Installation
1NZ-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY:
INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket, then install the engine coolant temperature sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
2. INSTALL NOISE FILTER
(a) Install the noise filter with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
3. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket, then install the exhaust manifold.
(b) Tighten the 3 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
(c) Install the exhaust manifold insulator with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
4. INSTALL IGNITION COIL
(a) Install the ignition coil with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
5. INSTALL IDLER PULLEY
(a) Temporarily install the idler pulley assembly to the engine mounting bracket RH with the nut.
HINT: Tighten the nut to the specified torque when installing the drive belt.
6. INSTALL DRIVE BELT (Installation)
7. INSTALL ENGINE OIL PRESSURE SWITCH (Testing and Inspection)
8. INSTALL KNOCK SENSOR (Installation)
9. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install a new gasket, then install the water by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
10. 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 in-lbf)
11. INSTALL OIL DIPSTICK GUIDE
(a) Apply engine oil to a new O-ring, then install it to the dipstick guide.
(b) Install the dipstick guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(c) Install the dipstick.
12. INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
NOTE: Remove any oil from the bolts and bolt holes.
(b) Using SST, hold the crankshaft.
SST: 09213-58013
91111-50845
SST: 09330-00021
(c) Install the flywheel with 6 new bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
(d) After tightening the new bolts to the specified torque, tighten each bolt by an additional 90°.
NOTE: Do not start the engine within 1 hour of installation.
13. INSTALL TRANSMISSION INPUT DAMPER
(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
SST: 09330-00021
(c) Tighten the 6 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
(a) Install the hybrid vehicle transaxle assembly to the engine assembly with the 6 bolts (Installation).
(b) Install the flywheel housing side cover and starter hole insulator with the 2 bolts.
Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
(c) Install the engine wire harness to the engine assembly with transaxle.
(d) Remove the bolts and engine hangers.
(e) Install the ground cable with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
15. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner with the 2 bolts and tighten the clamp.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
Torque: 3.0 Nm (31 kgf-cm, 27 in-lbf)
16. INSTALL ENGINE AND 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-lbf)
(d) Connect the engine mounting insulator bracket LH and engine mounting insulator LH with the nut.
Torque: 80 Nm (816 kgf-cm, 59 in-lbf)
17. INSTALL FRONT SUSPENSION CROSSMEMBER
(a) Install the front suspension crossmember with power steering gear assembly with the 4 bolts.
Torque: 113 Nm (1,152 kgf-cm, 83 in-lbf)
Torque: 157 Nm (1,602 kgf-cm, 116 in-lbf)
(b) Install the engine moving control rod with bracket with the 4 bolts and 2 nuts.
Torque: 100 Nm (1020 kgf-cm, 74 in-lbf)
Torque: 56 Nm (571 kgf-cm, 41 in-lbf)
18. INSTALL FRONT DRIVE SHAFT LH (Installation)
19. INSTALL FRONT DRIVE SHAFT RH (Installation)
20. INSTALL FRONT AXLE HUB LH (Installation)
21. INSTALL FRONT AXLE HUB RH
HINT: Use the same procedures described for the LH side.
22. INSTALL NO. 1 FRONT SUSPENSION ARM LOWER LH
23. INSTALL NO. 1 FRONT SUSPENSION ARM LOWER RH
HINT: Use the same procedures described for the LH side.
24. CONNECT TIE ROD END LH (Installation)
25. CONNECT TIE ROD END RH
HINT: Use the same procedures described for the LH side.
26. CONNECT FRONT STABILIZER LINK LH
27. INSTALL FRONT AXLE HUB NUT LH (Installation)
28. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.
29. CONNECT STEERING SLIDING YOKE
(a) Align the paint marks, then connect the steering sliding yoke with the bolt.
Torque: 35 Nm (357 kgf-cm, 26 in-lbf)
(b) Install the column hole cover silencer sheet with the 2 clips.
(c) Remove the seat belt from the steering wheel.
30. CONNECT COOLER COMPRESSOR WITH MOTOR ASSEMBLY
(a) Install the cooler compressor with the 3 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
31. CONNECT ENGINE WIRE
(a) Connect the ground cable.
(b) Connect the harness and clamp to the engine room main relay block.
(c) Push in the engine wire harness, and then connect the wire harness to the ECM.
32. CONNECT NO. 3 HEAT STORAGE WATER BY-PASS HOSE
(a) Connect the No. 3 heat storage water by-pass hose.
33. CONNECT HEATER WATER HOSE
34. CONNECT FUEL TUBE
(a) Push the fuel tube into the fuel delivery pipe until it makes a "click" sound.
- 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.
35. INSTALL PURGE VSV
(a) Install the purge VSV with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 5.5 in-lbf)
(b) Connect the hose and connector.
36. CONNECT NO. 1 AIR CLEANER INLET
(a) Connect the No. 1 air cleaner inlet to the air cleaner case, and then tighten the clamp.
Torque: 3.0 Nm (31 kgf-cm, 27 in-lbf)
37. CONNECT ENGINE WIRE
(a) Connect the ground cable with the bolt.
38. CONNECT NO. 1 HEAT STORAGE WATER BY-PASS HOSE
(a) Connect the hose as shown in the illustration.
39. CONNECT NO. 3 INVERTER COOLING HOSE
40. INSTALL NO. 2 RADIATOR ASSEMBLY
(a) Install the radiator to the vehicle (Installation).
41. INSTALL INVERTER WITH CONVERTER ASSEMBLY
(a) Install the inverter with converter to the vehicle (Installation).
42. INSTALL FRONT COWL TOP PANEL OUTER (Installation)
43. INSTALL WINDSHIELD WIPER LINK AND WIPER MOTOR ASSEMBLY
44. INSTALL COWL TOP VENTILATOR LOUVER RH
45. INSTALL COWL TOP VENTILATOR LOUVER LH
46. INSTALL HOOD TO COWL TOP SEAL
47. INSTALL FRONT WIPER ARM LH
48. INSTALL FRONT WIPER ARM RH
49. INSTALL WIPER ARM HEAD CAP
50. ADD TRANSAXLE OIL (Installation)
51. INSTALL SERVICE PLUG GRIP (Installation)
52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
53. INSTALL NO. 3 REAR FLOOR BOARD
54. INSTALL REAR DECK FLOOR BOX
55. INSTALL NO. 2 REAR FLOOR BOARD
56. ADD ENGINE COOLANT (Testing and Inspection)
57. CHECK FOR TRANSAXLE FLUID LEVEL (Installation)
58. INSPECT FOR ENGINE COOLANT LEAK (Testing and Inspection)
59. INSPECT FOR FUEL LEAK (Testing and Inspection)
60. INSPECT FOR OIL LEAK
61. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 in-lbf)
62. ADJUST FRONT WHEEL ALIGNMENT
(a) Adjust the front wheel alignment.
63. INSTALL NO. 3 ENGINE UNDER COVER
64. INSTALL NO. 4 CENTER ENGINE UNDER COVER
65. PERFORM INITIALIZATION
(a) Perform initialization.
NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative battery terminal. Repair Instruction - Initialization