC Made) Installation

28. INSTALL COMPRESSOR AND PULLEY (except TMC Made) Installation

29. INSTALL V-RIBBED BELT (for Compressor and Generator) Installation

30. INSTALL V-RIBBED BELT (for Vane Pump) Installation

31. INSTALL ENGINE WIRE

32. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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

NOTICE:
Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.

(b) Remove the 2 engine hangers.

(c) Install the engine assembly to the vehicle.

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

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

(d) Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts.

A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

B - Torque : 32 Nm (329 kgf-cm, 24 ft-lbf)

(e) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

C - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

D - Torque : 32 Nm (329 kgf-cm, 24 ft-lbf)

33. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)

(a) Using SST, hold the crankshaft pulley.

SST : 09213-54015

SST : 09330-00021

SST : 91551-80650

(b) Apply a few drops of adhesive to the first 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the 6 drive plate and torque converter clutch setting bolts.

Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

NOTICE:
Install the black colored bolt first, and then the 5 silver colored bolts.

34. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover.

35. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket with the 2 bolts.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

36. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

37. INSTALL FRONT AXLE ASSEMBLY LH Installation

38. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

39. INSTALL NO. 1 FRONT LOWER SUSPENSION ARM LH Installation

40. INSTALL NO. 1 FRONT LOWER SUSPENSION ARM RH

HINT
Use the same procedure described for the LH side.

41. INSTALL TIE ROD ASSEMBLY LH Installation

42. INSTALL TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

43. INSTALL FRONT SPEED SENSOR LH Installation

44. INSTALL FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

45. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (for TMC Made) Installation

46. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (for TMMK Made) Removal

47. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

48. INSTALL FRONT AXLE HUB NUT LH (for TMC Made) Installation

49. INSTALL FRONT AXLE HUB NUT LH (for TMMK Made) Installation

50. INSTALL FRONT AXLE HUB NUT RH

HINT
Use the same procedure described for the LH side.

51. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

52. INSTALL CLUTCH HOSE (for Manual Transaxle)

(a) Using a union nut wrench (10 mm), install the flexible hose tube.

Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

NOTICE:
Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench Service Precautions.

53. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.

NOTICE:
* Check for damage or contamination on the connected part of the pipe.
* Check if the pipe and the connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.

54. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Installation

55. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

56. CONNECT RETURN TUBE SUB-ASSEMBLY

(a) Connect the return tube sub-assembly.

57. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

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

58. CONNECT NO. 1 VACUUM HOSE CONNECTOR

(a) except PZEV:

(1) Connect the No. 1 vacuum hose connector.

(b) for PZEV:

(1) Connect the 2 No. 1 vacuum hose connectors.

59. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the engine moving control rod with the 4 bolts.

(b) Temporarily install the No. 2 engine mounting stay with the 2 bolts

(c) Tighten the 6 bolts.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

60. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Install the 2 transmission control cables to the control cable bracket with the 2 new clips*1.

(b) Install the 2 clips*2.

61. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

HINT
Adjustments.

62. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Install the transmission control cable assembly with a new clip and the nut.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

63. CONNECT ENGINE WIRE

(a) Install the positive (+) cable with the nut and 2 clamps.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(b) for Manual Transaxle:

(1) Connect the ECM connector and 2 clamps and install the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(c) for Automatic Transaxle:

(1) Connect the ECM connector and 2 clamps.

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

Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

(e) Connect the ground cable with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(f) Connect the engine wire to the engine room relay block.

(g) Install the nut, and connect the 3 connectors.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(h) Connect the ground cable with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(i) Connect the engine wire clamp.

(j) Connect the ground cable with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

64. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

65. CONNECT OUTLET HEATER WATER HOSE

(a) for Manual Transaxle:

(1) Connect the outlet heater water hose.

(b) for Automatic Transaxle:

(1) Connect the 3 outlet heater water hoses.

66. CONNECT INLET RADIATOR HOSE

(a) Connect the inlet radiator hose.

(b) Connect the clamp.

67. CONNECT OUTLET RADIATOR HOSE

(a) Connect the outlet radiator hose.

68. INSTALL BATTERY

(a) Install the battery and battery tray.

(b) Install the battery clamp with the bolt and nut.

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

Nut - Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

(c) Connect the positive (+) battery terminal

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

69. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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

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

(b) Connect the wire harness clamp.

70. INSTALL AIR CLEANER FILTER ELEMENT

71. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for PZEV) Installation

72. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (except PZEV) Installation

73. INSTALL INLET AIR CLEANER ASSEMBLY

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

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

74. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

75. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

76. ADD ENGINE OIL

77. BLEED CLUTCH LINE (for Manual Transaxle) Procedures

78. ADD ENGINE COOLANT Testing and Inspection

79. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) Service and Repair

80. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

HINT
Procedures.

81. ADD POWER STEERING FLUID

82. BLEED POWER STEERING FLUID Service and Repair

83. INSPECT FOR FUEL LEAK Fuel System

84. INSPECT FOR OIL LEAK

85. INSPECT FOR COOLANT LEAK Testing and Inspection

86. INSPECT FOR EXHAUST GAS LEAK

87. INSPECT AND ADJUST SHIFT LEVER POSITION (for Automatic Transaxle)

HINT
Adjustments.

88. ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

89. INSPECT IGNITION TIMING Engine

90. INSPECT ENGINE IDLE SPEED Engine

91. INSPECT CO/HC Engine

92. INSTALL FRONT FENDER APRON SEAL LH

93. INSTALL FRONT FENDER APRON SEAL RH

94. INSTALL ENGINE UNDER COVER LH

95. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

96. INSTALL ENGINE UNDER COVER RH

97. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

98. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the engine cover sub-assembly.

99. CHECK ABS SPEED SENSOR SIGNAL

(a) for BOSCH Made: Test Mode Procedure.

(b) for ADVICS Made: Test Mode Procedure.