Installation

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

(a) Using SST, install a new gasket and the ECT sensor.
SST: 09817-33190
Torque: 20 Nm (208 kgf-cm, 15ft-lbf)
2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil.
Adhesive:
Part No. 08833-00080 THREE BOND 1344 or equivalent

(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11ft-lbf)
3. INSTALL RADIO SETTING CONDENSER

(a) Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
4. INSTALL KNOCK SENSOR

(a) Install the sensor with the nut as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15ft-lbf)
5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
6. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
7. INSTALL ENGINE MOUNTING BRACKET RH

(a) Remove the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40ft-lbf)
8. INSTALL OIL COOLER PIPE (w/ Oil Cooler)

(a) Install a new gasket and the pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
9. INSTALL NO. 1 WATER BY-PASS PIPE

(a) Install a new gasket and the pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
10. INSTALL THERMOSTAT Installation
11. INSTALL WATER INLET Installation
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Except for PZEV:
(1) Install a new gasket onto the cylinder head.
(2) Temporarily tighten the exhaust manifold converter with the 5 nuts.

(3) Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (378 kgf-cm, 27ft-lbf)

(4) Connect the air-fuel ratio sensor connector.

(5) Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 12 Nm (122 kgf-cm, 9ft-lbf)
(b) For PZEV:
(1) Install a new gasket onto the cylinder head.
(2) Temporarily tighten the exhaust manifold converter with the 5 nuts.

(3) Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (378 kgf-cm, 27ft-lbf)

(4) Connect the air-fuel ratio sensor connector.
13. INSTALL NO. 2 MANIFOLD STAY

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32ft-lbf)
14. INSTALL MANIFOLD STAY

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32ft-lbf)
15. INSTALL OIL LEVEL GAUGE GUIDE

(a) Apply a light coat of engine oil to a new O-ring and install it to the guide.
(b) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
16. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
17. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47ft-lbf)
18. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

(a) Install the intake manifold insulator onto the cylinder block.
19. INSTALL NO. 2 VENTILATION HOSE
20. INSTALL INTAKE AIR CONTROL VALVE (for PZEV) Installation
21. INSTALL INTAKE MANIFOLD

(a) Install a new gasket into the intake manifold.

(b) Install the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (305 kgf-cm, 22ft-lbf)
22. INSTALL FUEL DELIVERY PIPE WITH INJECTOR Installation
23. REMOVE ENGINE STAND
24. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Installation
25. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) Reassembly
26. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) Reassembly
27. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Installation
28. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
HINT: Installation.

29. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
HINT: Installation.

30. INSTALL STARTER ASSEMBLY (for Manual Transaxle) Installation
31. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) Installation
32. INSTALL ENGINE WIRE
33. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
34. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
35. INSTALL FRONT FRAME ASSEMBLY

(a) for A/T:
Install the engine mounting insulator LH with the nut.
Torque: 95 Nm (969 kgf-cm, 70ft-lbf)

(b) for M/T:
Install the engine mounting insulator LH with the bolt.
Torque: 143 Nm (1,459 kgf-cm, 105ft-lbf)

(d) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (888 kgf-cm, 64ft-lbf)

(e) for M/T:
Install the engine lateral control rod with the bolt.
Torque: 89 Nm (910 kgf-cm, 66ft-lbf)
36. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32ft-lbf)
(b) Connect the oil pressure switch connector.
37. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side plate LH and RH with the 4 bolts and 2 nuts.
Bolt A - Torque: 85 Nm (867 kgf-cm, 63ft-lbf)
Bolt B and nut - Torque: 32 Nm (326 kgf-cm, 24ft-lbf)

(d) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Bolt C - Torque: 85 Nm (867 kgf-cm, 63ft-lbf)
Bolt D and nut - Torque: 32 Nm (326 kgf-cm, 24ft-lbf)
38. INSTALL STEERING SLIDING YOKE Installation
39. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the exhaust pipe support bracket with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14ft-lbf)
40. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) Installation
41. INSTALL FRONT AXLE ASSEMBLY LH Installation
42. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

43. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH Installation
44. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedure described for the LH side.

45. INSTALL TIE ROD ASSEMBLY LH Installation
46. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

47. INSTALL FRONT SPEED SENSOR LH Installation
48. INSTALL FRONT SPEED SENSOR RH
Torque: 8.0 Nm (82 kgf-cm, 71in-lbf)
49. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
50. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

51. INSTALL FRONT AXLE HUB NUT LH Installation
52. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedure described for the LH side.

