Installation

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL ENGINE WIRE
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Installation
3. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Installation
4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
HINT: Installation for E351.

5. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
HINT: Installation for E351.

6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
HINT:
- Installation for U250E.
- Installation for U140F.

7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
HINT: Installation for E351.

8. INSTALL STARTER ASSEMBLY (for Manual Transaxle) Installation
9. INSTALL STARTER ASSEMBLY (for Automatic Transaxle) Installation
10. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)

(a) Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
11. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the front engine mounting insulator with the nut and through bolt.
12. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 2WD)

(a) Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
13. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 4WD)

(a) Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
14. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

(a) Install the engine mounting insulator RH with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
15. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH with the 4 bolts.
(b) Tighten the 4 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.
NOTE: Place the engine on wooden blocks or equivalent so that the engine is level.

(b) Remove the 2 bolts and 2 engine hangers.
(c) Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulators 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.

(d) Install the engine mounting insulator RH with the bolt and 2 nuts.
Nut A - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Nut B - Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
Bolt - Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)

(e) Install the engine mounting insulator LH with the through bolt and nut.
Torque: 56 Nm (571 kgf-cm, 41 ft-lbf)
17. TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY
HINT:
- Installation for 2WD.
- Installation for 4WD.

18. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
HINT:
- Installation for 2WD.
- Installation for 4WD.

19. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY
HINT:
- Installation for 2WD.
- Installation for 4WD.

20. FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Fully tighten the front engine mounting insulator with the nut and through bolt.
Torque: 73 Nm (744 kgf-cm, 54 ft-lbf)
21. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 2WD)

(a) Fully tighten the rear engine mounting insulator to the engine mounting bracket with the through bolt.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)
22. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR (for 4WD)

(a) Fully tighten the rear engine mounting insulator to the engine mounting bracket with the through bolt.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)
23. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)
HINT:
- Installation for U250E.
- Installation for U140F.

24. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Installation
25. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
26. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT:
- Installation for 2WD.
- Installation for 4WD.

27. INSTALL STEERING KNUCKLE WITH AXLE HUB LH

(a) Align the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.
28. INSTALL STEERING KNUCKLE WITH AXLE HUB RH
HINT: Perform the same procedure for the LH side.

29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation
30. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

31. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
32. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

33. INSTALL TIE ROD END SUB-ASSEMBLY LH
HINT:
- Installation for 2WD.
- Installation for 4WD.

34. INSTALL TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure for the LH side.

35. INSTALL FRONT SPEED SENSOR LH Installation
36. INSTALL FRONT SPEED SENSOR RH
HINT: Perform the same procedure for the LH side.

37. INSTALL FRONT AXLE SHAFT LH NUT Installation
38. INSTALL FRONT AXLE SHAFT RH NUT
HINT: Perform the same procedure for the LH side.

39. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
40. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
41. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
42. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation
43. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation
44. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
HINT:
- Installation for 2WD.
- Installation for 4WD.

45. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation
46. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
(a) U250E Automatic Transaxle:

(1) Connect the transmission control cable to the control cable bracket.

(2) Connect the transmission control cable to the bracket with a new clip.
(3) Connect the transmission control cable assembly to the control shaft lever with the nut.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) U140F Automatic Transaxle:

(1) Connect the transmission control cable to the control cable bracket.

(a) Install the 2 transmission control cables to the control cable bracket with 2 new clips*1.
(b) Install the 2 transmission control cables to the transaxle with 2 new clips*2.
48. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
HINT: Installation for E351.

49. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the union to connector tube hose.
50. 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.
51. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose with the clamp.
52. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose with the clamp.
53. INSTALL BREATHER HOSE (for Automatic Transaxle)

(a) Install the breather hose.
54. CONNECT OIL COOLER HOSE (for Automatic Transaxle)

(a) Connect the 2 oil cooler hoses with the clamps.
55. INSTALL NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose with the clamp.
56. INSTALL NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose with the clamp.
57. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY Installation
58. INSTALL GENERATOR ASSEMBLY Installation
59. INSTALL V-RIBBED BELT Installation
60. INSTALL THROTTLE BODY ASSEMBLY Installation
61. INSTALL WIRE HARNESS

(a) Install the ground cable to the transmission with the bolt and clamp (for Manual Transaxle).
Torque: 13 Nm (130 kgf-cm, 10 ft-lbf)

(b) Install the ground wire to the transmission with the bolt and clamp (for Automatic Transaxle).
Torque: 26 Nm (260 kgf-cm, 19 ft-lbf)

(e) Connect the connector to the ECM with the clamp and lock lever.
62. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Connect the 2 wire harness clamps.
63. INSTALL BATTERY
(a) Install the battery tray, battery and battery insulator.

(b) Install the battery clamp with the bolt and nut.
Bolt - Torque: 6.5 Nm (66 kgf-cm, 58 in-lbf)
Nut - Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
64. INSTALL AIR CLEANER CASE

(a) Install the air cleaner case with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
(b) Install the engine wire clamp to the air cleaner case.
(c) Install the air cleaner filter element.
65. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE Installation
66. INSTALL RADIATOR RESERVE TANK ASSEMBLY

(a) Install the radiator reserve tank assembly with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
67. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
HINT: Service and Repair for E351.

68. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle)
HINT: Testing and Inspection for E351.

69. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)
HINT:
- Installation for U250E.
- Installation for U140F.

70. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)
HINT:
- Procedures for U250E.
- Procedures for U140F.

71. ADD TRANSFER OIL (for 4WD)
72. INSPECT TRANSFER OIL (for 4WD)
73. ADJUST TRANSFER OIL
74. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle)
HINT:
- Installation for U250E.
- Installation for U140F.

75. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle)
HINT:
- Installation for U250E.
- Installation for U140F.

76. ADD ENGINE COOLANT Service and Repair
77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
78. WARM UP ENGINE
79. FILL BRAKE FLUID RESERVOIR (for Manual Transaxle)
HINT: Installation for E351.

80. BLEED CLUTCH LINE (for Manual Transaxle)
HINT: Installation for E351.

81. INSPECT FLUID LEVEL (for Manual Transaxle)
HINT: Installation for E351.

82. INSPECT FOR FUEL LEAK Testing and Inspection
83. INSPECT FOR COOLANT LEAK Testing and Inspection
84. INSPECT FOR OIL LEAK
85. INSPECT FOR EXHAUST GAS LEAK
86. INSTALL ENGINE UNDER COVER LH
87. INSTALL ENGINE UNDER COVER RH
88. INSTALL FRONT WHEELS
Torque: 103 Nm (1050 kgf-cm, 76 ft-lbf)
89. INSPECT IGNITION TIMING Engine
90. INSPECT ENGINE IDLING SPEED Engine
91. INSPECT CO/HC Engine
92. ADJUST FRONT WHEEL ALIGNMENT
HINT: Service and Repair.

93. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Install the No. 1 engine cover sub-assembly with the 2 nuts.
94. CHECK ABS SPEED SENSOR SIGNAL
HINT:
- Test Mode Procedure for w/o VSC.
- Test Mode Procedure for w/ VSC.