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ENGINE ASSEMBLY INSTALLATION

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  1. Click here

    INSTALL ENGINE HANGER


    1. A01DRRME01

      Install 2 engine hangers with 4 bolts as shown in the illustration.

      33 N*m 337 kgf*cm 24 ft.*lbf
      Table 1. Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      Tip:
      No. 1 Engine Hanger 12281-31110
      No. 2 Engine Hanger 12282-31140
      Bolt 91671-C0830
  2. Click here

    REMOVE ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

    3. Place the engine onto a work bench.

  3. Click here

    INSTALL ENGINE ASSEMBLY


    1. Attach an engine sling device and hang the engine with a chain block.

    2. Slowly lower the engine into the engine compartment.

    3. A01DT50E02

      Install the front engine mounting insulator LH with the 3 nuts.

      for nut A
      72 N*m 734 kgf*cm 53 ft.*lbf
      for nut B
      40 N*m 408 kgf*cm 30 ft.*lbf

    4. Install the front engine mounting insulator RH with the 3 nuts.

      for nut A
      72 N*m 734 kgf*cm 53 ft.*lbf
      for nut B
      40 N*m 408 kgf*cm 30 ft.*lbf
      A01DS07E01
      Tip:

      For RHD vehicles only:

      When tightening the nut closer to the rear of the vehicle for the engine mounting bracket on the right side, make sure that the claw (stopper) of the bolt does not protrude past the rear edge of the bracket.

      Table 2. Text in Illustration
      *1 Claw (Stopper)
      *2 Bracket
      *a Correct
      *b Incorrect

    5. Remove the 2 engine hangers and 4 bolts.

  4. Click here

    INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. Using SST, hold the crankshaft.

      09213-54015 91651-60855
      09330-00021
    2. A01DUT4E01

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

      Table 3. Text in Illustration
      *1 Front Spacer
      *2 Drive Plate and Ring Gear
      *3 Rear Spacer
      A01DQPB Automatic Transmission Side
      Tip:

      As the front spacer, drive plate and ring gear and rear spacer are not reversible, be sure to install it in the direction shown in the illustration.

    3. Apply adhesive to 2 or 3 threads at the end of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    4. A01DS46E01

      Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

      83 N*m 846 kgf*cm 61 ft.*lbf
      Note:

      Do not start the engine for at least 1 hour after installing.

  5. Click here

    INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. Using SST, hold the crankshaft.

      09213-54015 91651-60855
      09330-00021

    2. Temporarily install the flywheel with 8 new bolts.

    3. Install and tighten the 8 bolts uniformly in several steps.

      30 N*m 306 kgf*cm 22 ft.*lbf

    4. Mark the top of the bolts with paint.

    5. Tighten the 8 bolts 90° in the same sequence.

    6. Check that the paint marks are now at a 90° angle to the top.

  6. Click here

    INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)


    1. A01DN0RE01

      Insert SST into the clutch disc, and then install SST and the clutch disc together to the flywheel.

      09301-00110
      Table 4. Text in Illustration
      A01DQPB Flywheel Side
      Note:

      Be sure to install the clutch disc so that it is facing in the correct direction.

  7. Click here

    INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. Align the matchmark on the clutch cover with the one on the flywheel.

      Table 5. Text in Illustration
      *a Matchmark

    2. Following the order shown in the illustration, tighten the 6 bolts, starting with the bolt located near the knock pin at the top.

      09301-00110
      19 N*m 194 kgf*cm 14 ft.*lbf
      Tip:

      • Following the order in the illustration, tighten the bolts evenly one at a time.

      • Move SST up and down, and right and left lightly after checking that the clutch disc assembly is in the center, and then tighten the bolts.

  8. Click here

    INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

      09333-00013
      Maximum misalignment
      1.3 mm (0.0512 in.)

      If the misalignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.

  9. Click here

    CONNECT OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. Connect the oil cooler tube with the bolt.

      14 N*m 143 kgf*cm 10 ft.*lbf
  10. Click here

    CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Connect the suction hose with the bolt.

      7.8 N*m 80 kgf*cm 69 in.*lbf
  11. Click here

    INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for Manual Transmission)


    1. Install the engine No. 1 mounting insulator rear with the 4 bolts.

      65 N*m 663 kgf*cm 48 ft.*lbf
  12. Click here

    INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for Automatic Transmission)


    1. Install the rear engine mounting insulator to the transmission with the 4 bolts.

      65 N*m 663 kgf*cm 48 ft.*lbf

    2. Install the rear engine mounting heat insulator to the engine mounting insulator with the bolt.

      12 N*m 122 kgf*cm 9 ft.*lbf
  13. Click here

    INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Install the manual transmission to the vehicle (Click here).

  14. Click here

    INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Install the automatic transmission to the vehicle (Click here).

