Operation CHARM: Car repair manuals for everyone.
Home >> Scion >> 2011 >> tC L4-2.5L (2AR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Installation

Installation





2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

CAUTION:
As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

NOTICE:
for Manual Transaxle:

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

1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Install the engine mounting insulator with the 4 bolts.

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

2. INSTALL ENGINE MOUNTING SPACER

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Temporarily install the engine mounting spacer with the 2 bolts.





(b) Tighten the 2 bolts in the sequence shown in the illustration.

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

3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Install the engine mounting insulator with the 3 bolts.

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

(b) Install the 2 cooler pipe brackets with the 2 bolts and nut.

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

(c) Attach the 3 cooler pipe clamps.

4. INSTALL REAR ENGINE MOUNTING INSULATOR

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Install the engine mounting insulator with the 2 bolts and 2 nuts.

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

5. INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(a) Install the engine mounting insulator with the 2 bolts.

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

6. INSTALL ENGINE HANGER Removal

7. REMOVE ENGINE FROM ENGINE STAND

NOTICE:
* Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

(a) Attach a sling device and hang the engine with a chain block.

(b) Lift the engine and remove it from the engine stand.

8. FIX ENGINE ASSEMBLY Removal

9. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine.

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

Installation

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

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

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

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

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

16. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

Installation

17. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

Installation

18. INSTALL STARTER ASSEMBLY Installation

19. TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.





20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Place the engine on an engine lifter.

HINT
Place the engine on wooden blocks or equivalent so that the engine is level.

(b) Operate the engine lifter and install the engine to the vehicle.

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.

(c) Temporarily install the front suspension crossmember with the 2 bolts.





(d) Temporarily install the member rear brace RH and LH with the 6 bolts.





(e) Install the engine mounting insulator LH with the through bolt and nut.

Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

(f) Install the engine mounting insulator RH with the bolt and 2 nuts.





for bolt and nut A - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

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

(g) Tighten the 2 front suspension member bolts.





Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

(h) Tighten the 6 member rear brace bolts.





for bolt A - Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

for bolt B - Torque : 93 Nm (948 kgf-cm, 69 ft-lbf)

21. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY





(a) Install the front crossmember with the 6 bolts.

for bolt A - Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

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





(b) Tighten the bolt and nut holding the front engine mounting insulator.

Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

22. TIGHTEN FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Tighten the rear engine mounting insulator bolt.

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

23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

(a) Install the reinforcement with the 4 bolts.

Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

24. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

(a) Install the reinforcement with the 4 bolts.

Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

25. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transaxle) Installation

26. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover.

27. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the bracket with the 3 bolts.

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

28. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING Reassembly

29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

31. INSTALL FRONT AXLE ASSEMBLY LH

Installation

32. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

33. CONNECT FRONT STABILIZER LINK ASSEMBLY LH Installation

34. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

35. INSTALL FRONT AXLE SHAFT NUT LH Installation

36. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Use the same procedure described for the LH side.

37. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

38. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

39. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

40. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

41. CONNECT WIRE HARNESS AND HOSE

(a) for Automatic Transaxle:





(1) Connect the 2 oil cooler hoses to the oil cooler tube.

(b) Connect the transmission wire with the bolt.

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

(c) Attach the clamp.

(d) Connect the vacuum hose.

(e) Attach the 2 clamps to install the wire harness, and then install the 2 nuts.

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

(f) Connect the 3 wire harness connectors to the engine room No. 1 junction block.

(g) Connect the ECM connector and lower the lever.





NOTICE:
* When connecting the connector, make sure that dirt, water or other foreign matter does not get caught between the connector and other parts.
* Make sure that the lever is securely lowered.

(h) Attach the wire harness clamp.

42. CONNECT HEATER WATER HOSE

(a) Connect the 2 heater water hoses.

43. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector Fuel System: Precaution.

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

44. CONNECT NO. 1 RADIATOR HOSE Installation

45. INSTALL RADIATOR HOSE CLAMP Installation

46. CONNECT CLUTCH HOSE (for Manual Transaxle)

(a) Temporarily install the clutch line.





(b) Install the clutch hose with a new clip.

(c) Using a union nut wrench, tighten the 2 clutch lines to the clutch accumulator assembly.

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

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

47. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Connect the control cable support to the rear engine mounting insulator with the bolt.

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

(b) Connect the 2 transmission control cables with 2 new clips.

(c) Install the 2 clips.

48. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Connect the control cable support to the rear engine mounting insulator with the bolt.

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

(b) Connect the transmission control cable to the control cable bracket with a new clip.

(c) Connect the transmission control cable to the control shaft lever with the nut.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

49. INSTALL BATTERY CARRIER Installation

50. INSTALL BATTERY TRAY

51. INSTALL BATTERY

52. INSTALL BATTERY INSULATOR

53. INSTALL BATTERY CLAMP SUB-ASSEMBLY Installation

54. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

56. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

57. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

58. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Installation

59. CONNECT NO. 2 RADIATOR HOSE Installation

60. INSTALL GENERATOR ASSEMBLY Installation

61. INSTALL FAN AND GENERATOR V BELT Installation

62. CONNECT RADIATOR RESERVOIR ASSEMBLY

(a) Install the grommet to the radiator reservoir.

(b) Connect the radiator reservoir with the 2 bolts.

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

63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

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

65. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) Testing and Inspection

66. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

67. ADD ENGINE COOLANT Service and Repair

68. ADD ENGINE OIL Replacement

69. INSPECT FOR FUEL LEAK Installation

70. INSPECT FOR COOLANT LEAK Testing and Inspection

71. INSPECT FOR OIL LEAK Replacement

72. INSPECT FOR EXHAUST GAS LEAK Installation

73. INSPECT IGNITION TIMING Engine

74. INSPECT ENGINE IDLE SPEED Engine

75. INSPECT CO/HC Engine

76. INSTALL FRONT WHEEL

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

77. ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

78. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the under cover with the 5 clips.

79. INSTALL REAR ENGINE UNDER COVER RH Installation

80. INSTALL REAR ENGINE UNDER COVER LH

(a) Install the under cover with the 5 clips.

81. CONNECT FRONT FENDER LINER RH

(a) Connect the front fender liner with the screw.

82. CONNECT FRONT FENDER LINER LH

(a) Connect the front fender liner with the screw.

83. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the under cover with the 2 bolts and 7 clips.

84. INSTALL CENTER ENGINE UNDER COVER

(a) Install the center engine under cover with the 6 screws and 6 bolts.
pro multis · About Operation CHARM