Installation

2ZR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

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

(a) Using SST, hold the crankshaft.

SST : 09213-58013

91651-60855

SST : 09330-00021

(b) Clean the bolt and the bolt hole.

(c) Apply adhesive to 2 or 3 threads of the bolt end.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Install the front spacer, drive plate and rear spacer with the 8 bolts.

Uniformly tighten the 8 bolts.

Torque : 88 Nm (897 kgf-cm, 65 ft-lbf)

2. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) Installation

3. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Installation

4. INSTALL TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle)

5. INSTALL NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) Installation

6. INSTALL NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) Installation

7. INSTALL NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle) Installation

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

(a) Hold the crankshaft with SST.

SST : 09213-58013

91651-60855

SST : 09330-00021

(b) Clean the 8 bolts and their holes.

(c) Apply adhesive to the 2 or 3 end threads of the bolts.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

(d) Install the flywheel with the 8 bolts in the order shown in the illustration.

Torque : 49 Nm (500 kgf-cm, 38 ft-lbf)

(e) Mark paint marks on the upper edge of the bolt heads.

Text in Illustration

(f) Tighten the bolts 90° in the sequence order shown in the illustration.

NOTICE:
Do not start the engine for at least 1 hour after performing the installation.

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

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

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

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

13. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transaxle)

(a) Install the control cable bracket with 2 bolts.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

14. INSTALL STARTER ASSEMBLY Installation

15. INSTALL FLYWHEEL HOUSING SIDE COVER Installation

16. INSTALL ENGINE MOVING CONTROL ROD (for Automatic Transaxle) Installation

17. INSTALL ENGINE MOVING CONTROL ROD (for Manual Transaxle) Installation

18. INSTALL ENGINE MOVING CONTROL ROD COVER Installation

19. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the engine moving control rod with the through bolt.

Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)

(b) Remove the 2 bolts and remove the 2 engine hangers.

(c) Install the air fuel ratio sensor bracket with bolt.

Torque : 43 Nm (439 kgf-cm, 32 ft-lbf)

20. INSTALL TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Install the transverse engine mounting insulator with the 5 bolts.

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

21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.

(b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator RH and transverse engine mounting insulator can be installed.

(c) Install the transverse engine mounting insulator with the through bolt and nut.

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

(d) Install the engine mounting insulator RH with the 6 bolts and nut.

Text in Illustration

Torque : 88 Nm (897 kgf-cm, 65 ft-lbf) for Bolt A

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

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

(e) Install the engine mounting stay RH with the 2 bolts.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

(f) Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts.

(g) Insert SST into the datum holes in the front suspension crossmember RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.

Text in Illustration

SST : 09670-00010

Torque : 70 Nm (714 kgf-cm, 52 ft-lbf) for Bolt A

Torque : 160 Nm (1631 kgf-cm, 118 ft-lbf) for Bolt B with Bolt Strength Class 11T

Torque : 135 Nm (1377 kgf-cm, 100 ft-lbf) for Bolt B with Bolt Strength Class 10T

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

CAUTION:
* Insert SST into the datum hole vertically.
* If impossible to insert SST vertically, loosen all bolts and then insert SST again.
22. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) Installation

23. INSTALL FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle) Installation

24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

26. INSTALL FRONT AXLE ASSEMBLY LH Installation

27. INSTALL FRONT AXLE ASSEMBLY RH

HINT
The installation procedure for the RH side is the same as that for the LH side.

28. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation

29. INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
The installation procedure for the RH side is the same as that for the LH side.

30. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

31. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
The installation procedure for the RH side is the same as that for the LH side.

32. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation

33. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT
The installation procedure for the RH side is the same as that for the LH side.

34. INSTALL SPEED SENSOR FRONT LH Installation

35. INSTALL SPEED SENSOR FRONT RH

HINT
The installation procedure for the RH side is the same as that for the LH side.

36. INSTALL FRONT AXLE SHAFT LH NUT Installation

37. INSTALL FRONT AXLE SHAFT RH NUT

HINT
The installation procedure for the RH side is the same as that for the LH side.

38. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Using vernier calipers, measure the free length of the compression spring.

Minimum length (Front side):

40.5 mm (1.594 in.)

Minimum length (Rear side):

38.5 (1.516 in.)

If the length is not as specified, replace the compression spring.

(b) Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.

Text in Illustration

NOTICE:
* Install the exhaust pipe gasket in the correct direction.
* Do not damage the outer surface of the exhaust pipe gasket.
* Do not reuse the exhaust pipe gasket.
* Do not push in the gasket with the exhaust pipe when connecting it.

(c) Install the 3 exhaust pipe supports.

(d) Install the exhaust front pipe assembly and a new exhaust pipe gasket with the 4 compression springs and 4 bolts.

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

(e) Pass the sensor connector through the floor panel and install the grommet.

(f) Connect the heated oxygen sensor connector.

39. INSTALL FRONT FLOOR BRACE CENTER Installation

40. INSTALL FRONT CONSOLE BOX Installation

41. INSTALL REAR CONSOLE BOX ASSEMBLY Installation

42. INSTALL CONSOLE BOX COVER REAR Installation

43. INSTALL CONSOLE BOX CARPET Installation

44. INSTALL CONSOLE PANEL UPPER Installation

45. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle) Installation

46. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

47. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY Installation

48. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

49. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)

(a) Install the clutch release cylinder and clutch pipe with the 4 bolts.

