EXHAUST MANIFOLD INSTALLATION

INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)

1. 

   Using SST, install the air fuel ratio sensor to the exhaust manifold sub-assembly RH.

   09224-00010

   40 N*m	408 kgf*cm	30 ft.*lbf	for use with SST
   44 N*m	449 kgf*cm	32 ft.*lbf	for use without SST

   Tip:
   

   • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

   • Make sure that SST and the wrench are connected in a straight line.

INSTALL FRONT EXHAUST PIPE ASSEMBLY

1. 

   Install a new gasket to the front exhaust pipe assembly.

2. Install the front exhaust pipe assembly with 2 new nuts.

   56 N*m

   571 kgf*cm

   41 ft.*lbf

3. 

   Connect the heated oxygen sensor (for bank 2 sensor 2) connector.

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 (for 4WD)

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 (for 4WD)

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 FUEL RATIO SENSOR NO.2 (for Bank 2 Sensor 1)

1. 

   Using SST, install the air fuel ratio sensor to the exhaust manifold sub-assembly LH.

   09224-00010

   40 N*m	408 kgf*cm	30 ft.*lbf	for use with SST
   44 N*m	449 kgf*cm	32 ft.*lbf	for use without SST

   Tip:
   

   • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

   • Make sure that SST and the wrench are connected in a straight line.

2. 

   Connect the air fuel ratio sensor connector and install the clamp.

INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE

1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

2. Apply a light coat of engine oil to the O-ring.

3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.

4. 

   Install the No. 2 oil level dipstick guide with the bolt.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

CONNECT NO. 1 RADIATOR HOSE

1. 

   Connect the No. 1 radiator hose to the radiator.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the cylinder block drain cock plug. (for Bank 1)

   13 N*m

   130 kgf*cm

   9 ft.*lbf

3. Tighten the cylinder block drain cock plug. (for Bank 2, w/ Cylinder Block Drain Cock Plug)

   13 N*m

   130 kgf*cm

   9 ft.*lbf

4. Loosen the air drain cock plug on the water inlet housing.

5. 

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

   Table 1. Text in Illustration

   *1	Air Drain Plug

6. Add engine coolant to the radiator inlet opening until engine coolant overflows from the engine air drain cock hole. Then tighten the air drain cock plug.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

7. Continue to add engine coolant to the radiator inlet opening until engine coolant overflows from the radiator air drain hole. Then tighten the air drain plug.

   1.5 N*m

   15 kgf*cm

   13 in.*lbf

   Tip:

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

8. Slowly fill the radiator assembly with engine coolant.

   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)

   Note:

   Never use water as a substitute for engine coolant.

   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).

9. Slowly pour engine coolant into the radiator reservoir tank until it reaches the full line.

10. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

    If the engine coolant level is low, add engine coolant.

11. Bleed air from the cooling system.

    
    

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

       Tip:

       The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.

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

    3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.

       CAUTION:

       When squeezing the No. 1 radiator hose and No. 2 radiator hose:

       
       

       • Wear protective gloves.

       • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

       • Keep your hands away from the fan and No. 2 fan.

       Note:
       

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

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

       • If the radiator reservoir tank does not have enough engine coolant, the engine may overheat or be seriously damaged.

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

12. Stop the engine, and wait until the engine coolant cools down.

13. Add engine coolant to the full line on the radiator reservoir tank.

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.

INSTALL NO. 2 ENGINE UNDER COVER

1. 

   Install the No. 2 engine under cover with the 2 bolts.

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.

INSTALL V-BANK COVER SUB-ASSEMBLY

1. 

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