ENGINE ASSEMBLY INSTALLATION

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

1. 

   Using SST, hold the crankshaft.

   09213-70011	09213-70020
   09330-00021

2. 

   Apply adhesive to 2 or 3 threads of the mounting bolt end.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   
   
   1. 

      Install the front spacer, drive plate and rear spacer on the crankshaft.

   2. Install and tighten the 8 mounting bolts uniformly in several steps.

      83 N*m

      850 kgf*cm

      61 ft.*lbf

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)

1. 

   Install the automatic transaxle to the engine with the 10 bolts.

   Bolt A
   64 N*m	650 kgf*cm	47 ft.*lbf
   Bolt B
   46 N*m	470 kgf*cm	34 ft.*lbf
   Bolt C
   43 N*m	438 kgf*cm	32 ft.*lbf

2. Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

3. 

   Install the 6 torque converter clutch mounting bolts.

   41 N*m

   418 kgf*cm

   30 ft.*lbf

   Note:

   First install the different colored bolt, and then the remaining 5 bolts.

4. 

   Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.

   7.8 N*m

   80 kgf*cm

   69 in.*lbf

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD)

1. 

   Install the automatic transaxle with transfer to the engine with the 10 bolts.

   Bolt A
   64 N*m	650 kgf*cm	47 ft.*lbf
   Bolt B
   46 N*m	470 kgf*cm	34 ft.*lbf
   Bolt C
   43 N*m	438 kgf*cm	32 ft.*lbf

2. Apply a few drops of adhesive to each of 2 threads on the tip of the 6 torque converter clutch mounting bolts.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

3. 

   Install the 6 torque converter clutch mounting bolts.

   41 N*m

   418 kgf*cm

   30 ft.*lbf

   Note:

   First install the different colored bolt, and then the remaining 5 bolts.

4. 

   Install the flywheel housing under cover to the automatic transaxle with the 2 bolts.

   7.8 N*m

   80 kgf*cm

   69 in.*lbf

INSTALL TRANSFER STIFFENER PLATE RH (for 4WD)

1. 

   Install the transfer stiffener plate RH with 4 bolts to the transfer and engine mounting bracket RR.

   Bolt A
   34 N*m	350 kgf*cm	25 ft.*lbf
   Bolt B
   78 N*m	796 kgf*cm	58 ft.*lbf

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

1. 

   Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.

   Note:
   

   • Set the shaft snap ring with the opening facing down.

   • Be careful not to damage the drive shaft dust cover, boot, or oil seal.

   • Move the drive shaft assembly while keeping it level.

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)

1. Install the front drive shaft assembly RH.

2. 

   Install a new bearing bracket hole snap ring and bolt.

   32 N*m

   330 kgf*cm

   24 ft.*lbf

   Note:
   

   • Do not damage the boot or oil seal.

   • Move the drive shaft assembly while keeping it level.

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

INSTALL POWER STEERING LINK ASSEMBLY (for 4WD)

1. 

   Install the power steering link assembly with the 2 bolts and 2 nuts.

   70 N*m

   713 kgf*cm

   51 ft.*lbf

   Note:
   

   • Make sure to tighten the bolts starting from the left side of the vehicle.

   • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut fixed.

INSTALL FRONT STABILIZER BAR

1. Install the front stabilizer bar by inserting it from the right side of the vehicle.

INSTALL STARTER ASSEMBLY

1. 

   Install the starter assembly with the 2 bolts.

   37 N*m

   377 kgf*cm

   27 ft.*lbf

2. 

   Connect the starter connector.

3. Connect the starter wire with the nut and cover the nut with the cap.

   9.8 N*m

   100 kgf*cm

   87 in.*lbf

TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH

1. 

   Temporarily install the compressor and magnetic clutch with the bolts.

   Tip:

   Temporarily tighten the bolts in the order shown in the illustration.

CONNECT SUCTION HOSE SUB-ASSEMBLY

1. Remove the attached vinyl tape from the hose.

2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

   Compressor oil
   ND-OIL 8 or equivalent

3. Install the O-ring onto the suction hose sub-assembly.

4. 

   Install the suction hose sub-assembly onto the compressor and magnetic clutch with the bolt.

   9.8 N*m

   100 kgf*cm

   87 in.*lbf

CONNECT DISCHARGE HOSE SUB-ASSEMBLY

1. Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser assembly.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint.

