Installation

2ZR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL FLYWHEEL SUB-ASSEMBLY

(a) Gently place the engine assembly onto wood blocks or equivalent.

NOTICE:
This step should be done while hanging the engine assembly using the engine hangers and a chain block.

(b) Install the flywheel sub-assembly Installation.

2. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

(a) Gently place the engine assembly onto wood blocks or equivalent.

NOTICE:
This step should be done while hanging the engine assembly using the engine hangers and a chain block.

(b) Install the transmission input damper assembly Installation.

3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Install the hybrid vehicle transaxle assembly Installation.

NOTICE:
Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.

4. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine.

5. INSTALL STARTER HOLE INSULATOR Installation

6. INSTALL FLYWHEEL HOUSING SIDE COVER Installation

7. INSTALL RADIATOR PIPE

(a) Install the radiator pipe with the 2 bolts.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(b) Install the No. 3 radiator hose with the clamp.

8. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

(a) Position the engine mounting insulator sub-assembly RH as shown in the illustration.

(b) Temporarily install the engine mounting insulator sub-assembly RH with bolt A.

(c) Tighten the 3 bolts to the engine mounting insulator sub-assembly RH in the order the bolt B, bolt C and bolt A.

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

(d) Connect the wire harness clamp to the engine mounting insulator sub-assembly RH.

(e) Install the 2 cooler brackets with the 2 bolts.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

9. INSTALL ENGINE MOUNTING INSULATOR LH

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

(a) Temporarily install the engine mounting insulator LH with the bolt A.

(b) Tighten the 4 bolts to the engine mounting insulator LH in the order the bolt C, bolt B, bolt D and bolt A.

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

10. INSTALL REAR ENGINE MOUNTING INSULATOR

(a) Install the rear engine mounting insulator to the engine mounting bracket with the bolt.

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

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

11. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the front engine mounting insulator with the bolt and nut.

12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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

HINT
Place the engine on wooden blocks or equivalents so that the engine is level.

(b) Remove the 2 bolts and 2 engine hangers.

(d) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember 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.

(e) Install the front crossmember with the 4 bolts.

Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

(f) Install the front engine mounting insulator to the front crossmember with the 2 bolts.

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

(g) Install the engine mounting insulator LH with the bolt and nut.

Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

NOTICE:
When installing the engine mounting insulator, tighten the nut while holding the bolt.

(h) Install the engine mounting insulator sub-assembly 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)

(i) Tighten the front engine mounting insulator with the bolt and nut.

Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

14. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH Installation

15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

HINT
Perform the same procedure as for the LH side.

16. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH Installation

17. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH Installation

18. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT Installation

19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Installation

20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

HINT
Perform the same procedure as for the LH side.

21. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

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

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

HINT
Perform the same procedure as for the LH side.

25. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

26. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

27. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

28. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

29. INSTALL FRONT SPEED SENSOR LH Installation

30. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

31. INSTALL FRONT AXLE SHAFT NUT LH Installation

32. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

33. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System) Installation

34. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System) Installation

35. INSTALL FRONT CENTER FLOOR BRACE Installation

36. INSTALL FRONT NO. 3 ENGINE UNDER COVER Installation

37. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation

38. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

39. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

40. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

41. INSTALL WIRE HARNESS

(a) Connect the wire harness with the 2 clamps.

(b) Install the earth wire with the bolt.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(c) Connect the wire harness with the 3 clamps.

(d) Connect the wire harness to the engine room junction block.

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

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

(g) Connect the 2 clamps.

42. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY Installation

43. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector and fuel pipe.

NOTICE:
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.

44. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose with the clamp.

45. CONNECT HEATER HOSE

(a) Connect the heater hose with the clamp.

46. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose with the clamp.

47. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose with the clamp.

48. CONNECT NO. 5 INVERTER COOLING HOSE

(a) Connect the No. 5 inverter cooling hose with the clamp.

49. CONNECT NO. 3 INVERTER COOLING HOSE

(a) Connect the No. 3 inverter cooling hose with the clamp.

