Installation

2AZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:

INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.
(b) Install the sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
2. INSTALL KNOCK SENSOR

(a) Install the sensor with the nut as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft-lbf)
3. 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:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
4. INSTALL WATER BY-PASS PIPE NO.1
(a) Install a new gasket and the by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
5. INSTALL FUEL DELIVERY PIPE W/INJECTOR (Installation)

6. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
7. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY ()

9. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
10. INSTALL THERMOSTAT (Installation)

11. INSTALL WATER INLET
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Install a new gasket and the exhaust manifold converter with the 5 nuts. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (378 kgf-cm, 27 ft-lbf)

(b) Install the manifold stays with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)

(c) Install the No. 2 manifold stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft-lbf)
13. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
14. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to the O-ring and install it to the guide.
(b) Install the oil level gage and guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
15. INSTALL INTAKE MANIFOLD

(a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
16. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY

(a) Using SST, fix the crankshaft.
SST: 09960-10010
09962-01000
09963-01000
(b) Clean the bolt and the bolt hole.
(c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1344 or equivalent

(d) Install the front spacer, drive plate and rear spacer with the 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 98 Nm (1,000 kgf-cm, 72 ft-lbf)
17. INSTALL FLYWHEEL SUB-ASSEMBLY

(d) Install the flywheel with the 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 130 Nm (1,330 kgf-cm, 96 ft-lbf)
18. INSTALL CLUTCH DISC ASSEMBLY (Reassembly)

19. INSTALL CLUTCH COVER ASSEMBLY (Reassembly)

20. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (Installation)

21. INSTALL MANUAL TRANSAXLE ASSEMBLY (Installation)

22. INSTALL STARTER ASSEMBLY (Installation)

23. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (Installation)

24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (Installation)

25. INSTALL FRONT FRAME ASSEMBLY

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

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

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

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

(a) Install the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)
(b) Connect the PS oil pressure switch connector.
27. 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, 63 ft-lbf)
Bolt B and nut - Torque: 32 Nm (326 kgf-cm, 24 ft-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, 63 ft-lbf)
Bolt D and nut - Torque: 32 Nm (326 kgf-cm, 24 ft-lbf)
28. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY

(a) Align the matchmarks on the intermediate shaft and control valve shaft.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)

(b) Tighten the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
29. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Fix the crankshaft, and install the 6 setting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft-lbf)
30. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH

(a) Install the drive shaft to the steering knuckle.
(b) Install the suspension lower arm with the bolt and 2 nuts.
Torque: 75 Nm (765 kgf-cm, 55 ft-lbf)
31. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Use the same procedures described for the LH side.

32. INSTALL TIE ROD ASSEMBLY LH
(a) Connect the tie rod end to the steering knuckle with the castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

NOTICE:
- Prevent lubricants from contacting the thread and taper portions.
- After tightening the castle nut, tighten it an additional 60°C so that a cotter pin can be inserted.

(b) Insert a new cotter pin.
33. INSTALL TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

34. INSTALL SPEED SENSOR FRONT LH
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
35. INSTALL SPEED SENSOR FRONT RH
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
36. INSTALL FRONT AXLE SHAFT LH NUT
(a) Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.

NOTICE:
- Be sure to perform this work for a new drive shaft.
- Keep the threaded parts free of oil and foreign objects.

(b) Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft-lbf)
(c) Using a chisel and hammer, tapped the hub LH nut.
37. INSTALL FRONT AXLE SHAFT RH NUT

HINT: Use the same procedures described for the LH side.

38. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(a) Using a 5 mm socket hexagon wrench, fix the stud bolt and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft-lbf)
39. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

40. INSTALL FRONT EXHAUST PIPE ASSEMBLY (Installation)

41. CONNECT FUEL TUBE SUB-ASSEMBLY
42. INSTALL RETURN TUBE SUB-ASSEMBLY

(a) Install return tube sub-assembly.
43. INSTALL OIL RESERVOIR TO PUMP HOSE NO.1

(a) Install oil reservoir to pump hose No.1.
44. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (Installation)

45. INSTALL GENERATOR ASSEMBLY (Installation)

46. INSTALL FAN AND GENERATOR V BELT ()

47. CONNECT ENGINE WIRE NO.2
48. CONNECT ENGINE WIRE
49. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 52 Nm (531 kgf-cm, 38 ft-lbf)
50. INSTALL ENGINE MOUNTING STAY NO.2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
51. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET

(a) Install the engine mounting control rod with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
52. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
54. ADD AUTOMATIC TRANSAXLE FLUID
55. ADD MANUAL TRANSAXLE OIL
56. ADD ENGINE OIL
57. ADD ENGINE COOLANT (Service and Repair)

58. ADD POWER STEERING FLUID
59. BLEED POWER STEERING FLUID
60. INSPECT FOR OIL LEAK
61. INSPECT FOR COOLANT LEAK (Service and Repair)

62. INSPECT FUEL LEAK (Testing and Inspection)

63. INSTALL FRONT WHEEL
64. ADJUST FRONT WHEEL ALIGNMENT

HINT: (Service and Repair)

65. INSPECT IDLE SPEED AND IGNITION TIMING

HINT: (Engine)

66. INSPECT CO/HC
67. CHECK ABS SPEED SENSOR SIGNAL (W/ABS)

HINT: (Test Mode Procedure)

68. PERFORM INITIALIZATION
Perform initialization procedure ( (Service Precautions)).

CAUTION: Some systems need initialization after reconnecting the cable to the negative battery terminal.