53. INSTALL FRONT EXHAUST PIPE ASSEMBLY
HINT: Installation.

54. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

(a) Install the compressor with the 4 bolts.
Torque: 25 Nm (250 kgf-cm, 18ft-lbf)
NOTICE: Tighten the bolts in the order shown in the illustration to install the compressor.

55. INSTALL GENERATOR ASSEMBLY Installation
56. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
NOTICE:
- Check for damage or contamination on the connected part of the pipe.
- Check if the pipe and the connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.
57. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
HINT: Installation.

58. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)
HINT: Installation.

59. CONNECT RETURN TUBE SUB-ASSEMBLY

(a) Connect the return tube sub-assembly.
60. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Connect the No. 1 oil reservoir to pump hose.
61. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Connect the ends of the 2 cables and install the 2 washers and 2 clips.
(b) Install 2 new clips to the control cable bracket.
62. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Install the control lever with a new clip and the nut.
Torque: 13 Nm (133 kgf-cm, 10ft-lbf)
(b) Connect the cable to the transaxle.
63. CONNECT ENGINE WIRE
(a) Connect the clamp.

(b) Install the ground cables with the 2 bolts to the body.
Bolt A - Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
Bolt B - Torque: 12 Nm (123 kgf-cm, 9ft-lbf)

(d) Connect the 3 connectors to the engine room junction block. Then, install them with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
64. INSTALL ECM
HINT: Installation.

65. CONNECT HEATER WATER HOSE INLET

(a) Connect the heater inlet water hose.
66. CONNECT HEATER WATER HOSE OUTLET

(a) Connect the heater outlet water hose.
67. CONNECT OIL COOLER INLET HOSE Installation
68. CONNECT OIL COOLER OUTLET HOSE Installation
69. CONNECT RADIATOR HOSE INLET

(a) Install the radiator hose inlet with the clamp.
70. CONNECT RADIATOR HOSE OUTLET

(a) Install the radiator hose outlet with the clamp.
71. CONNECT NO. 1 VACUUM HOSE CONNECTOR

(a) Install the vacuum hose connector with the clamp.
72. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH

(a) Install the No. 2 mounting bracket RH with the 3 bolts.
Torque: 52 Nm (531 kgf-cm, 38ft-lbf)
73. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Install the engine moving control rod with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47ft-lbf)

(b) Install the ground cable with the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
74. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 mounting stay RH with the 2 bolts.
Torque: 64 Nm (653 kgf-cm, 47ft-lbf)
75. INSTALL BATTERY
(a) Install the battery and battery tray.

(b) Install the battery clamp with the bolt and nut.
Bolt - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
Nut - Torque: 3.5 Nm (36 kgf-cm, 31in-lbf)
76. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
(b) Connect the hose clamp.
77. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
78. INSTALL AIR CLEANER INLET ASSEMBLY

(a) Install the air cleaner inlet with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
79. INSTALL V-RIBBED BELT Installation
80. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
81. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
HINT: Installation.

82. INSTALL FRONT WHEEL
Torque: 103 Nm (1050 kgf-cm, 76ft-lbf)
83. ADD ENGINE OIL
84. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 6.9 Nm (70 kgf-cm, 61in-lbf)
85. BLEED CLUTCH LINE (for Manual Transaxle) Installation
86. ADD ENGINE COOLANT Testing and Inspection
87. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle) Installation
88. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Installation
89. ADD POWER STEERING FLUID
90. BLEED POWER STEERING FLUID Service and Repair
91. INSPECT FOR FUEL LEAK Testing and Inspection
92. INSPECT FOR ENGINE OIL LEAK
93. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
94. INSPECT FOR EXHAUST GAS LEAK
95. CHECK SHIFT LEVER POSITION On-Vehicle Inspection
96. ADJUST FRONT WHEEL ALIGNMENT
HINT: Service and Repair.

97. CHECK IGNITION TIMING Engine
98. CHECK ENGINE IDLE SPEED Engine
99. INSPECT CO/HC Engine
100. INSTALL FRONT FENDER APRON SEAL RH
101. INSTALL ENGINE UNDER COVER LH
102. INSTALL ENGINE UNDER COVER RH
103. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Install the engine cover with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
104. CHECK ABS SPEED SENSOR SIGNAL
(a) for ABS: Test Mode Procedure.
(b) for VSC (made by BOSCH): Test Mode Procedure.
(c) for VSC (made by ADVICS): Test Mode Procedure.