  15. Click here

    INSTALL PROPELLER SHAFT ASSEMBLY


    1. Align the matchmarks on the propeller shaft flange and differential flange.

    2. Install the propeller shaft assembly with the 4 washer, 4 bolts and 4 nuts.

      88 N*m 899 kgf*cm 65 ft.*lbf

    3. Align the matchmarks on the propeller shaft flange and transfer flange.

    4. Install the propeller shaft assembly with the 4 washers and 4 nuts.

      88 N*m 899 kgf*cm 65 ft.*lbf
  16. Click here

    INSTALL FRONT PROPELLER SHAFT ASSEMBLY


    1. Align the matchmarks on the yoke and differential flange.

    2. Install the propeller shaft assembly with the 4 washers, 4 bolts and 4 nuts.

      88 N*m 899 kgf*cm 65 ft.*lbf

    3. Align the matchmarks on the yoke and transfer flange.

    4. Install the propeller shaft assembly with the 4 washers and 4 nuts.

      88 N*m 899 kgf*cm 65 ft.*lbf
  17. Click here

    CONNECT NO. 1 AND NO. 2 FUEL PIPES


    1. Connect the No. 1 and No. 2 fuel pipes (Click here).

    2. Install the No. 2 fuel pipe clamp to the fuel tube connector.

  18. Click here

    CONNECT HEATER WATER HOSE ASSEMBLY


    1. A01DN5IE01

      w/ Rear heater:

      Connect the 4 hoses and heater water hose.

      Table 6. Text in Illustration
      *A w/o Rear Heater
      *B w/ Rear Heater
      *a Top
      *b LH
      *c RR
      Tip:

      The direction of the hose clamp is indicated in the illustration.

    2. w/o Rear heater

      Connect the 2 hoses and heater water hose.

      Tip:

      The direction of the hose clamp is indicated in the illustration.

  19. Click here

    CONNECT ENGINE WIRE


    1. Connect the ECM connector.


      1. A01DR4QE01

        Attach the grommet to the wire harness support.

        Table 7. Text in Illustration
        *1 Grommet
        *2 Wire Harness Support

      2. Pass the wire harness into the vehicle and install the wire harness support.

      3. A01DQG8E01

        Connect the 9 connectors and attach the clamp.

        Table 8. Text in Illustration
        *A for LHD
        *B for RHD

    2. Install the glove compartment door (Click here).

    3. A01DM9D

      Connect the connector and install the bolt.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  20. Click here

    INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)


    1. A01DOOL

      Turn the crankshaft to gain access to the installation locations of the 6 torque converter clutch setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

      48 N*m 489 kgf*cm 35 ft.*lbf
      Note:

      Install the black bolt first, and then the 5 silver bolts.

    2. Install the flywheel housing side cover.

  21. Click here

    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 wire with the bolt and nut.

      for bolt
      8.0 N*m 82 kgf*cm 71 in.*lbf
      for nut
      9.8 N*m 100 kgf*cm 87 in.*lbf

    3. Close the terminal cap.

    4. Connect the starter connector.

    5. Connect the ground wire with the bolt.

      13 N*m 133 kgf*cm 10 ft.*lbf
  22. Click here

    INSTALL GENERATOR ASSEMBLY


    1. Install the generator bracket to the generator with the bolt.

      20 N*m 204 kgf*cm 15 ft.*lbf

    2. Install the generator with the 2 bolts.

      43 N*m 438 kgf*cm 32 ft.*lbf

    3. Install the generator bracket with the bolt.

      20 N*m 204 kgf*cm 15 ft.*lbf

    4. Connect the wire harness clamp.

    5. Install the wire harness with the 2 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    6. Connect the generator connector to the generator.

    7. Connect the generator wire with the nut.

      9.8 N*m 100 kgf*cm 87 in.*lbf

    8. Close the terminal cap.

  23. Click here

    INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with the bolt.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    2. Attach the clamp.

  24. Click here

    INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01DRL8E01

      Install a new gasket to the cylinder head.

      Table 9. Text in Illustration
      *1 Protrusion
      A01DQPB Front
      Note:

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. A01DNGSE01

      Tighten the 6 nuts in the sequence shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 10. Text in Illustration
      *1 w/ Secondary Air Injection System *2 w/o Secondary Air Injection System

    4. Connect the air fuel ratio sensor connector.

  25. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      13 N*m 133 kgf*cm 10 ft.*lbf
  26. Click here

    INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A01DS0TE01

      Install 2 new gaskets to the No. 2 air tube.

      Table 11. Text in Illustration
      *1 New Gasket
      *2 No. 2 Air Tube

    2. Install the No. 2 air tube with the 2 bolts and 2 nuts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  27. Click here

    INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      40 N*m 408 kgf*cm 30 ft.*lbf
  28. Click here

    INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01DMZ6E01

      Install a new gasket to the cylinder head.

