ENGINE ASSEMBLY INSTALLATION


  1. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the bolt and wire harness clamp bracket.

  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01BHBU

      Clean the threads of the oil pressure switch, and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01BA4M

      Using a 24 mm deep socket wrench, install the oil pressure switch.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

  3. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install a new gasket and oil filter bracket with the 10 bolts and 2 nuts.

      Torque:
      30 N*m  { 300 kgf*cm, 22 ft.*lbf }

  4. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter installation surface.

    2. Apply clean engine oil to the rubber gasket of a new oil filter.

    3. Instal the oil filter, and tighten it by hand until the rubber gasket contacts the installation surface.

    4. A01BDC6E01

      Using SST, tighten it by an additional 3/4 turn to seat the filter.

      SST
      09228-44011

  5. INSTALL EXHAUST MANIFOLD


    1. A01BD1XE01

      Install a new gasket to the cylinder head.

      Tech Tips

      Be sure to install a new gasket in the correct direction as shown in the illustration.

    2. A01BB18

      Install the exhaust manifold with the 6 bolts and 2 new nuts. Uniformly tighten the bolts and nuts in several steps.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  6. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A01BDOWE01

      Install the heat insulator with the 3 bolts.

      Torque:
      Bolt (A)
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
      Bolt (B)
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  7. INSTALL OIL LEVEL GAGE GUIDE


    1. Install the oil level gage guide to the cylinder head.

  8. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY


    1. Install the oil level gage sub-assembly to the cylinder head.

  9. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH


    1. A01BGGI

      Install the 6 bolts and engine mounting bracket front No.1 RH.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  10. INSTALL GENERATOR W/ VACUUM PUMP ASSEMBLY


    1. A01BCCL

      Temporarily tighten the bolt and generator w/ vacuum pump assembly.

    2. A01BFJB

      Install the clip with the hose connected.

    3. Install the bolt with the hose connected.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }

  11. INSTALL PUMP BRACKET


    1. A01BHPZE01

      Install the 6 bolts and pump bracket.

      Torque:
      Bolt (A)
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }
      Bolt (B)
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

  12. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1


    1. A01BBDT

      Install the 2 bolts, exhaust pipe support bracket No.1 and stiffener plate RH.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  13. INSTALL ENGINE OIL LEVEL SENSOR


    1. A01BC4M

      Install the 4 bolts and engine oil level sensor.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  14. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Clean the threads of the water drain cock, and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the water drain cock.

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

  15. INSTALL WATER BY-PASS HOSE UNION


    1. Clean the threads of the water by-pass hose union, and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the water by-pass hose union.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  16. INSTALL INTAKE MANIFOLD


    1. A01BDRBE01

      Install a new gasket to the cylinder head with the protrusion facing upward.

    2. A01BDG0

      Install the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.

      Torque:
      24 N*m  { 240 kgf*cm, 17 ft.*lbf }

  17. INSTALL WATER OUTLET HOUSING


    1. A01BEX8

      Install a new gasket, the water outlet and outlet hosing assembly with the 3 bolts.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  18. INSTALL CRANK POSITION SENSOR


    1. Coat a O-ring with engine oil.

    2. A01BG03

      Install the crank position sensor with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the crank position sensor connector.

  19. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A01BBBJ

      Install the injection or supply pump assembly to timing gear case, and temporarily tighten the 2 nuts.

    2. Install injection pump stay No.1 to the injection or supply pump assembly rear end, and temporarily tighten the 3 bolts.

    3. A01BA9U

      Rotate the pump body to make the marking of pump flange conform to the making of timing of gear case.

    4. Tighten the 2 nuts to install the injection or supply pump assembly.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

    5. Tighten the 3 bolts to install the injection pump stay No.1.

      Torque:
      Injection pump stay No.1 x Cylinder Block
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }
      Injection pump stay No.1 x Injection Pump
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    6. Connect the 3 fuel hoses.