50. CONNECT NO. 4 WATER BY-PASS HOSE

(a) Connect the No. 4 water by-pass hose with the clamp.

51. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose with the clamp.

52. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose with the clamp.

53. INSTALL INVERTER TRAY BRACKET

(a) Position the inverter tray bracket as shown in the illustration.

(b) Temporarily install the inverter tray bracket with bolt B.

(c) Tighten the 5 bolts to the inverter tray bracket in the order the bolt A, bolt C, bolt D, bolt E and bolt B.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

(d) Connect the 2 clamps to the inverter tray bracket.

54. INSTALL INVERTER RESERVE TANK ASSEMBLY

(a) Temporarily install the inverter reserve tank assembly with bolt A.

(b) Tighten the 2 bolts to the inverter reserve tank assembly in the order the bolt B and bolt A.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

55. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

56. CONNECT WATER HOSE Installation

57. CONNECT NO. 2 ENGINE ROOM WIRE Installation

58. REMOVE INVERTER TERMINAL COVER Installation

59. CONNECT NO. 2 ENGINE WIRE Installation

60. CONNECT HIGH VOLTAGE CABLE OF FRONT TRANSAXLE Installation

61. CONNECT FRAME WIRE Installation

62. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

63. INSTALL INVERTER TERMINAL COVER Installation

64. CONNECT ENGINE ROOM MAIN WIRE Installation

65. INSTALL NO. 1 INVERTER BRACKET Installation

66. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

67. 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) Connect the No. 4 water by-pass hose to the air cleaner case with the 3 clamps.

(c) Install the air cleaner filter element.

68. INSTALL INLET AIR CLEANER ASSEMBLY

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

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

69. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

(a) Install the air cleaner cap sub-assembly with the 2 clamps and hose band.

(b) Connect the air flow meter connector.

70. INSTALL SERVICE PLUG GRIP Installation

71. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

72. INSTALL REAR NO. 3 FLOOR BOARD Installation

73. INSTALL REAR DECK FLOOR BOX Installation

74. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type) Installation

75. ADD HYBRID TRANSAXLE FLUID Procedures

76. INSPECT HYBRID TRANSAXLE FLUID Procedures

77. ADD COOLANT (for Engine) Coolant (for Engine)

78. ADD COOLANT (for Inverter) Coolant (for Inverter)

79. ADD ENGINE OIL Replacement

80. INSPECT ENGINE OIL LEVEL Testing and Inspection

81. INSPECT FOR FUEL LEAK Fuel System

82. INSPECT FOR COOLANT LEAK (for Engine) Cooling System

83. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection

84. INSPECT FOR OIL LEAK

85. INSPECT FOR EXHAUST GAS LEAK

86. INSTALL NO. 2 ENGINE UNDER COVER

87. INSTALL NO. 1 ENGINE UNDER COVER

88. INSTALL FRONT BUMPER LOWER ABSORBER (w/ Cover)

89. INSTALL FRONT SPOILER COVER (w/ Front Spoiler)

90. INSTALL REAR ENGINE UNDER COVER LH

91. INSTALL REAR ENGINE UNDER COVER RH

92. INSTALL FRONT WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

93. INSPECT IGNITION TIMING Engine

94. INSPECT ENGINE IDLE SPEED Engine

95. INSPECT CO/HC Engine

96. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

97. INSTALL NO. 2 CYLINDER HEAD COVER

(a) Engage the 3 clips to install the cover.

NOTICE:
* Be sure to engage the clips securely.
* Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.

98. INSTALL RADIATOR SUPPORT OPENING COVER Installation

99. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

100. INSTALL COWL BODY MOUNTING REINFORCEMENT LH Installation

101. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

102. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

103. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH Installation

104. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH Installation

105. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

106. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

107. INSTALL FRONT WIPER ARM HEAD CAP Installation

108. CHECK ABS SPEED SENSOR SIGNAL

HINT
Test Mode Procedure.