Installation

3MZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:

INSTALLATION

1. INSTALL KNOCK CONTROL SENSOR Installation

2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY






(a) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent






(b) Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
3. INSTALL THERMOSTAT Installation

4. INSTALL WATER INLET Installation

5. INSTALL WATER INLET PIPE Installation

6. INSTALL INTAKE AIR CONNECTOR BRACKET NO.2






(a) Install the intake air connector bracket No.2 with the 2 bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
7. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
(a) Temporarily install the mounting bracket with the 4 bolts.






(b) Install the mounting bracket by tightening the 4 bolts in the order shown in the illustration.
8. INSTALL ENGINE MOUNTING STAY BRACKET






(a) Install the 3 bolts, nut and engine mounting stay bracket.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
9. INSTALL ENGINE MOUNTING BRACKET RH






(a) Install the 3 bolts and engine mounting bracket RH.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
10. INSTALL ENGINE MOUNTING BRACKET REAR






(a) Install the 3 bolts and engine mounting bracket rear.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
11. INSTALL MANIFOLD STAY NO.2
(a) Install the 2 bolts and manifold stay No.2.
Torque: 58 Nm (591 kgf-cm, 43 ft-lbf)
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 Installation

13. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 Installation

14. INSTALL MANIFOLD CONVERTER INSULATOR NO.3 Installation

15. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (80 kgf-cm, 71 in-lbf)
16. INSTALL WATER OUTLET Installation

17. INSTALL INTAKE MANIFOLD Installation

18. INSTALL INTAKE AIR SURGE TANK Installation

19. INSTALL EMISSION CONTROL VALVE SET Installation

20. INSTALL ENGINE HANGER NO.2






(a) Install the No.2 engine hanger in the correct direction shown in the illustration.
Torque: 20 Nm (199 kgf-cm, 14 ft-lbf)
21. REMOVE ENGINE STAND
22. INSTALL FLYWHEEL SUB-ASSEMBLY Installation

23. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY Installation

24. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY Installation

25. INSTALL ENGINE MOUNTING BRACKET FRONT Installation

26. INSTALL FLYWHEEL HOUSING UNDER COVER Installation

27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

29. INSTALL FRONT FRAME ASSEMBLY






(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)






(b) Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft-lbf)






(c) Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft-lbf)
30. INSTALL HV TRANSAXLE MASS DAMPER






(a) Install the bolt and transaxle mass damper.
Torque: 14 Nm (138 kgf-cm, 10 ft-lbf)
31. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

32. INSTALL MANIFOLD STAY Installation

33. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Installation

34. INSTALL ENGINE WIRE
35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE






(a) Set the engine assembly with transaxle on the engine lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.
Bolt A - Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)
Bolt B - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
Nut C - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)






(d) Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
Bolt A - Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)
Bolt B - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
Nut C - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
36. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation

37. INSTALL FRONT AXLE ASSEMBLY LH
(a) Install the drive shaft assembly LH to the front axle assembly LH.
NOTICE:
- Be careful not to damage the outboard joint boot.
- Be careful not to damage the speed sensor rotor.

38. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

39. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH Installation

40. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT: Perform the same procedure as above on the opposite side.

41. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

42. CONNECT TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

43. INSTALL SPEED SENSOR FRONT LH Installation

44. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure as above on the opposite side.

45. INSTALL FRONT AXLE SHAFT LH NUT Installation

46. INSTALL FRONT AXLE SHAFT RH NUT
HINT: Perform the same procedure as above on the opposite side.

47. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

48. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

49. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3






(a) Using vernier calipers, measure the free length of the compression spring.
Minimum length:
41.5 mm (1.634 in.)
HINT: If the free length is less than the minimum, replace the compression spring.





(b) Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.






(c) Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Bolt - Torque: 48 Nm (490 kgf-cm, 35 ft-lbf)
Nut - Torque: 56 Nm (571 kgf-cm, 41 ft-lbf)
(d) Connect the heated oxygen sensor connector.
50. INSTALL EXHAUST PIPE ASSEMBLY FRONT






(a) Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Torque: 56 Nm (571 kgf-cm, 41 ft-lbf)
(b) Connect the heated oxygen sensor connector.
51. CONNECT WIRE HARNESS
(a) Connect the power steering link connector and clamp.
(b) Install the ground cable.
52. CONNECT ENGINE WIRE
(a) Install the 2 nuts and pull in the engine wire harness.
Torque: 8.4 Nm (85 kgf-cm, 74 in-lbf)
(b) Connect the engine wire harness to the ECM and the junction block.
(c) Install the body ground and connector.
53. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation

54. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2 Installation

55. CONNECT WATER HOSE
56. INSTALL HEATER WATER PUMP ASSEMBLY






(a) Install the bolt and heater water pump assembly.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
57. CONNECT OIL COOLER INLET TUBE SUB-ASSEMBLY (W/ OIL COOLER)






(a) Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler inlet tube.
58. CONNECT OIL COOLER OUTLET TUBE SUB-ASSEMBLY (W/ OIL COOLER)
HINT: Connection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

59. CONNECT RADIATOR HOSE INLET
60. CONNECT RADIATOR HOSE OUTLET
61. CONNECT HEATER WATER INLET HOSE






(a) Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose.
62. CONNECT HEATER WATER OUTLET HOSE
HINT: Connection of the heater water outlet hose is the same as for the heater water inlet hose.

63. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1






(a) Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel tube sub-assembly to the fuel delivery pipe.
(b) Install the EFI fuel pipe clamp.
64. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY






(a) Install the control cable to the transaxle with the bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft-lbf)






(b) Install the control shaft lever with the nut.
Torque: 6.9 Nm (70 kgf-cm, 61 in-lbf)
(c) Install the control cable and a new clip to the bracket.
65. INSTALL INVERTER BRACKET NO.1






(a) Install the 4 bolts and inverter bracket.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
(b) Install the harness clamp and hose clamp.
66. INSTALL COMPRESSOR W/ MOTOR ASSEMBLY
(a) Temporarily install the compressor and magnetic clutch with the 3 bolts.






(b) Install the compressor and magnetic clutch by tightening the 3 bolts in the order shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18 ft-lbf)
(c) Connect the 2 connectors.
67. INSTALL ENGINE MOUNTING STAY NO.2 RH Installation

68. INSTALL ENGINE MOVING CONTROL ROD Installation

69. INSTALL AIR CLEANER BRACKET






(a) Install the 2 bolts and air cleaner bracket.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
70. INSTALL RESERVOIR BRACKET






(a) Install the 2 bolts, nut and reservoir bracket.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(b) Connect the clamp.
71. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY






(a) Install the 2 bolts and brake master cylinder reservoir to the bracket.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(b) Connect the connector.
72. INSTALL W/ CONVERTER INVERTER ASSEMBLY Installation

73. INSTALL INVERTER BRACKET NO.4 Installation

74. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY Installation

75. REMOVE INVERTER COVER Installation

76. INSTALL NO.3 WIRE FRAME Installation

77. INSTALL MG ECU CONNECTOR Installation

78. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Installation

79. INSTALL ENGINE WIRE NO.4 Installation

80. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

81. INSTALL INVERTER COVER Installation

82. INSTALL POWER STEERING ECU BRACKET Installation

83. CONNECT WATER HOSE Installation

84. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY Installation

85. CONNECT ENGINE ROOM WIRE NO.2 Installation

86. CONNECT CIRCUIT BREAKER SENSOR NO.1 Installation

87. INSTALL POWER STEERING ECU ASSY Installation

88. INSTALL INVERTER BRACKET NO.5 Installation

89. INSTALL AIR CLEANER CASE W/ RESONATOR Installation

90. INSTALL AIR CLEANER CAP W/ INLET
(a) Install the air cleaner filter element to the air cleaner case.






(b) Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
91. INSTALL COOL AIR INTAKE DUCT SEAL
(a) Install the 4 clips and cool air intake duct seal.
92. INSTALL BATTERY CARRIER SUB-ASSEMBLY






(a) Install the 5 bolts and battery carrier.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
93. INSTALL BATTERY
(a) Install the battery clamp and battery.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
94. INSTALL SERVICE PLUG GRIP Installation

95. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
(a) Remove the 4 shock absorber nuts.






(b) Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(c) Install the 4 shock absorber nuts (B).
Torque: 80 Nm (815 kgf-cm, 59 ft-lbf)
(d) Install the wire harness clamp and grommet (A).
96. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

97. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
98. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

99. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

100. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
101. ADD AND INSPECT HYBRID TRANSAXLE FLUID (W/O OIL COOLER) Transaxle Fluid

102. ADD AND INSPECT HYBRID TRANSAXLE FLUID (W/ OIL COOLER) Transaxle Fluid

103. ADD ENGINE OIL
104. ADD COOLANT (for Inverter) Coolant (for Inverter)

105. ADD COOLANT (for Engine) Testing and Inspection

106. INSPECT FOR OIL LEAK
107. INSPECT FOR COOLANT LEAK (for Inverter)
108. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection

109. INSPECT FOR FUEL LEAK Testing and Inspection

110. INSPECT FOR EXHAUST GAS LEAK
111. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Front
112. INSTALL ENGINE UNDER COVER NO.2
(a) Install the 2 bolts and engine under cover No.2.
113. INSTALL FRONT FENDER APRON SEAL LH






(a) Install the 2 bolts, clip and fender apron seal LH.
114. INSTALL FRONT FENDER APRON SEAL RH
HINT: Perform the same procedure as above on the opposite side.

115. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH






(a) Install the fender splash shield with the screw.
116. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

117. INSTALL ENGINE UNDER COVER NO.1






(a) Install the 6 bolts, 2 screws, 2 clips and engine under cover.
118. INSPECT STEERING WHEEL CENTER POINT
119. INSPECT IGNITION TIMING Testing and Inspection

120. INSPECT ENGINE IDLE SPEED Testing and Inspection

121. INSPECT CO/HC Testing and Inspection

122. CHECK ABS SPEED SENSOR SIGNAL
Test Mode Procedure
123. PERFORM INITIALIZATION
(a) Some system need initialization when reconnecting the cable from the battery terminal. Repair Instruction - Initialization

124. INSTALL ENGINE ROOM COVER SIDE






(a) Install the 5 clips and engine room cover side
125. INSTALL ENGINE ROOM SIDE LH COVER NO.2






(a) Fit the clips and install the engine room side LH cover.