Installation

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

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

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 AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) Installation

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

8. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the bracket with the 3 bolts.

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

9. INSTALL REAR ENGINE MOUNTING INSULATOR SUB-ASSEMBLY

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

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

10. 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 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.

11. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

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

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

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

HINT
Install the through bolt by tightening the nut.

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

12. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH Installation

13. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY

(a) Install the front crossmember with the 4 bolts.

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

(b) Install the front engine mounting insulator with the 2 bolts.

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

HINT
Only perform this procedure when replacement of the engine mounting insulator in necessary.

(c) Install the engine mounting insulator front to the engine mounting bracket front with the bolt and nut.

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

14. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Support the front suspension crossmember with a transmission jack.

(b) While inserting SST into the reference holes on the front suspension crossmember RH and LH alternately, tighten 2 bolts A, 2 bolts B, and 2 nuts on the RH and LH sides to the respective specified torque in several steps.

SST : 09670-00020

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

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

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

15. INSTALL FRONT SUSPENSION MEMBER BRACE REAR LH

(a) Install the front suspension member rear brace LH with the 3 bolts.

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

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

16. INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH

HINT
Perform the same procedure for the LH side.

17. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

(a) Install the front suspension member reinforcement LH with the 4 bolts.

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

NOTICE:
Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D, and A.

18. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

HINT
Perform the same procedure for the LH side.

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

20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

22. INSTALL FRONT AXLE ASSEMBLY LH Installation

23. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

24. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

25. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

26. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation

27. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

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

29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

30. INSTALL FRONT SPEED SENSOR LH Installation

31. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure for the LH side.

32. INSTALL FRONT AXLE HUB NUT LH Installation

33. INSTALL FRONT AXLE HUB NUT RH

HINT
Perform the same procedure for the LH side.

34. CONNECT ENGINE WIRE

(a) Install the ground cable with the bolt located near the starter.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(b) Connect the ground cable to the clamp located near the starter.

(c) Connect the ground cable connector.

(d) Connect the engine wire to the positive battery terminal with the nut.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(e) Connect the 2 engine wire connectors and install the nut.

(f) Install the engine room relay block cover.

(g) Attach the clamp of the engine wire cover.

(h) Install the engine wire cover to with the bolt.

35. CONNECT ECM

(a) Connect the connector to the engine control computer with the clamp and lock lever.

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

37. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

38. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

39. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) Installation

40. INSTALL STARTER ASSEMBLY (for Manual Transaxle) Installation

41. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) Installation

42. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Installation

43. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle) Installation

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

Installation

45. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)

Refer to the procedures under "INSTALL CLUTCH ACCUMULATOR ASSEMBLY" Installation

46. CONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

(a) Connect the check valve to connector tube hose.

47. INSTALL FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector and fuel pipe.

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 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.

(a) Connect the inlet heater water hose.

49. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.

50. CONNECT OUTLET RADIATOR HOSE

(a) Connect the outlet radiator hose.

51. CONNECT INLET RADIATOR HOSE

(a) Connect the inlet radiator hose.

(b) Engage the heated oxygen sensor wire harness clamp.

52. CONNECT BREATHER HOSE (for Automatic Transaxle)

(a) Engage the clamp and connect the breather hose.

53. CONNECT NO. 1 OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transaxle) Installation

54. INSTALL COMPRESSOR ASSEMBLY Installation

55. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

56. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

57. INSTALL GENERATOR ASSEMBLY Installation

58. INSTALL FAN AND GENERATOR V BELT Installation

59. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Installation

60. INSTALL NO. 2 BATTERY CARRIER Installation

61. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

62. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE Installation

63. INSTALL RADIATOR RESERVE TANK ASSEMBLY Installation

64. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

Minimum length:

41.5 mm (1.634 in.)

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

(b) Install the new exhaust pipe gasket to the exhaust manifold converter.

(c) Install the front exhaust pipe with the 2 compression springs and 2 bolts.

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

65. INSTALL CENTER EXHAUST PIPE ASSEMBLY

(a) Install the new gasket onto the front exhaust pipe.

(b) Install the center exhaust pipe with the 2 bolts.

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

66. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Installation

67. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Procedures

68. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

69. INSPECT AND ADJUST MANUAL TRANSAXLE OIL (for Manual Transaxle) Testing and Inspection

70. INSTALL BATTERY Installation

71. ADD ENGINE COOLANT Service and Repair

72. CHARGE REFRIGERANT Service and Repair

73. WARM UP ENGINE Service and Repair

74. ADD CLUTCH FLUID (for Manual Transaxle)

75. BLEED CLUTCH LINE (for Manual Transaxle) Procedures

76. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transaxle)

77. INSPECT CLUTCH FLUID LEVEL IN RESERVOIR (for Manual Transaxle)

78. INSPECT FOR FUEL LEAK Installation

79. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

80. INSPECT REFRIGERANT LEAK Service and Repair

81. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK (for Automatic Transaxle)

82. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle) Initial Inspection and Diagnostic Overview

83. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle) Installation

84. INSPECT EXHAUST GAS LEAK

85. INSTALL REAR ENGINE UNDER COVER LH

86. INSTALL REAR ENGINE UNDER COVER RH

87. INSTALL NO. 2 ENGINE UNDER COVER

88. INSTALL NO. 1 ENGINE UNDER COVER

89. INSTALL CENTER TRANSMISSION UNDER COVER ASSEMBLY

90. INSTALL FRONT WHEELS

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

91. INSTALL HOOD Installation

92. INSPECT HOOD Adjustments

93. ADJUST HOOD Adjustments

94. INSPECT ENGINE IDLING SPEED Engine

95. INSPECT CO/HC Engine

96. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

97. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

(a) Inspect and adjust the front wheel alignment Front Wheel Alignment.

98. INSPECT ABS SPEED SENSOR SIGNAL