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf) for bolt A

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

50. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector and fuel pipe, and install the No. 1 fuel pipe clamp.

CAUTION:
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 the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

51. CONNECT HEATER WATER HOSE INLET A

(a) Connect heater water inlet hose A to the heater unit.

52. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

(a) Connect heater water outlet hose A to the heater unit.

53. CONNECT ENGINE WIRE

(a) Connect the 2 engine wire harness connectors and 2 wire harness clamps to the engine room junction block.

(b) Connect the engine wire harness connector to the ECM.

(e) Install the transaxle earth wire with the bolt and 2 wire harness clamps (for Manual Transaxle).

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

(f) Install the transaxle earth wire with the bolt and wire harness clamp (for Automatic Transaxle).

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

54. INSTALL NO. 1 FUEL VAPOR FEED HOSE

(a) Install the No. 1 fuel vapor feed hose into the vacuum switching valve assembly.

55. INSTALL UNION TO CHECK VALVE HOSE

(a) Install the union to check valve hose with the clip.

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

(a) Install the transmission control cable assembly onto the control shaft lever with the nut.

Text in Illustration

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

(b) Fix the transmission control cable assembly onto the control cable bracket with a new clip.

NOTICE:
Make sure that the marking on the cable is aligned with the slit in the transmission control cable bracket before installing the cable.

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

(a) Install the control cable assembly onto the control cable bracket with 2 new clips.

(b) Connect the control cable assembly and install the 2 washers and 2 clips.

(c) Install the control cable assembly onto the shift lever retainer.

Text in Illustration

NOTICE:
* Install the cable with the protruding portion of the cable outer facing upward.
* After installing. check that the lock of the cable outer is protruding beyond portion A. as shown in the illustration.

58. INSTALL WITH PULLEY COMPRESSOR ASSEMBLY Installation

59. INSTALL RADIATOR ASSEMBLY Installation

60. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY Installation

61. INSTALL UPPER RADIATOR SUPPORT ABSORBER Reassembly

62. INSTALL NO. 1 COOLER COVER Installation

63. INSTALL HOOD LOCK ASSEMBLY Installation

64. CONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle) Installation

65. CONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle) Installation

66. CONNECT NO. 1 RADIATOR HOSE Installation

67. INSTALL NO. 2 RADIATOR HOSE

(a) Install the No. 2 radiator hose with the 2 clips.

68. INSTALL FRONT BUMPER COVER Installation

69. INSTALL FAN & GENERATOR V BELT Installation

70. ADJUST FAN & GENERATOR V BELT Installation

71. INSPECT FAN & GENERATOR V BELT Installation

72. INSTALL NO. 2 CYLINDER HEAD COVER Installation

73. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 5 bolts.

Torque : 17 Nm (173 kgf-cm, 13 ft-lbf)

(b) Install the clamp.

74. INSTALL AIR CLEANER BRACKET

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

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

(b) Connect the wire harness clamp to the air cleaner bracket.

75. INSTALL AIR CLEANER ASSEMBLY

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

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

(b) Connect the wire harness to the air cleaner case.

(c) Install the air cleaner element.

(d) Install and lock the air cleaner cap with air cleaner hose and then tighten the air cleaner hose clamp.

Torque : 3.0 Nm (31 kgf-cm, 27 in-lbf)

(e) Connect the ventilation hose to the air cleaner hose.

(f) Connect the intake air flow meter connector and 2 wire harness clamps.

76. INSTALL OUTER COWL TOP PANEL

(a) Install the outer cowl top panel with the 9 bolts.

Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)

(b) Connect the wire harness clamp.

77. INSTALL FRONT AIR SHUTTER SEAL RH

(a) Engage the 2 claws to install the front air shutter seal RH.

78. INSTALL FRONT WIPER MOTOR AND LINK Installation

79. INSTALL COWL TOP VENTILATOR LOUVER LH Installation

80. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

81. INSTALL HOOD TO COWL TOP SEAL Installation

82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

84. INSTALL FRONT WIPER ARM HEAD CAP Installation

85. INSTALL BATTERY TRAY

86. INSTALL BATTERY

(a) Install the battery onto the vehicle with the battery clamp.

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

(b) Connect the cable to the battery terminal.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

87. ADD ENGINE COOLANT Service and Repair

88. ADD AUTOMATIC TRANSAXLE OIL (for Automatic Transaxle)

89. INSPECT AUTOMATIC TRANSAXLE OIL (for Automatic Transaxle) Procedures

90. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

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

92. INSPECT FOR FUEL LEAK

93. INSPECT FOR ENGINE OIL LEAK

94. INSPECT FOR EXHAUST GAS LEAK

95. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

96. INSTALL ENGINE UNDER COVER RH

97. INSTALL ENGINE UNDER COVER LH

98. INSTALL FRONT WHEELS

Torque : 103 Nm (1,050 kgf-cm, 76 ft-lbf)

99. INSPECT IGNITION TIMING Engine

100. INSPECT ENGINE IDLING SPEED Engine

101. INSPECT CO/HC Engine

102. INSPECT FRONT WHEEL ALIGNMENT

Front Wheel Alignment

103. CHECK VSC SENSOR SIGNAL

Test Mode Procedure