   Compressor oil
   ND-OIL 8 or equivalent

3. Install the O-ring on the discharge tube sub-assembly.

4. 

   Install the discharge tube sub-assembly on the cooler condenser assembly with the bolt.

   9.8 N*m

   100 kgf*cm

   87 in.*lbf

INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

1. 

   Align the matchmarks on the steering intermediate shaft sub-assembly and the power steering link assembly.

2. 

   Install a new bolt.

   35 N*m

   360 kgf*cm

   26 ft.*lbf

3. 

   Install the steering intermediate shaft sub-assembly to the steering column hole shield.

4. 

   Tighten the bolt.

INSTALL FRONT AXLE ASSEMBLY LH

1. 

   Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

INSTALL NO. 1 FRONT SUSPENSION LOWER ARM LH

1. 

   Install the front lower suspension arm to the front lower ball joint with the bolt and 2 nuts.

   92 N*m

   938 kgf*cm

   68 ft.*lbf

INSTALL TIE ROD ASSEMBLY LH

1. Connect the tie rod assembly LH to the steering knuckle with the nut.

   49 N*m

   500 kgf*cm

   36 ft.*lbf

2. Install a new cotter pin.

   Note:

   Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

INSTALL FRONT SPEED SENSOR LH

1. 

   Install the resin clamp and front speed sensor with the bolt.

   8.0 N*m

   82 kgf*cm

   71 in.*lbf

   Note:
   

   • Prevent foreign matter from attaching to the sensor tip.

   • Firmly insert the sensor body into the knuckle before tightening the bolt.

   • After installing the sensor to the knuckle, make sure that there is no clearance between the sensor stay and knuckle. Also make sure that no foreign matter is stuck between the parts.

   • To prevent interference between the sensor and magnetic rotor, do not rotate the sensor body during or after the insertion of the sensor body to the knuckle.

INSTALL FRONT AXLE HUB NUT LH

1. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.

   Tip:
   

   • Be sure to perform this work for a new drive shaft.

   • Keep the threaded parts free of oil and foreign objects.

2. 

   Using a socket wrench (30 mm), install a new axle hub nut.

   294 N*m

   2996 kgf*cm

   216 ft.*lbf

3. Using a chisel and hammer, stake the front axle hub nut.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH

1. 

   Install the front stabilizer link assembly LH with the nut.

   74 N*m

   755 kgf*cm

   55 ft.*lbf

   Tip:

   If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

1. 

   Install 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.

2. Install the front No. 3 exhaust pipe sub-assembly with 2 new nuts and the 2 bolts.

   56 N*m

   571 kgf*cm

   41 ft.*lbf

3. 

   Install the 3 clamps and connect the heated oxygen sensor (for bank 1 sensor 2) connector.

4. 

   Tighten the front exhaust pipe assembly bolt.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL CENTER EXHAUST PIPE ASSEMBLY

1. 

   Using vernier calipers, measure the free length of the compression spring.

   Minimum

   41.5 mm (1.63 in.)

   Tip:

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

2. 

   Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the front No. 3 exhaust pipe sub-assembly.

   Note:
   

   • Tap in the gasket in the correct direction.

   • Do not reuse the removed gasket.

   • Do not push in the gasket while installing the center exhaust pipe assembly.

3. Connect the 3 exhaust pipe supports, and install the center exhaust pipe assembly.

4. 

   Install the 2 compression springs and 2 bolts.

   48 N*m

   489 kgf*cm

   35 ft.*lbf

INSTALL TAIL EXHAUST PIPE ASSEMBLY

1. 

   Using vernier calipers, measure the free length of the compression spring.

   Minimum

   40.5 mm (1.59 in.)

   Tip:

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

2. 

   Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the center exhaust pipe assembly.

   Note:
   

   • Tap in the gasket in the correct direction.

   • Do not reuse the removed gasket.

   • Do not push in the gasket while installing the tail exhaust pipe assembly.

3. Connect the exhaust pipe support, and install the tail exhaust pipe assembly.

4. 

   Install the 2 compression springs and 2 bolts.

   48 N*m

   489 kgf*cm

   35 ft.*lbf

TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

1. 

   Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, 4 washers and 4 nuts.

2. 

   Remove SST from the transaxle.

3. Insert the yoke into the transaxle.

4. 

   Install the 4 adjusting shims and propeller shaft with center bearing, and temporarily tighten the 4 bolts.

