Installation

2AZ-FXE 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 pressure switch.
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 V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner with the 2 bolts.
Bolt A - Torque: 52 Nm (530 kgf-cm, 38ft-lbf)
Bolt A - Torque: 21 Nm (214 kgf-cm, 16ft-lbf)
8. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40ft-lbf)
9. INSTALL IDLER PULLEY BRACKET

(a) Install the idler pulley bracket to the engine with the 2 bolts.
Torque: 60 Nm (607 kgf-cm, 44ft-lbf)
10. 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)
11. INSTALL THERMOSTAT Installation
12. INSTALL WATER INLET Installation
13. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Install a new gasket onto the cylinder head.
(b) Temporarily tighten the exhaust manifold converter with the 5 nuts.

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

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

(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32ft-lbf)
16. 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)
17. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
18. INSTALL DRIVE SHAFT BEARING BRACKET

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

(a) Install the No. 1 intake manifold insulator onto the cylinder block.
20. INSTALL NO. 2 VENTILATION HOSE
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 Installation
25. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY Installation
26. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
HINT: Installation.

27. INSTALL ENGINE WIRE
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
29. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
30. INSTALL FRONT FRAME ASSEMBLY

(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70ft-lbf)

(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (888 kgf-cm, 64ft-lbf)
31. INSTALL HV TRANSAXLE MASS DAMPER

(a) Install the bolt and transaxle mass damper.
Torque: 14 Nm (140 kgf-cm, 10ft-lbf)
32. 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 A - 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 C - Torque: 32 Nm (326 kgf-cm, 24ft-lbf)
33. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
34. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the No. 1 exhaust pipe support bracket with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14ft-lbf)
35. INSTALL FRONT AXLE ASSEMBLY LH Installation
36. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

37. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH Installation
38. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.

39. INSTALL TIE ROD ASSEMBLY LH Installation
40. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

41. INSTALL FRONT SPEED SENSOR LH Installation
42. INSTALL FRONT SPEED SENSOR RH
Torque: 8.0 Nm (82 kgf-cm, 71in-lbf)
43. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
44. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

45. INSTALL FRONT AXLE HUB NUT LH Installation
46. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

47. INSTALL FRONT EXHAUST PIPE ASSEMBLY
HINT: Installation.

48. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Temporarily install the compressor with the 3 bolts.

(b) Install the compressor with the 3 bolts by tightening the bolts in the order shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18ft-lbf)
NOTICE: Tighten the bolts in the order shown in the illustration to install the compressor.

(c) Connect the No. 4 engine wire clamps.
CAUTION: Wear insulated gloves when performing the procedures.

(d) Connect the 2 connectors.

(e) Lock the green-colored lock.
49. 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.
50. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install a new clip and nut, and connect the control lever.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)
(b) Connect the cable to the 2 clamps.
51. CONNECT ENGINE WIRE

(a) Install the 2 bolts and power steering wire to the power steering link assembly.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
(b) Connect the 3 wire harness connectors to the power steering link assembly and securely lock the connector.

(d) Install the 2 bolts and clamp to the body.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)

(e) Connect the 3 connectors and 2 clamps to the engine room junction block.

(f) Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
52. INSTALL POWER STEERING ECU ASSEMBLY Installation
53. INSTALL HYBRID VEHICLE CONTROL ECU Installation
54. CONNECT HEATER INLET WATER HOSE

(a) Connect the heater inlet water hose.
55. CONNECT HEATER OUTLET WATER HOSE
(a) Connect the heater outlet water hose.
56. CONNECT WATER HOSE

(a) Install the 2 clamps and connect the 2 water hoses.
57. CONNECT RADIATOR HOSE INLET

(a) Install the clamp and connect the radiator hose inlet.
58. CONNECT RADIATOR HOSE OUTLET

(a) Install the clamp and connect the radiator hose outlet.
59. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH

(a) Install the 3 bolts and No. 2 engine mounting bracket RH.
Torque: 52 Nm (531 kgf-cm, 38ft-lbf)
(b) Install the ground cable with the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
60. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Install the engine moving control rod by tightening the 3 bolts in the order shown in the illustration.
Torque: 64 Nm (653 kgf-cm, 47ft-lbf)
61. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the 2 bolts.
Torque: 64 Nm (653 kgf-cm, 47ft-lbf)
62. INSTALL WATER WITH MOTOR AND BRACKET PUMP ASSEMBLY Installation
63. INSTALL INVERTER TRAY BRACKET

(a) Install the inverter tray bracket with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71in-lbf)
64. INSTALL INVERTER WITH CONVERTER ASSEMBLY
HINT: Installation.

65. 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.
66. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
67. INSTALL AIR CLEANER INLET ASSEMBLY

(a) Install the air cleaner inlet with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
68. INSTALL V-RIBBED BELT Installation
69. INSTALL V-RIBBED BELT TENSIONER COVER SUB-ASSEMBLY Installation
70. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
71. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
72. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
73. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
74. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation
75. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation
76. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
77. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
78. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76ft-lbf)
79. ADD ENGINE OIL
80. INSTALL SERVICE PLUG GRIP Installation
81. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)
82. INSTALL LUGGAGE TRIM SERVICE HOLE COVER
83. ADD COOLANT (for Engine) Testing and Inspection
84. ADD COOLANT (for Inverter) Service and Repair
85. ADD AND INSPECT HYBRID TRANSAXLE FLUID Procedures
86. CHECK FOR FUEL LEAKS Testing and Inspection
87. CHECK FOR ENGINE OIL LEAKS
88. CHECK FOR COOLANT LEAKS (for Engine) Testing and Inspection
89. CHECK FOR COOLANT LEAKS (for Inverter) Testing and Inspection
90. CHECK FOR EXHAUST GAS LEAKS
91. CHECK SHIFT LEVER POSITION Adjustments
92. ADJUST FRONT WHEEL ALIGNMENT
HINT: Service and Repair.

93. CHECK IGNITION TIMING Engine
94. CHECK ENGINE IDLE SPEED Engine
95. INSPECT CO/HC Engine
96. INSTALL FRONT FENDER APRON SEAL RH
97. INSTALL ENGINE UNDER COVER LH
98. INSTALL ENGINE UNDER COVER RH
99. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Install the No. 1 engine cover with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
100. CHECK ABS SPEED SENSOR SIGNAL
HINT: Test Mode Procedure.

101. PERFORM INITIALIZATION
(a) Perform initialization procedure Repair Instruction - Initialization.
HINT: Some vehicle systems require initialization after reconnecting the cable to the negative battery terminal.