Installation
2AZ-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
1. REMOVE ENGINE ON ENGINE STAND
(a) Remove the bolts and engine on engine stand.
2. INSTALL FLYWHEEL SUB-ASSEMBLY
(a) Gently place the engine assembly onto wooden blocks or equivalent.
NOTICE:
This step should be done while hanging the engine assembly using the engine hangers and a chain block.
(b) Install the flywheel sub-assembly Installation.
3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY
(a) Gently place the engine assembly onto wooden blocks or equivalent.
NOTICE:
This step should be done while hanging the engine assembly using the engine hangers and a chain block.
(b) Install the transmission input damper assembly Installation.
4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
(a) Install the hybrid vehicle transaxle assembly Installation.
NOTICE:
Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.
5. INSTALL ENGINE WIRE
6. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the drive shaft bearing bracket with 3 new bolts.
Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)
7. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
(a) Position the engine mounting insulator sub-assembly RH as shown in the illustration.
(b) Temporarily install bolt A to the engine mounting insulator sub-assembly RH.
(c) Tighten the 3 bolts to the engine mounting insulator sub-assembly RH in the order bolt B, bolt C and bolt A.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
(d) Install the 2 cooler brackets with the 2 bolts.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
8. INSTALL RADIATOR RESERVE TANK ASSEMBLY
(a) Install the radiator reserve tank assembly with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
9. INSTALL ENGINE MOUNTING INSULATOR LH
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
(a) Temporarily install bolt A to the engine mounting insulator LH.
(b) Tighten the 4 bolts to the engine mounting insulator LH in the order bolt C, bolt B, bolt D and bolt A.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
(a) Install the rear No. 1 engine mounting insulator to the engine mounting bracket with the through bolt.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
11. INSTALL FRONT ENGINE MOUNTING INSULATOR
(a) Temporarily install the front engine mounting insulator with the bolt and nut.
12. 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.
* Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
HINT
Place the engine on wooden blocks or equivalents so that the engine is level.
(b) Remove the 2 bolts and 2 engine hangers.
(c) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.
(d) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.
CAUTION:
Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
NOTICE:
* 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.
(e) Install the front cross member sub-assembly with the 4 bolts.
Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)
(f) Install the front engine mounting insulator to the front cross member with the 2 bolts.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
(g) Install the engine mounting insulator LH with the through bolt and nut.
Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)
NOTICE:
When installing the engine mounting insulator, tighten the nut while holding the bolt.
(h) Install the engine mounting insulator RH with the bolt and 2 nuts.
Nut A - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut B - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
Bolt - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
(i) Tighten the front engine mounting insulator with the bolt and nut.
Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)
13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation
14. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH Installation
15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH
HINT
Perform the same procedure as for the LH side.
16. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH Installation
17. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH Installation
18. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING Installation
19. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
20. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
21. INSTALL FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation
22. INSTALL FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
23. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
24. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
25. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation
26. CONNECT TIE ROD END SUB-ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
27. INSTALL FRONT SPEED SENSOR LH Installation
28. INSTALL FRONT SPEED SENSOR RH
HINT
Perform the same procedure as for the LH side.
29. INSTALL FRONT AXLE SHAFT NUT LH Installation
30. INSTALL FRONT AXLE SHAFT NUT RH
HINT
Perform the same procedure as for the LH side.
31. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
32. INSTALL FRONT NO. 3 ENGINE UNDER COVER Installation
33. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation
34. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
35. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
36. INSTALL ELECTRIC INVERTER COMPRESSOR
(a) Using an E8 "TORX" socket, install the 2 stud bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Install the electric inverter compressor with the bolt and 2 nuts.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
(c) Connect the connector (B).
CAUTION:
Wear insulated gloves.
(d) Lock the green-colored lock.
CAUTION:
Wear insulated gloves.
(e) Connect the connector (A).
(f) Install the bolt.
Torque : 12 Nm (117 kgf-cm, 8 ft-lbf)
37. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube connector and fuel pipe.
NOTICE:
Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.
(b) Engage the claw and install the No. 1 fuel pipe clamp.
38. CONNECT NO. 1 MOTOR COOLING HOSE Installation
39. CONNECT NO. 2 MOTOR COOLING HOSE Installation
40. INSTALL WIRE HARNESS
(a) Install the heater hose bracket with the bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
(b) Install the bracket to the cylinder head with the bolt.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
(c) Connect the earth wire with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(d) Connect the wire harness with the 2 clamps.
(e) Connect the earth wire with the bolt.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(f) Connect the wire harness to the engine room junction block with the 2 clamps.
(g) Connect the 2 connectors to the engine room junction block.
(h) Connect the wire harness with the 3 clamps.
