KNOCK SENSOR INSTALLATION


  1. INSTALL KNOCK CONTROL SENSOR


    1. A017GBNE03

      Install the 2 knock control sensors with the 2 bolts as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the 2 knock control sensor connectors.

  2. INSTALL INTAKE MANIFOLD

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    Intake Manifold and Cylinder Head Sub-assembly RH
    Intake Manifold and Cylinder Head Sub-assembly LH

    1. A017BGBE03

      Set 2 new gaskets on each cylinder head.

      Note


      • Align the port holes of the gaskets and cylinder head.

      • Make sure that the gaskets are installed in the correct direction.

    2. Set the intake manifold on the cylinder heads.

    3. Install the intake manifold with the 6 bolts and 4 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  3. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for LHD)


    1. Install the No. 2 engine mounting stay RH.

    2. A017E8LE03

      Install the bolt [A].

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Install the 2 nuts [B].

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

    4. Install the bolt [C].

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    5. Install the 3 bolts [D].

      Torque:
      8.3 N*m  { 84 kgf*cm, 73 in.*lbf }

  4. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for RHD)


    1. A017ECDE03

      Install the No. 2 engine mounting stay RH.

    2. Install the bolt [E].

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Install the 2 nuts [F].

      Torque:
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

    4. Install the bolt [G].

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  5. INSTALL FUEL MAIN TUBE


    1. A017COKE02

      Push in the tube connector onto the pipe until the tube connector makes a "click" sound.

      Note


      • Before connecting the tube, make sure that it is not damaged. Make sure that there is no dirt present on the connecting surfaces.

      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

    2. Install the No. 2 fuel pipe clamp.

  6. TEMPORARILY INSTALL NO. 1 SURGE TANK STAY

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    No. 1 Surge Tank Stay and Cylinder Head Cover RH

    1. A017FPE

      Temporarily install the intake air surge tank assembly with 3 new gaskets on the intake manifold.

      Note

      Do not allow the gaskets to slip out of place during installation.

    2. Temporarily install the No. 1 surge tank stay with the 2 bolts.

  7. TEMPORARILY INSTALL THROTTLE BODY BRACKET

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    Throttle body bracket and Intake Air Surge Tank Assembly
    Throttle body bracket and Cylinder Head Cover RH

    1. A017CBD

      Temporarily install the throttle body bracket with the 2 bolts.

  8. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    Intake Manifold and Intake Air Surge Tank Assembly

    1. A017E68E03

      Install the surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      Bolt
      18 N*m  { 183 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Use a 5 mm hexagon socket wrench to tighten the 4 bolts.

    2. A017C1K

      Connect the 2 water by-pass hoses to the throttle with motor body assembly.

    3. A017DJ7

      Connect the connector.

    4. Install the clamp and connect the throttle with motor body assembly connector.

    5. A017FGBE03

      Connect the 4 hoses.

      Tech Tips


      • H: vapor feed hose

      • I: union to check valve hose

      • J: No. 1 ventilation hose

      • K: vacuum hose

  9. FULLY TIGHTEN NO. 1 SURGE TANK STAY

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    No. 1 Surge Tank Stay and Cylinder Head Cover RH

    1. A017B0YE02

      Fully tighten the 2 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  10. FULLY TIGHTEN THROTTLE BODY BRACKET

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Parts
    Throttle body bracket and Intake Air Surge Tank Assembly
    Throttle body bracket and Cylinder Head Cover RH

    1. A017CBDE02

      Fully tighten the 2 bolts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  11. CONNECT ENGINE ROOM MAIN WIRE


    1. A017EFP

      Connect the 5 harness clamps.

  12. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A017DHBE01

      Install the air cleaner filter element, align the groove on the air cleaner hose with the throttle body alignment tab and tighten the clamp as shown in the illustration.

      Tech Tips


      • A = 30°

      • B = 11 to 14 mm (0.433 in. to 0.551 in.)

    2. Install the air cleaner cap with the 2 bolts and clips.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A017BB9

      Connect the 3 vacuum hoses.

