2NZ-FE ENGINE MECHANICAL  ENGINE ASSEMBLY  INSTALLATION  


CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.


PROCEDURE

Hide 2.REMOVE ENGINE FROM ENGINE STAND

a.

Remove the engine assembly from the engine stand.


Hide 13405 3.INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>INSTALLATION

Hide 31250 4.INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for C50)>INSTALLATION

Hide 31210 5.INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

Click hereDrivetrain>CLUTCH>CLUTCH UNIT(for C50)>INSTALLATION

Hide 30300 6.INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

Click hereDrivetrain>C50 MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSAXLE ASSEMBLY>INSTALLATION

Hide 32101 7.INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>INSTALLATION

Hide 30500 8.INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>INSTALLATION

Hide 82121 9.INSTALL ENGINE WIRE

a.

Install the engine wire to the engine assembly with transaxle.


Hide 28100 10.INSTALL STARTER ASSEMBLY

Click hereEngine / Hybrid System>2NZ-FE STARTING>STARTER>INSTALLATION

Hide 11363A 11.INSTALL FLYWHEEL HOUSING SIDE COVER

a.

Insert the protruding portion into the end of the cylinder block sub-assembly and fit the claw into the oil pan sub-assembly.

NOTICE:
·

Make sure that the claw makes a click sound, indicating that it fits tightly.

·

Replace the flywheel housing side cover with a new one if the claw does not fit tightly or is deformed.




Hide 12361A 12.TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

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


a.

Temporarily install the front engine mounting insulator to the front engine mounting bracket with the through bolt and nut.


Hide 12371A 13.TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

HINT:

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


a.

Temporarily install the rear engine mounting insulator to the rear engine mounting bracket with the through bolt.


Hide 12372A 14.INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

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


a.

Temporarily install the engine mounting insulator LH with the 4 bolts.


b.
A327509C02
0.052,0.063 0.427,0.302 0.375,0.24 12 true *A 0.083,2.427 0.458,2.667 0.375,0.24 12 true *B 2.51,0.344 2.667,0.542 0.156,0.198 10 true 1 2.51,2.813 2.667,3.01 0.156,0.198 10 true 1 1.885,0.01 2.042,0.208 0.156,0.198 10 true 2 1.896,2.469 2.052,2.667 0.156,0.198 10 true 2 1.24,0.552 1.396,0.75 0.156,0.198 10 true 3 1.229,3.042 1.385,3.24 0.156,0.198 10 true 3 2.052,1.844 2.208,2.042 0.156,0.198 10 true 4 2.063,4.323 2.219,4.521 0.156,0.198 10 true 4
*A for Manual Transaxle
*B for Automatic Transaxle


Fully tighten the 4 bolts in the order shown in the illustration.

Torque:
52 N*m (530 kgf*cm, 38 ft.*lbf)


Hide 12305 15.INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.


a.

Install the engine mounting insulator sub-assembly RH with the 3 bolts.

Torque:
52 N*m (530 kgf*cm, 38 ft.*lbf)


b.
C292591N02
2.76,0.542 2.917,0.74 0.156,0.198 10 true 1 1.563,1.594 1.719,1.792 0.156,0.198 10 true 2 0.146,0.406 0.302,0.604 0.156,0.198 10 true 3

Install the radiator reserve tank assembly with the 3 bolts.

Torque:
7.0 N*m (71 kgf*cm, 62 in.*lbf)

NOTICE:

Tighten the 3 bolts in the order shown in the illustration.



c.
C293142C01
2.26,1.063 2.563,1.063 2.563,1.063 2.729,0.781 true 2.083,0.979 2.396,1.135 0.313,0.156 10 false *a
*a Hose


Insert the hose to the radiator reserve tank assembly and install the reserve tank cap sub-assembly.


d.

Engage the clamp to install the reserve hose.


Hide 16.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

a.

Set the engine assembly with transaxle on an engine lifter.

NOTICE:
·

Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

·

To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.




b.

Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.

CAUTION:

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


NOTICE:
·

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

·

While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.




c.

Install the engine mounting insulator LH with the through bolt and nut.

Torque:
56 N*m (571 kgf*cm, 41 ft.*lbf)

HINT:

Tighten the through bolt while holding the nut.



d.
A192413

Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

Torque:
52 N*m (530 kgf*cm, 38 ft.*lbf)


Hide 51204A 17.TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>INSTALLATION

Hide 51201 18.INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>INSTALLATION

Hide 51204A 19.FULLY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>INSTALLATION

Hide 12361A 20.FULLY INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

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


a.