5. 

   Tighten the 4 bolts.

   74 N*m

   750 kgf*cm

   54 ft.*lbf

FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

1. 

   Remove the piece of cloth from the joint.

2. Using a hexagon wrench (6 mm), tighten the 6 bolts.

   26 N*m

   265 kgf*cm

   19 ft.*lbf

3. 

   With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft as shown in the illustration.

   (A)
   58.0 +/- 0.5 mm (2.283 +/- 0.02 in.)

4. 

   Under the same condition as above, adjust the front and rear dimensions between the edge surface of the center support bearing and the edge surface of the cushion respectively as shown, and then tighten the bolts.

   37 N*m

   375 kgf*cm

   27 ft.*lbf

   (B)
   12.5 +/- 1.0 mm (0.492 +/- 0.039 in.)

5. Check that the center line of the bracket is at the right angle in the shaft axial direction.

6. If any vibration or noise occurs, perform joint angle check as follows and replace the adjusting shim with a proper one.

   
   

   1. Turn the propeller shaft several times by hand to stabilize the center support bearings.

   2. Using a jack, raise and lower the differential to stabilize the differential mounting cushion.

   3. Remove the transfer dynamic damper.

   4. Using SST, measure the transfer installation angle (A) and front propeller shaft installation angle (B).

      09370-50010

      No. 1 joint angle
      (A) - (B) = -1.3° to -3.3°

   5. 

      Using SST, measure the rear propeller shaft installation angle (C) and rear differential shaft installation angle (D).

      09370-50010

      No. 2 joint angle
      (C) - (D) = 1.8° to 3.5°

      Tip:

      If the measured angle is not within the specification, adjust it with the center support bearing adjusting shim.

      Center support bearing adjusting shim thickness
      Thickness mm (in.) Thickness mm (in.) 3.2 (0.126) 11.0 (0.433) 4.5 (0.177) 13.5 (0.531) 6.5 (0.256) 15.5 (0.610) 9.0 (0.354) 17.5 (0.689)

   6. Install the transfer dynamic damper.

      26 N*m

      265 kgf*cm

      19 ft.*lbf

INSTALL AIR CLEANER CASE SUB-ASSEMBLY

1. 

   Install the air cleaner case with the 3 bolts.

   5.0 N*m

   51 kgf*cm

   44 in.*lbf

2. Connect the hose and connector.

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

1. 

   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.

   Tip:
   

   • 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.

   5.0 N*m

   51 kgf*cm

   44 in.*lbf

3. 

   Connect the 3 vacuum hoses.

4. 

   Connect the mass air flow meter connector.

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

INSTALL NO. 1 AIR CLEANER INLET

1. 

   Install the No. 1 air cleaner inlet with the 2 bolts.

   7.0 N*m

   71 kgf*cm

   62 in.*lbf

   [A]

   5.0 N*m

   51 kgf*cm

   44 in.*lbf

   [B]

2. Connect the 2 vacuum hoses.

INSTALL NO. 2 AIR CLEANER INLET

1. 

   Install the No. 2 air cleaner inlet with the 2 bolts.

   7.0 N*m

   71 kgf*cm

   62 in.*lbf

2. Connect the 2 vacuum hoses and harness clamps.

INSTALL V-RIBBED BELT

1. 

   Install the V-ribbed belt.

2. Using SST, turn the V-ribbed belt tensioner assembly counterclockwise and remove the bar.

   09961-00950

3. 

   If it is difficult to install the V-ribbed belt, perform the following procedure:

   
   

   1. Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration.

   2. Release the V-ribbed belt tension by turning the V-ribbed belt tensioner assembly counterclockwise, and put the V-ribbed belt on the V-ribbed belt tensioner assembly pulley.

      Note:
      

      • Put the backside of the V-ribbed belt on the V-ribbed belt tensioner assembly pulley and No. 2 idler pulley sub-assembly.

      • Check that the V-ribbed belt is properly set to each pulley.

   3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the V-ribbed belt has not slipped out of the grooves on the bottom of the crankshaft pulley by hand.

INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

1. 

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

   7.0 N*m

   71 kgf*cm

   62 in.*lbf

2. Connect the connector.

INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

1. 

   Engage the 20 claws.

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

3. 

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

4. 

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

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. 

      Clean the wiper arm serrations.

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

3. 