    7. Connect the engine speed sensor connector.

    8. Connect the spill control valve connector.

    9. Connect the correction unit connector.

    10. Connect the timer control valve connector.

    11. Connect the fuel temperature sensor connector.

    12. Connect the engine wire clamp.

  20. INSTALL INJECTION PUMP DRIVE PULLEY


    1. A01BEIWE01

      Using SST, install the injection pump drive pulley with the nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  21. INSTALL GLOW PLUG ASSEMBLY


    1. Using a 12 mm deep socket wrench, install the 4 glow plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  22. INSTALL NOZZLE HOLDER & NOZZLE SET


    1. Place 4 new injection nozzle seat gaskets and 4 injection nozzle seats into the injection nozzle holes of the cylinder head.

    2. Using SST, install the 4 nozzle holder and nozzle sets.

      SST
      09268-64010   ( 09268-64020 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  23. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Install 4 new ring packing washers and the leakage pipe assembly with the 4 nuts.

      Torque:
      30 N*m  { 300 kgf*cm, 22 ft.*lbf }

    2. Connect the fuel hose to the leakage pipe.

  24. INSTALL GLOW PLUG NO.1 CONNECTOR

    Torque:
    1.0 N*m  { 10 kgf*cm, 9 in.*lbf }

  25. INSTALL INJECTION PIPE SET


    1. Connect the 2 lower clamps on the intake manifold.

    2. Install the 4 injection pipes.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Secure the injection pipes with the 2 upper pipe clamps and 2 nuts.

      Torque:
      5.0 N*m  { 50 kgf*cm, 44 in.*lbf }

  26. INSTALL VENTURI ASSEMBLY


    1. Install a new gasket and venturi.

    2. A01BFXZE01

      Connect the throttle control motor connector.

    3. A01BAY2E01

      Connect the throttle open switch connector.

  27. INSTALL INTAKE AIR CONNECTOR BRACKET


    1. A01BDYM

      Install the 2 bolts and intake air connector bracket.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  28. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. A01BCJN

      Install a new gasket and intake air connector with the bolt and 3 nuts.

      Torque:
      bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the turbo pressure sensor connector.

    3. Connect the ventilation hose.

  29. INSTALL TIMING BELT

    Click here

  30. INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning)


    1. Temporarily install the compressor mounting bracket with the 4 bolts.

    2. A01BFW5E01

      Using several steps, uniformly install and tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    3. A01BDNC

      Temporarily tighten the bolt and spacer.

    4. A01BDQDE01

      Temporarily install the compressor mounting bracket with the 3 bolts.

    5. Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      47 N*m  { 475 kgf*cm, 36 ft.*lbf }

  31. INSTALL FAN BELT ADJUSTING BAR (w/o Air Conditioning)


    1. A01BDYY

      Install the 2 bolts and fan belt adjusting bar.

      Torque:
      45 N*m  { 460 kgf*cm, 33 ft.*lbf }
    2. A01BFF7

      Temporarily install the bolt.

  32. CONNECT ENGINE MOUNTING INSULATOR FRONT


    1. Connect the engine mounting insulator front with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  33. CONNECT VANE PUMP ASSEMBLY


    1. Temporarily install the vane pump assembly with the 2 bolts.

    2. A01BB47E01

      Install the pulley to the pump shaft.

    3. Using SST, stop the pulley rotation and torque the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

  34. INSTALL ENGINE WIRE

  35. INSTALL REAR END PLATE


    1. Install the 2 bolts and rear end plate.

      Torque:
      27 N*m  { 275 kgf*cm, 19 ft.*lbf }

  36. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A01BH90E01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and bolt holes.

    3. Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the flywheel on the crankshaft.

    5. A01BDSCE01

      Install and uniformly tighten the 8 bolts in several steps, in the sequence shown.

      Torque:
      123 N*m  { 1,250 kgf*cm, 90 ft.*lbf }

      Note

      Do not start the engine within an hour after installing.

  37. INSTALL CLUTCH DISC ASSEMBLY


    1. A01BAMZE01

      Insert SST into the clutch disc assembly, then insert them into the flywheel sub-assembly.