    4. A017EEU

      Connect the mass air flow meter connector.

    5. Connect the No. 2 ventilation hose and fuel vapor feed hose assembly.

  13. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for cylinder block drain cock plugs }

    3. Loosen the air drain cock plug from the water inlet housing.

    4. A017G9AE01

      Loosen the air drain plug at the top of the radiator 3 or 4 turns.

    5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf, for air drain cock plug }

    6. Continue to add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the radiator air drain hole. Then close the air drain plug at the top of the radiator.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf, for air drain plug }

      Tech Tips

      If the coolant level at the radiator inlet opening drops after squeezing the No. 1 and No. 2 radiator hoses, add coolant.

    7. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Standard capacity
      w/o Engine oil cooler
      Condition Specified Condition
      w/ Rear Heater 11.0 liters (11.6 US qts, 9.7 Imp. qts)
      w/o Rear Heater 8.8 liters (9.3 US qts, 7.7 Imp. qts)
      w/ Engine oil cooler
      Condition Specified Condition
      w/ Rear Heater 11.7 liters (12.4 US qts, 10.3 Imp. qts)
      w/o Rear Heater 9.5 liters (10.1 US qts, 8.4 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).

      • Contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    8. Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

    9. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    10. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

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

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When squeezing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

        Note


        • Make sure that the radiator reservoir still has some coolant in it.

        • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

        • If there is not enough coolant, the engine may overheat or be seriously damaged.

        • If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line.

    11. Stop the engine and wait until the engine coolant cools down.

    12. Add engine coolant to the FULL line on the radiator reservoir.

  14. INSPECT FOR COOLANT LEAK

    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.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. A017G83

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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.

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

  15. INSPECT FOR FUEL LEAK


    1. Check fuel pump operation.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch on (IG) and turn the intelligent tester main switch on.

        Note

        Do not start the engine.

      3. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.

      4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.

    2. Check for fuel leaks.


      1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

    3. Turn the ignition switch off.

    4. Disconnect the intelligent tester from the DLC3.

  16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A017F9GE01

      Install the outer cowl top panel sub-assembly with the 8 bolts and 6 nuts.

      Torque:
      Nut A
      85 N*m  { 866 kgf*cm, 63 ft.*lbf }
      Bolt B
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      Nut C
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
    2. A017G69

      Engage the 4 clamps.

  17. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A017FR2

      Install the windshield wiper motor and link assembly with the 4 bolts.

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

    2. Connect the connector.

  18. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Engage the 20 claws.

      A017F5J

    2. Install the cowl top ventilator louver sub-assembly with the 2 clips.

    3. A017EML

      Engage the 2 claws and connect the front fender to cowl side seal LH.

    4. A017F5E

      Engage the 2 claws and connect the front fender to cowl side seal RH.

  19. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. When reinstalling:


      1. A017C5CE01

        Clean the wiper arm serrations.

      2. Clean the wiper pivot serrations with a wire brush.

    3. A017D7ZE01

      Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the wiper arm by hand when tightening the nut.

      Area Measurement
      A 25.6 mm (1.00 in.)

  20. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. When reinstalling:


      1. A017C5CE01

        Clean the wiper arm serrations.

      2. Clean the wiper pivot serrations with a wire brush.

    3. A017D4VE01

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the wiper arm by hand when tightening the nut.

      Area Measurement
      A 31.9 mm (1.26 in.)

    4. Operate the front wipers while spraying washer fluid onto the windshield glass. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

  21. INSTALL NO. 1 ENGINE UNDER COVER


    1. A017B8T

      Install the No. 1 engine under cover with the 6 bolts and 2 clips.

  22. INSTALL ENGINE UNDER COVER ASSEMBLY


    1. A017FXN

      Install the engine under cover assembly with the 2 bolts, 2 screws and 5 clips.

    2. A017FPR

      Install the engine under cover assembly RR with the 2 bolts.

  23. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A017EFM

      Fit the 3 retainers and install the V-bank cover.