(i) Connect the connector to the hybrid vehicle control ECU with the lock lever.
41. CONNECT INLET HEATER WATER HOSE
(a) Connect the inlet heater water hose with the clamp.
Text in Illustration
HINT
Make sure that the claws on the clamp are positioned as shown in the illustration.
42. CONNECT OUTLET HEATER WATER HOSE
(a) Connect the outlet heater water hose with the 2 clamps to the heater hose bracket.
(b) Connect the outlet heater water hose with the clamp.
Text in Illustration
HINT
Make sure that the claws on the clamp are positioned as shown in the illustration.
43. CONNECT NO. 3 INVERTER COOLING HOSE
(a) Connect the No. 3 inverter cooling hose with the clamp.
44. CONNECT NO. 5 INVERTER COOLING HOSE
(a) Connect the No. 5 inverter cooling hose with the clamp.
45. CONNECT NO. 2 RADIATOR HOSE
(a) Connect the No. 2 radiator hose to the water inlet with the clamp.
46. CONNECT NO. 3 RADIATOR HOSE
(a) Connect the No. 3 radiator hose with the clamp.
47. INSTALL INVERTER BRACKET ASSEMBLY
(a) Position the inverter bracket assembly as shown in the illustration.
(b) Temporarily install bolt A to the inverter bracket assembly.
(c) Tighten the 5 bolts to the inverter bracket assembly in the order bolt B, bolt A, bolt C, bolt D and bolt E.
Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)
48. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
(b) Install the air cleaner filter element.
49. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the air cleaner cap sub-assembly with the 2 clamps and hose band.
(b) Connect the clamp and vacuum switching valve connector.
(c) Connect the No. 2 fuel vapor feed hose to the vacuum switching valve assembly.
(d) Connect the No. 1 fuel vapor feed hose to the vacuum switching valve assembly and air cleaner hose.
(e) Connect the clamp and air flow meter connector.
50. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation
51. CONNECT LOW VOLTAGE CONNECTOR Installation
52. REMOVE CONNECTOR COVER ASSEMBLY Removal
53. CONNECT FRAME WIRE Installation
54. CONNECT AIR CONDITIONING HARNESS ASSEMBLY Installation
55. INSTALL CONNECTOR COVER ASSEMBLY Installation
56. CONNECT WATER HOSE Installation
57. INSTALL INVERTER RESERVE TANK ASSEMBLY Installation
58. CONNECT MOTOR CABLE Installation
59. CONNECT GENERATOR CABLE Installation
60. INSTALL NO. 5 INVERTER BRACKET Installation
61. INSTALL SERVICE PLUG GRIP Installation
62. INSTALL BATTERY SERVICE HOLE COVER Installation
63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation
64. INSTALL LUGGAGE COMPARTMENT FLOOR MAT Installation
65. ADD ENGINE OIL Replacement
66. ADD HYBRID TRANSAXLE FLUID Procedures
67. ADD COOLANT (for Inverter) Coolant (for Inverter)
68. ADD COOLANT (for Engine) Coolant (for Engine)
69. INSPECT AND ADJUST HYBRID TRANSAXLE FLUID Procedures
70. INSPECT ENGINE OIL LEVEL Testing and Inspection
71. INSPECT FOR FUEL LEAK Fuel System
72. INSPECT FOR COOLANT LEAK (for Engine) On-Vehicle Inspection
73. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection
74. INSPECT FOR OIL LEAK
75. INSPECT FOR EXHAUST GAS LEAK
76. INSTALL NO. 1 ENGINE UNDER COVER
77. INSTALL ENGINE UNDER COVER
78. INSTALL REAR ENGINE UNDER COVER LH
79. INSTALL REAR ENGINE UNDER COVER RH
80. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
81. INSTALL COWL BODY MOUNTING REINFORCEMENT RH Installation
82. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL Installation
83. INSTALL WATER GUARD PLATE RH Installation
84. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
85. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
86. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
87. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
88. INSTALL FRONT WIPER ARM HEAD CAP Installation
89. INSTALL FRONT WHEELS
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
90. INSPECT IGNITION TIMING On-Vehicle Inspection
91. INSPECT ENGINE IDLE SPEED On-Vehicle Inspection
92. INSPECT CO/HC On-Vehicle Inspection
93. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT
Front Wheel Alignment.
94. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
(a) Engage the 3 clips to install the cover.
NOTICE:
* Be sure to engage the clips securely.
* Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
95. INSTALL COOL AIR INTAKE DUCT SEAL
(a) Install the cool air intake duct seal with the 11 clips.
96. CHECK ABS SPEED SENSOR SIGNAL
HINT
Test Mode Procedure.