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

   24 N*m

   245 kgf*cm

   18 ft.*lbf

   Tip:

   Hold the wiper arm by hand when tightening the nut.

   Area	Measurement
   A	25.6 mm (1.00 in.)

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. 

      Clean the wiper arm serrations.

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

3. 

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

   24 N*m

   245 kgf*cm

   18 ft.*lbf

   Tip:

   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.

ADD ENGINE OIL

1. Add clean engine oil and install the oil filler cap.

   Engine oil
   Oil Grade Oil Viscosity (SAE) .API grade SL and energy-conserving .API grade SM and energy-conserving .ILSAC multigrade engine oil 10W-30 API grade SL 15W-40 API grade SM 20W-50
   Table 1. Standard capacity (w/ Oil Cooler): Item Standard Condition Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 lmp. qts) Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts) Dry fill 7.1 liters (7.5 US qts, 6.2 lmp. qts)
   Table 2. Standard capacity (w/o Oil Cooler): Item Standard Condition Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 lmp. qts) Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts) Dry fill 6.8 liters (7.2 US qts, 6.0 lmp. qts)

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the 2 cylinder block drain cock plugs.

   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. 

   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.

   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.

   1.5 N*m

   15 kgf*cm

   13 in.*lbf

   for air drain plug

   Tip:

   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
   Table 3. 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)
   Table 4. 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)

   Tip:
   

   • 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.

       Tip:

       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.

CHECK AUTOMATIC TRANSAXLE FLUID

1. Park the vehicle on a level surface and set the parking brake.

2. 

   With the engine idling and the brake pedal depressed, move the shift lever to all positions from P to S1 and return to the P position.

3. Take out the dipstick and wipe it clean.

4. Put the dipstick back all the way.

5. Take out the dipstick again and check that the fluid level is within the HOT range.

   If the fluid level is below the HOT range, add new fluid and recheck the fluid level.

   If the fluid level exceeds the HOT range, drain the fluid once, add the proper amount of new fluid and recheck the fluid level.

   If there are leaks, it is necessary to repair or replace O-rings, FIPGs, oil seals, plugs and/or other parts.

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.

INSPECT FOR ENGINE OIL LEAK

1. Start the engine.

2. Check for engine oil leaks from the oil filter cap and oil filter drain plug.

3. Install the oil filter element service hole cover.

INSPECT FOR COOLANT LEAK

1. 

   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.

INSPECT FOR EXHAUST GAS LEAK

If exhaust gas is leaking, repair the leak. Replace damaged or worn parts as necessary.

CHECK SHIFT LEVER POSITION

1. Apply the parking brake and turn the ignition switch on (IG).

2. Depress the brake pedal and check that the engine starts when the shift lever is set in the N position or P position, but does not start in the other positions.

3. Check that the back-up light illuminates when the shift lever is set in the R position, but does not function in the other positions.

   If a malfunction is found, check the park/neutral position switch for continuity.

CHECK IGNITION TIMING

1. When using the intelligent tester:

   Check the ignition timing.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Warm up the engine.

   3. Turn the tester on.

   4. Enter the following menu items: Powertrain / Engine and ECT / Data List / IGN Advance.

   5. Read the value displayed on the tester.

      Ignition timing
      8 to 12° BTDC at idle

      Tip:

      Refer to the intelligent tester operator's manual for help when selecting the DATA LIST.

2. 

   When not using the intelligent tester:

   Check the ignition timing.

   
   

   1. Warm up the engine.

   2. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      09843-18040

      Note:
      

      • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      • Turn off all electrical systems before connecting the terminals.

      • Perform this inspection after the cooling fan motor is turned off.

   3. Remove the V-bank cover sub-assembly.

   4. 

      Pull out the red lead wire harness.

   5. Connect the tester terminal of the timing light to the red lead wire as shown in the illustration.

      Note:

      Use a timing light which detects the cylinder 1 ignition signal.

   6. Check the ignition timing at idle.

      Standard ignition timing
      8 to 12° BTDC at idle

      Note:

      When checking the ignition timing, the transmission should be in the neutral position.

      Tip:

      Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed.

   7. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

   8. Check the ignition timing at idle.

      Standard ignition timing
      7 to 24° BTDC at idle

   9. Confirm that the ignition timing advances immediately when the engine rpm is increased.

   10. Remove the timing light from the engine.

CHECK ENGINE IDLE SPEED

1. When using the intelligent tester:

   Check the idle speed.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Warm up the engine.

