ENGINE OIL COOLER INSTALLATION

INSTALL ENGINE OIL COOLER
1. Clean the oil cooler contact surface on the cooler mounting.
2. Install a new O-ring to the oil cooler.
3. Install the oil cooler assembly with the union bolt.
  
  Torque:
  
  68 N*m { 683 kgf*cm, 50 ft.*lbf }
4. Install the 2 water by-pass hoses with the bolt, 2 clamps, and 4 clips.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL EXHAUST MANIFOLD ASSEMBLY LH
1. Install a new gasket.
2. Install the exhaust manifold assembly LH by tightening the 6 nuts in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.
  
  Torque:
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
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.
  
  Torque:
  
  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.
  
  Torque:
  
  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.
  
  Torque:
  
  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.)
  
  Tech Tips
  
  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.
  
  Torque:
  
  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.)
  
  Tech Tips
  
  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.
  
  Torque:
  
  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.
  
  Torque:
  
  74 N*m { 750 kgf*cm, 54 ft.*lbf }

FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)

Remove the piece of cloth from the joint.
Using a hexagon wrench (6 mm), tighten the 6 bolts.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }
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.)
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.

Torque:

37 N*m { 375 kgf*cm, 27 ft.*lbf }

(B)

12.5 +/- 1.0 mm (0.492 +/- 0.039 in.)
Check that the center line of the bracket is at the right angle in the shaft axial direction.

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

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

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

Turn the propeller shaft several times by hand to stabilize the center support bearings.
Using a jack, raise and lower the differential to stabilize the differential mounting cushion.
Remove the transfer dynamic damper.
Using SST, measure the transfer installation angle (A) and front propeller shaft installation angle (B).

SST

09370-50010

No. 1 joint angle

(A) - (B) = -1.3° to -3.3°

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

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

SST: 09370-50010

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

Tech Tips

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)

Install the transfer dynamic damper.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }

INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator by tightening the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
2. Connect the air fuel ratio sensor connector and install the clamp.
INSTALL NO. 2 ENGINE 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-rings.
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 engine oil level dipstick guide with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
5. Install the engine oil level dipstick.
INSTALL RADIATOR RESERVE TANK ASSEMBLY
1. Install the radiator reserve tank assembly with the 2 bolts [A].
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
2. Connect the hose [B].
CONNECT NO. 1 RADIATOR HOSE
1. Connect the No. 1 radiator hose to the radiator.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
1. Install the air cleaner case with the 3 bolts.
  
  Torque:
  
  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.
  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. 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.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf, [A] }
  
  Torque:
  
  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.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the 2 vacuum hoses and harness clamps.
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 11 clips.
INSTALL BATTERY
Note

When reconnected the cable, some systems need to be initialized. Click here.
1. Install the battery tray and battery.
2. Install the battery clamp with the bolt and nut.
  
  Torque:
  
  Bolt
  
  5.4 N*m { 55 kgf*cm, 47 in.*lbf }
  
  Nut A
  
  5.4 N*m { 55 kgf*cm, 47 in.*lbf }
3. Connect the positive battery terminal, and tighten the nut.
  
  Torque:
  
  Nut B
  
  6.4 N*m { 64 kgf*cm, 57 in.*lbf }
4. Connect the negative battery terminal, and tighten the nut.
  
  Torque:
  
  Nut C
  
  6.4 N*m { 64 kgf*cm, 57 in.*lbf }

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the 2 cylinder block drain cock plugs.

Torque:

13 N*m { 130 kgf*cm, 9 ft.*lbf, for cylinder block drain cock plugs }
Loosen the air drain cock plug from the water inlet housing.
Loosen the air drain plug at the top of the radiator 3 or 4 turns.
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 }
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.

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.

Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.
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.
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.
Stop the engine and wait until the engine coolant cools down.
Add engine coolant to the FULL line on the radiator reservoir.

ADD ENGINE OIL

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

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)

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)

INSPECT FOR COOLANT LEAK
1. Connect the intelligent tester to the DLC3.
2. Turn the ignition switch on (IG).
3. Enter the following menus: Powertrain / Engine / Active Test / Control the Cooling Fan.
4. Check the operation of the cooling fan while operating it using the intelligent tester.
  
  If the cooling fan motor does not operate, check the cooling fan circuit Click here.
INSPECT FOR OIL LEAK
1. Start the engine.
2. Check for engine oil leaks from the oil cooler assembly and the union bolt.
INSPECT FOR EXHAUST GAS LEAK

If exhaust gas is leaking, repair the leak. Replace damaged or worn parts as necessary.
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.
CHECK ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait for 5 minutes.
2. Check that the engine oil level is between the L and F marks of the oil dipstick. If low, check for leakage and add oil up to the F mark.
  
  Note
  
  Do not add engine oil above the F mark.