EM–106 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

INSTALLATION
1. INSTALL DRIVE PLATE SUB-ASSEMBLY
(a) Clean the 8 bolts and 8 bolt holes.
(b) Apply adhesive to 2 or 3 threads of the 8 bolts.
Adhesive:
Toyota Genuine Adhesive 1342, Three Bond
1342 or Equivalent
(c) Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021

SST
EM A126932E01

(d) Install the front spacer.

HINT:
Align the pin of the front spacer with the pin hole of
the crankshaft.

A114342

(e) Install the drive plate and rear spacer onto the
crankshaft.
Drive Plate

Transaxle

Rear Spacer

Transaxle

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 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–107

(f) Using several steps, uniformly install and tighten the

8 bolts in the sequence shown in the illustration.
1 Torque: 98 N*m (1,000 kgf*cm, 72 ft.*lbf)
6
3 2. INSTALL TORQUE CONVERTER CLUTCH
8 ASSEMBLY
7 (a) Install the torque converter clutch for U241E (2WD)
4 (see page AX-148).
5
2 (b) Install the torque converter clutch for U140F (4WD)
(see page AX-149).
A112224E01

3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

(a) Install the automatic transaxle for U241E (2WD)
(see page AX-149).
(b) Install the automatic transaxle for U140F (4WD)
(see page AX-150).
4. INSTALL STARTER ASSEMBLY (See page ST-14)
5. INSTALL TRANSFER ASSEMBLY (for 4WD) (See EM
page TF-75)
6. INSTALL DRIVE SHAFT BEARING BRACKET (for
2WD)
(a) Install the bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)

A098759E01

7. INSTALL DRIVE SHAFT BEARING BRACKET (for

4WD)
(a) Install the bracket with the 3 bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)

A114345

8. INSTALL ENGINE HANGER

(a) Install the No. 1 and No. 2 engine hangers.
No. 2 Engine Hanger Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
Part No.
No. 1 Engine Hanger
ITEM Part No.
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020

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 EM–108 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

(b) Attach the sling device and the engine with the
chain block.
9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Lift the engine assembly (with transaxle) with the
chain block.

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(b) Lower the engine out of the vehicle slowly and

carefully.
NOTICE:
Make sure the engine is clear of all wiring, hoses
and cables.

EM

A114337

10. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the 4
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)

A124845

(b) Install the engine mounting insulator LH with the

through bolt and nut.
HINT:
Install the through bolt by tightening the nut.
Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf)

Nut
Through Bolt
A124844E01

11. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the 2
B bolts and 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) for bolt
95 N*m (969 kgf*cm, 70 ft.*lbf) for nut A
52 N*m (530 kgf*cm, 38 ft.*lbf) for nut B
A

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 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–109

12. REMOVE ENGINE HANGER

(a) Remove the No. 1 and No. 2 engine hangers.

No. 2 Engine Hanger

No. 1 Engine Hanger

A112213E01

13. INSTALL ENGINE MOUNTING INSULATOR RR EM

(a) Install the engine mounting insulator RR with the 2
nuts and 2 bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)

A124842

(b) Install the through bolt which is used to secure the

rear engine mounting insulator, into the rear engine
mounting bracket.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)

A124841

14. INSTALL ENGINE MOUNTING INSULATOR FR

(a) Install the engine mounting insulator FR with the 2
bolts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)

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 EM–110 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

(b) Install the through bolt and nut which is used to

secure the front engine mounting bracket FR.
HINT:
Install the through bolt by tightening the nut.
Torque: 145 N*m (1,479 kgf*cm, 107 ft.*lbf)
Through Bolt
15. INSTALL PROPELLER SHAFT ASSEMBLY (for 4WD)
(a) Install the propeller shaft (see page PR-5).
Nut 16. INSTALL FRONT DRIVE SHAFT ASSEMBLY
A124839E02 (a) Install the front drive shaft RH (for 2WD) (see page
DS-32).
(b) Install the front drive shaft RH (for 4WD) (see page
DS-65).
17. INSTALL FRONT EXHAUST PIPE (See page EX-4)
18. CONNECT ENGINE WIRE
(a) Install the ground cable with the bolt located near
EM the starter.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(b) Connect the ground cable to the clamp located near
the starter.

A124837

(c) Connect the engine wire to the positive (+) battery

terminal with the nut.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)

A124836

(d) Connect the ground cable connector.

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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–111

(e) Connect the 2 engine wire connectors and install

the nut.
(f) Install the engine room relay block cover.