Fully install the front engine mounting insulator with the through bolt and nut.

Torque:
73 N*m (744 kgf*cm, 54 ft.*lbf)

HINT:

Tighten the through bolt while holding the nut.



Hide 12371A 21.FULLY INSTALL REAR ENGINE MOUNTING INSULATOR

HINT:

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


a.

Fully install the rear engine mounting insulator with the through bolt.

Torque:
95 N*m (969 kgf*cm, 70 ft.*lbf)


Hide 23.INSTALL WIRE HARNESS CLAMP BRACKET

a.

Install the wire harness clamp bracket with the bolt.

Torque:
39 N*m (398 kgf*cm, 29 ft.*lbf)


Hide 32101G 24.INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>INSTALLATION

Hide 11361J 25.INSTALL FLYWHEEL HOUSING UNDER COVER

a.

Install the flywheel housing under cover to the oil pan sub-assembly.


Hide 45025D 28.INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>INSTALLATION

Hide 45260 29.INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION

Hide 45259A 30.INSTALL COLUMN HOLE COVER SILENCER SHEET

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>INSTALLATION

Hide 31.CONNECT WIRE HARNESS

a.

Engage the clamp to connect the engine wire to the engine mounting bracket LH.


b.

Connect the No. 3 engine wire to the transaxle assembly with the bolt.

Torque:
25.5 N*m (260 kgf*cm, 19 ft.*lbf)


c.

Engage the 2 claws to connect the wire harness to the engine room relay block and junction block assembly.


d.

Connect the 3 wire harness connectors.


e.

Install the 2 nuts to the engine room relay block and junction block assembly.

Torque:
8.4 N*m (86 kgf*cm, 74 in.*lbf)


f.

Install the No. 1 engine room relay block cover to the engine room relay block and junction block assembly.


g.

Connect the ECM connector and lower the lever.


h.

Engage the wire harness clamp.


Hide 88310 32.INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

a.
E261282N01
1.24,0.927 1.396,1.125 0.156,0.198 10 true 1 1.333,1.927 1.49,2.125 0.156,0.198 10 true 2

Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

Torque:
9.8 N*m (100 kgf*cm, 87 in.*lbf)

HINT:

Tighten the 2 stud bolts in the order shown in the illustration to temporarily install the compressor assembly with pulley.



b.
E261281C04
0.958,0.302 1.417,0.5 0.458,0.198 10 false 1 0.896,1.823 1.073,2.021 0.177,0.198 10 false 2 1.844,0.479 2,0.667 0.156,0.188 10 true 3 1.531,1.979 1.698,2.156 0.167,0.177 10 false 4
V100135

Bolt
V100136

Nut


Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

Torque:
25 N*m (255 kgf*cm, 18 ft.*lbf)

HINT:

Tighten the 2 bolts and 2 nuts in the order shown in the illustration to install the compressor assembly with pulley.



c.

Connect the connector.


Hide 27020 33.INSTALL GENERATOR ASSEMBLY

Click herePower Source / Network>2NZ-FE BATTERY / CHARGING>GENERATOR>INSTALLATION

Hide 23901 37.CONNECT FUEL TUBE SUB-ASSEMBLY

a.

Connect the fuel tube connector and fuel pipe.

CAUTION:

Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If it is difficult to push the fuel tube connector in, apply a small amount of clean engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.



b.

Engage the claw and install the No. 1 fuel pipe clamp.


Hide 87246 39.CONNECT OUTLET HEATER WATER HOSE

Click hereEngine / Hybrid System>2NZ-FE ENGINE MECHANICAL>CYLINDER HEAD GASKET>INSTALLATION

Hide 44774 40.CONNECT UNION TO CONNECTOR TUBE HOSE

a.

Connect the union to connector tube hose to the air tube and slide the clip to secure it.


Hide 32922 41.INSTALL OUTLET NO. 1 OIL COOLER TUBE (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>INSTALLATION

Hide 32921 42.INSTALL INLET NO. 1 OIL COOLER TUBE (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>INSTALLATION

Hide 31470 43.INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)

a.
A154281N03
1.281,1.708 1.448,1.896 0.167,0.188 10 true A 1.677,1.615 1.844,1.802 0.167,0.188 10 true A 2.635,0.75 2.802,0.938 0.167,0.188 10 true C 2.26,1.208 2.427,1.396 0.167,0.188 10 true B

Install the clutch release cylinder assembly and clutch tube bracket with the 4 bolts.

