Part 3
PARTIAL ENGINE ASSY (1NZ-FXE)
REPLACEMENT
67. INSTALL INTAKE MANIFOLD
a. Install a new gasket, then install the intake manifold with the 3 bolts and 2 nuts.
b. Connect the water by-pass hose.
c. Connect the ventilation hose.
d. Install the knock control sensor with bracket with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
68. INSTALL OIL LEVEL GAGE GUIDE
a. Apply engine oil to a new O-ring, then install it to the oil level gage guide.
b. Install the oil level gage with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
c. Install the oil level gage.
69. INSTALL FLYWHEEL SUB-ASSY
a. Apply adhesive to the 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
NOTICE: Remove any oil from the bolts and bolt holes.
b. Using SST, hold the crankshaft.
SST 09213-58013 (91111-50845), 09330-00021
c. Install the flywheel with 6 new bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
d. After tightening the bolts with the specified torque, tighten each bolt by more 90°.
NOTICE: Do not start the engine within 1 hour of installation.
70. INSTALL TRANSMISSION INPUT DAMPER ASSY
a. Using SST, align the hole of the input damper. Then temporarily tighten the input damper cover with the 6 bolts.
SST 09301-00210
b. Using SST, hold the crankshaft.
SST 09213-58013 (91111-50845), 09330-00021
c. Tighten the 6 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
71. INSTALL HYBRID VEHICLE TRANSAXLE ASSY
a. Install the hybrid vehicle transaxle assembly to the engine assembly with the 6 bolts.
b. Install the flywheel housing side cover and starter hole insulator with the 2 bolts.
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
c. Install the engine wire harness to the engine assembly with transaxle.
d. Remove the bolt and engine hanger.
e. Install the ground cable with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
72. INSTALL AIR CLEANER ASSY
Torque:
7.0 Nm (71 kgf-cm, 62 inch lbs.) for bolt
3.0 Nm (31 kgf-cm, 27 inch lbs.) for clamp
73. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter as illustrated.
b. Operate the engine lifter, then install the engine assembly with transaxle to the vehicle.
c. Connect the engine mounting bracket RH and engine mounting insulator RH with the 2 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
d. Connect the engine mounting insulator bracket LH and engine mounting insulator LH with the nut.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
74. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Install the front suspension crossmember with power steering gear assembly with the 4 bolts.
Torque:
113 Nm (1152 kgf-cm, 83 ft. lbs.) for bolt A
157 Nm (1602 kgf-cm, 116 ft. lbs.) for bolt B
b. Install the engine moving control rod with the bracket with the 4 bolts and 2 nuts.
Torque:
100 Nm (1020 kgf-cm, 74 ft. lbs.) for bolt A
56 Nm (571 kgf-cm, 41 ft. lbs.) for bolt B
75. INSTALL FRONT DRIVE SHAFT ASSY LH
76. INSTALL FRONT DRIVE SHAFT ASSY RH
77. CONNECT FRONT AXLE ASSY LH
78. CONNECT FRONT AXLE ASSY RH
HINT: Connect it in the same procedure as the LH side.
79. CONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
80. CONNECT FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Connect it in the same procedure as the LH side.
81. CONNECT TIE ROD END SUB-ASSY LH
82. CONNECT TIE ROD END SUB-ASSY RH
HINT: Connect it in the same procedure as the LH side.
83. CONNECT FRONT STABILIZER LINK ASSY
84. INSTALL FRONT AXLE HUB LH NUT
85. INSTALL FRONT AXLE HUB RH NUT
HINT: Install it in the same procedure as the LH side.
86. INSTALL EXHAUST PIPE ASSY FRONT
87. CONNECT STEERING SLIDING YOKE SUB-ASSY
a. Align the paint marks, then connect the steering sliding yoke with the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
b. Install the column hole cover silencer sheet with the 2 clips.
c. Remove the seat belt from the steering wheel.
88. CONNECT W/MOTOR COMPRESSOR ASSY
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
89. CONNECT ENGINE WIRE
90. CONNECT HEAT STORAGE WATER BY-PASS HOSE NO.3
91. CONNECT HEATER WATER HOSE B
92. CONNECT FUEL TUBE SUB-ASSY
a. Push the fuel tube into the fuel delivery pipe until it makes a "click" sound.
HINT:
^ If the fuel tube is connected too tightly, apply a light coat of engine oil to the tip of the fuel delivery pipe.
^ After connecting, check that the fuel tube is securely connected by pulling it.
b. Install the fuel pipe clamp.
93. INSTALL VACUUM SWITCHING VALVE ASSY NO.2
Torque: 7.5 Nm (76 kgf-cm, 5.5 inch lbs.)
94. CONNECT AIR CLEANER INLET NO.1
Torque: 3.0 Nm (31 kgf-cm, 27 inch lbs.)
95. CONNECT ENGINE WIRE
96. CONNECT HEAT STORAGE WATER BY-PASS HOSE NO.1
97. CONNECT INVERTER COOLING HOSE NO.3
98. INSTALL NO.2 RADIATOR ASSY
99. INSTALL W/CONVERTER INVERTER ASSY
100. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT
101. INSTALL WINDSHIELD WIPER LINK ASSY
102. ADD TRANSAXLE OIL
103. INSTALL SERVICE PLUG GRIP
104. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
105. INSTALL REAR FLOOR BOARD NO.3
106. INSTALL DECK FLOOR BOX REAR
107. INSTALL REAR FLOOR BOARD NO.2
108. ADD ENGINE COOLANT
a. Add engine coolant to the radiator on the engine side.
b. Add engine coolant to the radiator on the hybrid side.
109. INSPECT TRANSAXLE FLUID LEVEL
110. CHECK FOR ENGINE COOLANT LEAKS
111. CHECK FOR FUEL LEAKS
112. INSPECT OIL LEAK
113. INSTALL FRONT WHEELS
Torque: 103 Nm (1050 kgf-cm, 76 ft. lbs.)
114. ADJUST FRONT WHEEL ALIGNMENT
115. INSTALL ENGINE UNDER COVER RH
116. INSTALL ENGINE UNDER COVER LH
117. POWER WINDOW CONTROL SYSTEM INITIALIZE Power Window Regulator Motor Initialization