A124834

(g) Attach the clamp of the engine wire cover.

(h) Install the engine wire cover to with the bolt.
19. INSTALL ECM (See page ES-430)
20. INSTALL COOLER COMPRESSOR ASSEMBLY (See
page AC-217)
21. INSTALL GENERATOR ASSEMBLY (See page CH-15)
EM
22. INSTALL FAN AND GENERATOR V BELT (See page
A124847 EM-7)
23. INSTALL FRONT SUSPENSION MEMBER
REINFORCEMENT RH (See page EM-7)
24. INSTALL TRANSAXLE CONTROL CABLE
ASSEMBLY
(a) Install the transaxle control cable for U241E (see
page AX-130).
(b) Install the transaxle control cable for U140F (see
page AX-130).
25. INSTALL INTAKE MANIFOLD INSULATOR (See page
ES-421)
26. INSTALL INTAKE MANIFOLD (See page ES-421)
27. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-13)
28. CONNECT NO. 2 VENTILATION HOSE (See page FU-
14)
29. INSTALL THROTTLE BODY ASSEMBLY (See page
ES-413)
30. CONNECT FUEL TUBE (See page FU-14)
31. CONNECT HEATER WATER OUTLET HOSE
(a) Connect the heater water outlet hose to the air
conditioner tube.

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 EM–112 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

32. CONNECT HEATER WATER INLET HOSE

(a) Connect the heater water inlet hose to the air
conditioner tube.

A124832

33. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the 2 union to connector tube hoses to the
booster vacuum tube.

EM

A124830

34. INSTALL BATTERY CARRIER BRACKET

(a) Install the battery carrier bracket with the nut and 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

A124829

35. INSTALL BATTERY BRACKET REINFORCEMENT

(a) Install the battery bracket reinforcement with the 2
bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

A124828

36. INSTALL FRONT BATTERY CARRIER

(a) Install the front battery carrier with the 4 bolts.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 clamps of the engine wire.
37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Connect the air cleaner case to the No. 1 air cleaner
inlet.

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2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–113

(b) Install the air cleaner case with the 3 bolts.

Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
38. INSTALL AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
39. INSTALL AIR CLEANER CAP (See page ES-413)
40. INSTALL PURGE VSV (See page EC-16)

A112221

41. INSTALL RADIATOR RESERVOIR

(a) Install the reservoir with the 2 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
42. INSTALL RADIATOR ASSEMBLY
(a) Install the radiator (see page CO-32).
43. INSTALL BATTERY TRAY EM
44. INSTALL BATTERY
(a) Install the battery.
A124838
(b) Install the battery clamp with the bolt and nut.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) for bolt
5.0 N*m (51 kgf*cm, 44 in.*lbf) for nut
45. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
46. ADD AUTOMATIC TRANSAXLE FLUID
(a) Add automatic transaxle fluid for U241E (2WD) (see
page AX-151).
(b) Add automatic transaxle fluid for U140F (4WD) (see
page AX-152).
47. CHECK FOR FUEL LEAKS (See page FU-14)
48. ADD ENGINE COOLANT (See page CO-6)
49. CHECK FOR ENGINE COOLANT LEAKS
(a) Check for engine coolant leaks (see page CO-1).
50. CHECK FOR AUTOMATIC TRANSAXLE FLUID
LEAKS
51. ADJUST SHIFT LEVER POSITION
(a) Adjust the shift lever position for U241E (2WD) (see
page AX-138).
(b) Adjust the shift lever position for U140F (4WD) (see
page AX-138).
52. INSTALL NO. 1 ENGINE COVER (See page EM-43)
53. INSTALL FRONT FENDER APRON RH
54. INSTALL NO. 2 ENGINE UNDER COVER
55. INSTALL NO. 1 ENGINE UNDER COVER
56. INSTALL FRONT WHEEL
57. INSTALL RADIATOR SUPPORT OPENING COVER
 EM–114 2AZ-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

58. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood (see page ED-7).
(b) Adjust the hood (see page ED-5).
59. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (see
page SP-3).
60. PERFORM REGISTRATION
(a) When replacing the engine assembly, perform
vehicle stability control system recognition in ECM
(see page CC-12).
61. RESET MEMORY (for Automatic Transaxle)
(a) When replacing the engine assembly, perform the
RESET MEMORY procedure (A/T initialization) for
U241E (2WD) (see page AX-18) and for U140F
(4WD) (see page AX-18).
EM