      SST
      09301-00110

      Note

      Take care not to insert the clutch disc assembly in the wrong direction.

  38. INSTALL CLUTCH COVER ASSEMBLY


    1. A01BG9GE02

      Align the matchmarks on the clutch cover assembly with the one on the flywheel sub-assembly.

    2. Following the procedures shown in the illustration, tighten the 6 bolts starting from the bolt located near the knock pin on the top.

      SST
      09301-00110
      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Evenly tighten the bolts by following the order shown in the illustration.

      • Tighten the bolts after checking that the disc is in the center by lightly moving the SST up and down, left and right.

  39. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01BCZQ

      Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

      Maximum non-alignment
      0.9 mm (0.035 in.)
    2. A01BEOPE01

      If alignment is not as specified, adjust the diaphragm spring tip alignment using SST.

      SST
      09333-00013

  40. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  41. INSTALL STARTER ASSEMBLY (for 2.2 kW Type)


    1. Install the starter with the 2 bolts and nut.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Install the stay with the 2 bolts and nut.

      Torque:
      69 N*m  { 104 kgf*cm, 51 ft.*lbf }

    3. Connect the 30 terminal with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

    4. Install the terminal cap.

    5. Connect the starter connector.

  42. INSTALL STARTER ASSEMBLY (for 2.7 kW Type)


    1. Install the starter with the 2 bolts, nut and stay.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Install the starter stay with the 2 bolts and nut.

      Torque:
      Bolt
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }
      Nut
      12.5 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Connect the 30 terminal with the nut.

      Torque:
      21 N*m  { 215 kgf*cm, 16 ft.*lbf }

    4. Install the terminal cap.

    5. Connect the starter connector.

  43. INSTALL ENGINE W/ TRANSMISSION ASSEMBLY


    1. Using the engine lifter, install the engine w/ transmission assembly to the vehicle.

    2. A01BCFWE03

      Install the 4 bolts and stabilizer bracket.

      Torque:
      Bolt (A)
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    3. Install the 16 bolts and front suspension cross member.

      Torque:
      Bolt (B)
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
      Bolt (C)
      150 N*m  { 1,530 kgf*cm, 111 ft.*lbf }

    4. Connect the rear engine mounting.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

      Note

      Tighten the nuts when install the engine mounting.

    5. Remove the engine lifter.

  44. CONNECT STEERING TORQUE SHAFT ASSEMBLY


    1. A01BG7RE01

      Align the matchmarks on the steering torque shaft assembly and the power steering link assembly.

    2. A01BH0EE01

      Install bolt (B) and tighten the 2 bolts.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  45. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01BI54

      Install the clutch release cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  46. CONNECT WIRE HARNESS


    1. A01BC02

      Connect the 2 connectors and clamp.

  47. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01BEMCE01

      Install 2 new clips to the transmission control cable bracket No.1.

    2. Install the transmission control cable assembly to the transmission control cable bracket No.1.

      Note


      • Be sure that A claws of the clips are firmly engaged into the bracket grooves.

      • Be sure the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.

    3. A01BG2ME01

      Align the matchmarks on the control cable assembly and the outer lever.

    4. Install the transmission control cable assembly to the outer levers with the 2 nuts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  48. CONNECT SHOCK ABSORBER ASSEMBLY FRONT LH

    Click here

  49. CONNECT SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  50. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER LH


    1. A01BCZVE02

      Connect the front suspension upper arm to the steering knuckle with the nut.

      Torque:
      113 N*m  { 1,150 kgf*cm, 83 ft.*lbf }

    2. Install a new cotter pin.

      Note


      • If the holes for the cotter pin are not aligned, tighten the nut up to 60°.

      • Do not damage the ball joint dust cover.

  51. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  52. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A01BB1EE01

      Install the brake caliper assembly to the steering knuckle with the 2 bolts.

      Torque:
      123 N*m  { 1,250 kgf*cm, 91 ft.*lbf }

  53. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  54. INSTALL SPEED SENSOR FRONT LH (w/ ABS)


    1. A01BFZEE01

      Install the speed sensor to the steering knuckle with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      Note


      • Prevent foreign matter from adhering to the speed sensor.