Torque:
Bolt (A) : 11.8 N*m (120 kgf*cm, 9 ft.*lbf)
Bolt (B) : 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Bolt (C) : 12 N*m (122 kgf*cm, 9 ft.*lbf)


Hide 33820B 44.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

a.
C304026N01
0.698,0.729 0.917,0.958 0.219,0.229 10 false A 1.51,1.583 1.729,1.813 0.219,0.229 10 false A 2.219,1.396 2.438,1.625 0.219,0.229 10 false B 2.125,0.698 2.344,0.927 0.219,0.229 10 false B

Connect the transmission control cable assembly to the control cable bracket assembly with 2 new clips (B).


b.

Connect the transmission control cable assembly to the manual transaxle assembly with the 2 clips (A).


Hide 33820B 45.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>PARK / NEUTRAL POSITION SWITCH>INSTALLATION

Hide 16572D 46.CONNECT NO. 2 RADIATOR HOSE

a.

Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.


Hide 16571C 47.CONNECT NO. 1 RADIATOR HOSE

a.

Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.


Hide 74411 48.INSTALL BATTERY CARRIER

a.

Install the battery carrier with the 4 bolts.

Torque:
12.8 N*m (131 kgf*cm, 9 ft.*lbf)


b.

Connect the radiator pipe to the battery carrier with the 2 bolts.

Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf)


c.

Connect the 2 wire harness clamps to the battery carrier.


Hide 28800 49.INSTALL BATTERY

a.

Install the battery clamp bolt to the battery carrier support.


b.

Install the battery tray and battery to the battery carrier.


c.
A311982C01
1.552,1.677 1.74,1.875 0.188,0.198 10 true *a 2.302,0.271 2.49,0.469 0.188,0.198 10 true *b
*a Bolt
*b Nut


Install the battery clamp sub-assembly with the bolt and nut.

Torque:
Bolt : 6.5 N*m (66 kgf*cm, 58 in.*lbf)
Nut : 3.5 N*m (36 kgf*cm, 31 in.*lbf)


d.

Connect the cable to the positive (+) battery terminal with the nut.

Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)


Hide 17701 50.INSTALL AIR CLEANER CASE SUB-ASSEMBLY

a.

Install the air cleaner case sub-assembly with the 3 bolts.

Torque:
7.0 N*m (71 kgf*cm, 62 in.*lbf)


b.

Connect the wire harness clamp to the air cleaner case sub-assembly.


c.

Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.


Hide 17705 51.INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>2NZ-FE ENGINE CONTROL>THROTTLE BODY>INSTALLATION

Hide 23826 52.CONNECT NO. 1 FUEL VAPOR FEED HOSE

a.

Connect the vacuum switching valve connector.


b.

Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.


Hide 53.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

a.

Connect the cable to the negative (-) battery terminal with the nut.

Torque:
5.4 N*m (55 kgf*cm, 48 in.*lbf)

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION



Hide 56.ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

Click hereDrivetrain>C50 MANUAL TRANSMISSION / TRANSAXLE>MANUAL TRANSAXLE OIL>REPLACEMENT

Hide 57.ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>VALVE BODY ASSEMBLY>INSTALLATION

Hide 59.INSPECT SHIFT LEVER POSITION (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>SHIFT LEVER>ON-VEHICLE INSPECTION

Hide 60.ADJUST SHIFT LEVER POSITION (for Manual Transaxle)

Click hereDrivetrain>C50 MANUAL TRANSMISSION / TRANSAXLE>TRANSMISSION CONTROL CABLE>ADJUSTMENT

Hide 61.ADJUST SHIFT LEVER POSITION (for Automatic Transaxle)

Click hereDrivetrain>U441E AUTOMATIC TRANSMISSION / TRANSAXLE>TRANSMISSION CONTROL CABLE>ADJUSTMENT

Hide 51442C 66.INSTALL ENGINE UNDER COVER LH

a.

Install the engine under cover LH with the 2 bolts, 4 screws and 3 clips.


Hide 51441C 67.INSTALL ENGINE UNDER COVER RH

a.

Install the engine under cover RH with the 3 bolts, 4 screws and 3 clips.


Hide 68.INSTALL FRONT WHEELS

Click hereSuspension>TIRE / WHEEL>TIRE AND WHEEL>INSTALLATION

Hide 11212 73.INSTALL NO. 2 CYLINDER HEAD COVER

a.

Install the No. 2 cylinder head cover with the 4 nuts.

Torque:
7.0 N*m (71 kgf*cm, 62 in.*lbf)