   3. Turn the tester on.

   4. Enter the following menu items: Powertrain / Engine and ECT / Data List / Engine Speed.

   5. Read the value displayed on the tester.

      Idle speed
      600 to 700 rpm

      Note:
      

      • When checking the idle speed, the transmission should be the in neutral position.

      • Check the idle speed with the cooling fan off.

      • Switch off all accessories and air conditioning before connecting the intelligent tester.

      Tip:

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

2. 

   When not using the intelligent tester:

   Check the idle speed.

   
   

   1. Warm up the engine.

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

      09843-18030

   3. Check the idle speed.

      Standard idle speed
      600 to 700 rpm

CHECK CO/HC

1. Start the engine.

2. Run the engine at 2500 rpm for approximately 180 seconds.

3. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe during idling.

4. Check CO/HC concentration at idle and/or 2500 rpm.

   Tip:

   Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2500 rpm).

   If the CO/HC concentration does not comply with regulations, perform troubleshooting in the following order.

   
   

   1. Check the air fuel ratio sensor and heated oxygen sensor operation.

   2. See the following table for possible causes, and then inspect and repair if necessary.

      CO	HC	Problem	Cause
      Normal	High	Rough idle	Faulty ignitions: Incorrect valve timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance (valve lash adjuster) Leaks in intake and exhaust valves Leaks in cylinders
      Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body assembly Brake booster line Lean mixture causing misfire
      High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty SFI system: Faulty fuel pressure regulator Defective engine coolant temperature sensor Defective mass air flow meter Faulty ECM Faulty injector assemblies Faulty throttle position sensor (built in throttle body assembly)

CHECK FUNCTION OF THROTTLE BODY ASSEMBLY

1. Listen to the throttle control motor operating sounds.

   
   

   1. Turn the ignition switch on (IG).

   2. When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure that no friction noise comes from the motor.

      If friction noise exists, replace the throttle body.

2. Inspect the throttle position sensor.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch on (IG).

   3. Check that the MIL turns off.

   4. Turn the tester on.

   5. Select the menu items: Powertrain / Engine and ECT / Data List / Throttle Position.

   6. Check the value of throttle valve angle is within the standard range below.

      Standard throttle valve opening percentage
      60% or more

      If the percentage is less than 60%, replace the throttle body.

      Note:

      When checking the throttle valve opening percentage, the transmission should be in neutral.

INSTALL FRONT FENDER LINER LH

1. 

   Install the front fender liner LH with the 5 clips and 8 screws.

2. 

   Install 2 new grommets.

3. Using a 4 mm hexagon wrench, install the 2 screws.

4. 

   Install the screw and pin hold clip.

   3.0 N*m

   31 kgf*cm

   27 in.*lbf

INSTALL FRONT FENDER LINER RH

1. 

   Install the front fender liner RH with the 5 clips and 7 screws.

2. 

   Install 2 new grommets.

3. Using a 4 mm hexagon wrench, install the 2 screws.

4. 

   Install the screw and pin hold clip.

   3.0 N*m

   31 kgf*cm

   27 in.*lbf

INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH

1. Clean the vehicle body surface.

   
   

   1. Using a heat light, heat the vehicle body surface.

   2. Remove the front fender side protector from the vehicle body.

   3. Wipe off any tape adhesive residue with cleaner.

2. 

   Clean the front fender moulding sub-assembly. (If reusing the front fender moulding sub-assembly)

   
   

   1. Using a heat light, heat the front fender moulding sub-assembly.

   2. Remove the front fender side protector from the front fender moulding sub-assembly.

   3. Wipe off any tape adhesive residue with cleaner.

   4. Install a new front fender side protector to the the front fender moulding sub-assembly.

3. Install 2 new No. 4 clips on the front fender moulding sub-assembly.

4. Install a new pad on the front fender moulding sub-assembly.

5. 

   Install the front fender moulding sub-assembly.

   
   

   1. Using a heat light, heat the vehicle body and the front fender moulding sub-assembly.

   2. Remove the release paper from the front fender moulding sub-assembly.

      Tip:

      After removing the release paper, keep the exposed adhesive free from foreign matter.

   3. Engage the 3 clips and install the front fender moulding sub-assembly.

6. 

   Using a 4 mm hexagon wrench, install the screw.

7. Install the clip.

INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH