FUEL INJECTOR INSTALLATION

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

1. 

   Install 6 new insulators to the intake manifold.

2. 

   Place the fuel delivery pipe which has the 6 fuel injectors installed to it in position on the intake manifold.

   Note:

   Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

3. Temporarily install the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

   Note:

   After installing the fuel injectors, check that they turn smoothly. If not, reinstall the injectors with new O-rings.

4. 

   Tighten the 5 bolts which are used to hold the fuel delivery pipe to the intake manifold.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

5. 

   Connect the 6 fuel injector connectors.

CONNECT FUEL TUBE SUB-ASSEMBLY

1. 

   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.

TEMPORARILY INSTALL NO. 1 SURGE TANK STAY

1. 

   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.

TEMPORARILY INSTALL THROTTLE BODY BRACKET

1. 

   Temporarily install the throttle body bracket with the 2 bolts.

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

1. 

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

   Nut
   16 N*m	163 kgf*cm	12 ft.*lbf
   Bolt
   18 N*m	183 kgf*cm	13 ft.*lbf

   Tip:

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

2. 

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

3. 

   Connect the connector.

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

5. 

   Connect the 4 hoses.

   Tip:
   

   • H: vapor feed hose

   • I: union to check valve hose

   • J: No. 1 ventilation hose

   • K: vacuum hose

FULLY TIGHTEN NO. 1 SURGE TANK STAY

1. 

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

   21 N*m

   214 kgf*cm

   15 ft.*lbf

FULLY TIGHTEN THROTTLE BODY BRACKET

1. 

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

   21 N*m

   214 kgf*cm

   15 ft.*lbf

CONNECT ENGINE ROOM MAIN WIRE

1. 

   Connect the 5 harness clamps.

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.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

INSPECT SRS WARNING LIGHT

1. Inspect the SRS warning light (Click here).

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.

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
   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 is 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.

INSPECT FOR ENGINE 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.

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

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

INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

1. 

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

   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. 

   Engage the 4 clamps.

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 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.

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 NO. 1 ENGINE UNDER COVER

1. 

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

INSTALL ENGINE UNDER COVER ASSEMBLY

1. 

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

2. 

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