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Installation





2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

HINT
Perform "Inspection After Repair" after replacing the engine assembly Programming and Relearning.

1. REMOVE ENGINE STAND

(a) Using a chain block and engine sling device, secure the engine assembly.

NOTICE:
* Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.
* Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

(b) Remove the engine stand from the engine.

2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Installation

4. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

5. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

6. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the front engine mounting insulator with the 3 nuts.

HINT
Perform this procedure only when replacement of the front engine mounting insulator is necessary.

7. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH with the 3 nuts.

HINT
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

8. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

(a) Temporarily install the engine mounting insulator RH with the 3 nuts.

HINT
Perform this procedure only when replacement of the engine mounting insulator RH is necessary.

9. INSTALL FRONT FRAME ASSEMBLY

(a) Install the engine mounting insulator LH with the nut.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(b) Install the engine mounting insulator RH with the nut.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(c) Install the front engine mounting insulator with the bolt.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(d) Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.





Text in Illustration





HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

A - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

B - Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(e) Install the 4 hole plugs.





Text in Illustration





HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

10. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Reassembly

11. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

12. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

13. INSTALL GENERATOR ASSEMBLY Installation

14. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY Installation

15. INSTALL V-RIBBED BELT Installation

16. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine with transaxle.

17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on an engine lifter.

NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
* Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
* To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
* Make sure to support the engine assembly with transaxle securely to prevent it from falling.

(b) Remove the engine hangers Removal.

(c) Install the engine assembly to the vehicle.

NOTICE:
Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

HINT
* 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 frame side rail plate RH and LH with the 4 bolts and 2 nuts.





A - Torque : 85 Nm (867 kgf-cm, 62 ft-lbf)

B - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

(e) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

C - Torque : 85 Nm (867 kgf-cm, 62 ft-lbf)

D - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

HINT
Perform "Inspection After Repair" after replacing the engine assembly Programming and Relearning.

18. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

(a) Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter setting bolts.





Text in Illustration





Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(b) Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.





Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

NOTICE:
Install the black colored bolt first, and then the 5 silver colored bolts.

19. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover.

20. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

21. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation

22. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

23. INSTALL TIE ROD ASSEMBLY LH Installation

24. INSTALL TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

25. INSTALL FRONT SPEED SENSOR LH Installation

26. INSTALL FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

27. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

28. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

29. INSTALL FRONT AXLE SHAFT NUT LH Installation

30. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Use the same procedure described for the LH side.

31. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

32. 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.





33. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Installation

34. INSTALL SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) Installation

35. INSTALL NO.1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made) Installation

36. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the union to connector tube hose.

37. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.

HINT
Perform this procedure only when replacement of the engine moving control rod is necessary.

38. INSTALL ENGINE MOVING CONTROL ROD BRACKET

(a) When the engine moving control rod has been replaced.

(1) Temporarily install the engine moving control rod bracket with the 4 bolts.





(2) Fully tighten the engine moving control rod bracket with the bolts except bolt A.





Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

(3) Fully tighten the bolt A.





SST : 09961-00950

Without SST - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

With SST - Torque : 33 Nm (340 kgf-cm, 25 ft-lbf)

NOTICE:
* The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.) and a torque wrench with a fulcrum length of 260 mm (10.24 in.) Service Precautions.
* The "with SST" torque value is effective when SST is parallel to the torque wrench.
* Fully tighten the bolt A using SST.

(b) When the engine moving control rod has been reused.





(1) Temporarily install the engine moving control rod bracket with the 4 bolts.

(2) Fully tighten the engine moving control rod bracket with the 4 bolts.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

39. INSTALL EARTH WIRE

(a) Install the earth wire with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

40. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the 2 bolts.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the control cable to the bracket with a new clip.





(b) Install the control cable to the control shaft lever with the nut.





Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

42. INSTALL NO. 1 AIR CLEANER BRACKET

(a) Install the No. 1 air cleaner bracket to the battery carrier with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Connect the 2 wire clamps.

43. CONNECT ENGINE WIRE

(a) Connect the 2 wire clamps.





(b) Connect the connector to the ECM with the lock lever.

(c) Connect the engine wire to the engine room relay block.

(d) Connect the 4 connectors.

(e) Connect the engine wire to the engine room relay block.





(f) Connect the wire clamp and install the 2 nuts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(g) Install the No. 1 relay block cover.

44. INSTALL STARTER ASSEMBLY Installation

45. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

46. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the 3 outlet heater water hoses.

47. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.

48. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose.

49. 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, 80 in-lbf)

Nut - Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

(c) Connect the positive (+) battery terminal

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

50. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.





Text in Illustration





(b) Tighten the 2 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(c) Connect the wire harness clamp.

51. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

(a) Install the air cleaner filter element sub-assembly.

NOTICE:
Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

52. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

53. INSTALL INLET AIR CLEANER ASSEMBLY

(a) Install the inlet air cleaner with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

54. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

(a) Connect the negative (-) battery terminal.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

55. ADD ENGINE OIL

56. ADD ENGINE COOLANT Service and Repair

57. ADD AUTOMATIC TRANSAXLE FLUID

Procedures

58. CHARGE WITH REFRIGERANT Service and Repair

59. WARM UP ENGINE

60. INSPECT FOR FUEL LEAK Fuel System

61. INSPECT FOR OIL LEAK

62. INSPECT FOR COOLANT LEAK Testing and Inspection

63. INSPECT FOR EXHAUST GAS LEAK

64. INSPECT REFRIGERANT LEAK Service and Repair

65. INSPECT IGNITION TIMING Engine

66. INSPECT ENGINE IDLE SPEED Engine

67. INSPECT CO/HC Engine

68. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the No. 1 engine cover sub-assembly.

69. INSTALL COOL AIR INTAKE DUCT SEAL Installation

70. INSPECT SHIFT LEVER POSITION

Adjustments

71. ADJUST SHIFT LEVER POSITION

Adjustments

72. INSTALL FRONT FENDER APRON SEAL LH

73. INSTALL FRONT FENDER APRON SEAL RH

74. INSTALL ENGINE UNDER COVER LH

75. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

76. INSTALL ENGINE UNDER COVER RH

77. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

78. INSTALL FRONT WHEEL

Torque : 103 Nm (1049 kgf-cm, 76 ft-lbf)

79. ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

80. CHECK ABS SPEED SENSOR SIGNAL

Test Mode Procedure
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