      • Be careful not to damage the speed sensor.

      • Do not twist the sensor wire when installing the speed sensor.

  55. INSTALL SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  56. INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    1. A01BGHTE01

      Remove the SST from the extension housing.

    2. Install the propeller shaft assembly in the extension housing.

    3. Align the matchmarks on the propeller shaft flange and differential flange.

    4. A01BHYPE01

      Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

      Torque:
      74 N*m  { 755 kgf*cm, 54 ft.*lbf }

  57. INSTALL PROPELLER SHAFT ASSEMBLY (for Super Long Wheelbase)


    1. A01BGHTE01

      Remove the SST from the extension housing.

    2. Install the propeller with center bearing shaft assembly in the extension housing.

    3. A01BGNF

      Install the center support bearing assembly No.1, and temporarily tighten the 2 bolts.

    4. A01BHYPE01

      Align the matchmarks on the propeller shaft flange and differential flange.

    5. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

      Torque:
      74 N*m  { 755 kgf*cm, 54 ft.*lbf }
    6. A01BCGFE01

      Check that the center line of the bracket is at right angles to the shaft axial direction.

    7. A01BDD9E01

      Adjust the center support bearing assembly No.1.

      Tech Tips


      • With the vehicle unladen, adjust the center support bearing No.1 to maintain the angles, as shown.

      • In the same conditions, check the center line in the axial direction. Adjust the bearing if necessary.

      • The center bearing center line and center bearing housing center line must be adjusted to within -1.0 to 1.0 mm (-0.0394 to 0.0394 in.) of each other in the vehicle's longitudinal direction with the vehicle unladen.

    8. Tighten the 2 bolts.

      Torque:
      36 N*m  { 369 kgf*cm, 27 ft.*lbf }

  58. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.1 (for Long Wheelbase)


    1. Install a new gasket and exhaust pipe sub-assembly front No.1 with the 3 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Tighten the clamp bolt, and install the exhaust pipe support bracket No.1 to the exhaust pipe sub-assembly front No.1.

  59. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.1 (for Super Long Wheelbase)


    1. Install a new gasket and exhaust pipe sub-assembly front No.1 with the 3 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Tighten the clamp bolt, install the exhaust pipe support bracket No.1 to the exhaust pipe sub-assembly front No.1.

  60. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Long Wheelbase)


    1. A01BCDO

      Inspect the compression spring.


      1. Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5 mm (1.594 in.)

        Tech Tips

        If the free length is less than the minimum, replace the compression spring.

    2. A01BD65E05

      Install the gasket.


      1. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1 by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust pipe sub-assembly front No.1 are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not damage the outer face.

        • Do not reuse the gasket.

        • To ensure a proper seal, do not use the exhaust pipe sub-assembly front No.2 to force the gasket onto the exhaust pipe sub-assembly front No.1.

    3. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.

      Torque:
      Exhaust pipe sub-assembly front No.1 side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Exhaust pipe assembly tail side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust pipe sub-assembly front No.2 and exhaust pipe sub-assembly front No.1.

  61. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)


    1. A01BCDO

      Inspect the compression spring.


      1. Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5 mm (1.594 in.)

        Tech Tips

        If the free length is less than the minimum, replace the compression spring.

    2. A01BD65E05

      Install the gasket.


      1. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1 by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust pipe sub-assembly front No.1 are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not damage the gasket.

        • Do not reuse the gasket.

        • To ensure a proper seal, do not use the exhaust pipe sub-assembly front No.2 to force the gasket onto the exhaust pipe sub-assembly front No.1.

    3. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.

      Torque:
      Exhaust pipe sub-assembly front No.1 side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Exhaust pipe assembly center side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust pipe sub-assembly front No.2 and exhaust pipe sub-assembly front No.1 .

  62. CONNECT ENGINE WIRE


    1. A01BFD1E02

      Install the connector and nut, as shown the illustration.

    2. Install the nut then remove the starter wire harness.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the clamp and ground cable of the engine wire.

    4. Connect the connectors to the ECM.

    5. Install the wire harness support to the ECM.

  63. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

      Install the vane pump oil reservoir assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  64. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

    Click here

  65. CONNECT AIR CLEANER HOSE NO.2


    1. Install the air cleaner hose No.2 with the clamp.

  66. CONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE

  67. CONNECT RADIATOR HOSE NO.4

  68. CONNECT RADIATOR HOSE INLET

  69. INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning)


    1. A01BBR9E01

      Install the V belt.

    2. Using a bar, adjust the tension of the V belt.

    3. Tighten the bolts A and B.

      Torque:
      Bolt A
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Bolt B
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    4. Check the tension of the V belt. Click here

  70. INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning)


    1. A01BAGHE01

      Install the V belt.

    2. Tightening the bolt C, adjust the tension of the V belt.

    3. Tighten the bolts A and B.

      Torque:
      Bolt A
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Bolt B
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    4. Check the tension of the V belt. Click here

  71. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1


    1. A01BEBYE01

      Install the V belt.

    2. Tightening the bolt B, adjust the tension of the V belt.

    3. Tighten nut A.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    4. Check the tension of the V belt. Click here

  72. INSTALL VANE PUMP V BELT


    1. A01BCBTE01

      Install the V belt.

    2. Using a bar, adjust the tension of the V-ribbed belt.

    3. Tighten the bolt A and nut B.

      Torque:
      Bolt (A)
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }
      Nut (B)
      64 N*m  { 635 kgf*cm, 47 ft.*lbf }

    4. Check the tension of the V belt. Click here

  73. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the 5 bolts and engine service hole cover.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  74. INSTALL FRONT DOOR SCUFF PLATE RH

  75. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Use the same procedures described for the LH side. Click here

  76. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

    Use the same procedures described for the LH side. Click here

  77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  78. INSTALL FRONT WHEEL

  79. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  80. ADD ENGINE OIL

  81. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 12.7 liters (13.4 US qts, 11.2 Imp. qts)
      w/ Front Heater 13.7 liters (14.5 US qts, 12.1 Imp. qts)
      w/ Front and Rear Heaters 15.7 liters (16.6 US qts, 13.8 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    3. A01BGFB

      Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.

    4. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    5. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  82. BLEED AIR FROM FUEL SYSTEM


    1. A01BEO7E01

      Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

  83. CHECK FUEL LEAK


    1. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.

      Tech Tips

      When checking for fuel leaks, make sure that there is pressure in the fuel line.

  84. CHECK FOR ENGINE OIL LEAKS

  85. CHECK FOR ENGINE COOLANT LEAKS

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.

  86. CHECK TRANSMISSION OIL


    1. A01BD8XE01

      Park the vehicle in a level place.

    2. Remove the transmission filler plug and gasket.

    3. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

      Oil grade
      GL-4
      Viscosity
      SAE 75W-90
      Capacity
      2.2 liters (2.3 US qts, 1.9 lmp. qts)

      Note


      • Problems may occur when the oil level is too high or too low.

      • After replacing the oil, drive the vehicle and check the oil level again.

    4. Check for oil leakage if the oil level is low.

    5. Install the transmission filler plug and a new gasket.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  87. CHECK FOR EXHAUST GAS LEAKS

  88. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  89. CHECK IDLE SPEED


    1. Warm up the engine.

    2. When using an intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Idle speed
        720 to 820 rpm (A/C OFF)
        750 to 850 rpm (A/C ON)

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

    3. A01BAF6E02

      When not using an intelligent tester:


      1. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18040

      2. Check the idle speed.

        Idle speed
        720 to 820 rpm (A/C OFF)
        750 to 850 rpm (A/C ON)

        Note

        Switch off all accessories.

  90. INSPECT MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Depress the accelerator pedal all the way.

    3. Check the maximum speed.

      Maximum speed
      4,850 to 4,950 rpm

  91. CHECK ABS SENSOR SIGNAL

    Click here

  92. PERFORM INITIALIZATION

    Click here