      Table 12. Text in Illustration
      *1 Protrusion
      A01DQPB Front
      Note:

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. A01DMLBE01

      Tighten the 6 nuts in the sequence shown in the illustration.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 13. Text in Illustration
      *1 w/ Secondary Air Injection System *2 w/o Secondary Air Injection System

    4. Connect the air fuel ratio sensor connector.

  29. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

      13 N*m 133 kgf*cm 10 ft.*lbf
  30. Click here

    CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)


    1. for Power tilt and power telescopic steering column:

      Connect the No. 2 steering intermediate shaft (Click here).

    2. for Manual tilt and manual telescopic steering column:

      Connect the No. 2 steering intermediate shaft (Click here).

  31. Click here

    INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A01DQXXE01

      Install 2 new gaskets to the air tube.

      Table 14. Text in Illustration
      *1 New Gasket
      *2 Air Tube

    2. Install the air tube with the 2 bolts and 2 nuts.

      10 N*m 102 kgf*cm 7 in.*lbf
  32. Click here

    INSTALL NO. 2 MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      40 N*m 408 kgf*cm 30 ft.*lbf
  33. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the front exhaust pipe (Click here).

  34. Click here

    INSTALL IDLER PULLEY ASSEMBLY (w/o Air Conditioning System)


    1. Install the idler pulley with the 3 bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf
  35. Click here

    INSTALL COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Install the stud bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Temporarily install the cooler compressor assembly with the 3 bolts and nut.

    3. Tighten the 3 bolts and nut in the sequence shown in the illustration.

      for bolt
      25 N*m 255 kgf*cm 18 ft.*lbf
      for nut
      25 N*m 255 kgf*cm 18 ft.*lbf

    4. Connect the connector.

  36. Click here

    CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Remove the attached vinyl tape from the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose.

    4. A01DR3EE04

      Connect the suction hose to the cooler compressor with the 2 bolts.

      for bolt C
      7.8 N*m 80 kgf*cm 69 in.*lbf
      for bolt D
      9.8 N*m 100 kgf*cm 87 in.*lbf
      Table 15. Text in Illustration
      *A except Model Code GRJ150L-GKFEKV, GRJ150L-GKAEKV
      *B Model Code GRJ150L-GKFEKV, GRJ150L-GKAEKV
  37. Click here

    CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Remove the attached vinyl tape from the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose.

    4. Connect the discharge hose to the cooler compressor with the bolt.

      9.8 N*m 100 kgf*cm 87 in.*lbf
  38. Click here

    CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump with the 2 bolts.

      43 N*m 438 kgf*cm 32 ft.*lbf

    2. Attach the 2 wire harness clamps.

    3. Connect the 2 connectors.

  39. Click here

    INSTALL FAN AND GENERATOR V BELT


    1. A01DOSEE01

      Set the V belt onto every part.

      Table 16. Text in Illustration
      *1 Vane Pump
      *2 Water Pump
      *3 No. 2 Idler
      *4 Generator
      *5 Cooler Compressor or Idler Pulley
      *6 No. 1 Idler
      *7 Crankshaft
      *8 V-ribbed Belt Tensioner

    2. While turning the belt tensioner counterclockwise, remove the pin.

      Note:

      Make sure that the V belt is properly installed to each pulley.

    3. Check that the belt fits properly in the ribbed grooves.

      Tip:

      Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

  40. Click here

    INSTALL INTAKE AIR SURGE TANK


    1. Install a new gasket to the intake air surge tank.

    2. A01DQ0IE01

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

      28 N*m 286 kgf*cm 21 ft.*lbf
      Table 17. Text in Illustration
      *1 Nut

    3. Install the No. 1 surge tank stay with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    4. Attach the wire harness clamp.

    5. Install the No. 2 surge tank stay with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf

    6. Install the throttle body bracket with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
    7. A01DNIQE01

      Connect the No. 1 ventilation hose.

    8. Connect the No. 1 vacuum switching valve connector.

    9. Connect the No.1 fuel feed hose.

      Table 18. Text in Illustration
      *a Front
      *b Matchmark
      *c Top
      Tip:

      Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

    10. A01DTUJE01

      Connect the throttle body connector.

    11. Connect the No. 4 water by-pass hose.

    12. Connect the No. 5 water by-pass hose.

      Tip:

      Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

    13. Connect the 2 heater hose clamps.

      Table 19. Text in Illustration
      *a Front
      *b Matchmark
      *c RH
  41. Click here

    INSTALL AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)


    1. A01DS57E01

      for Bank 1 Side:

      Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

      Table 20. Text in Illustration
      *1 Rib
      *2 Paint Mark
      *a RH Side
      *b Upper
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

    2. A01DS7EE01

      for Bank 2 Side:

      Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

      Table 21. Text in Illustration
      *1 Paint Mark
      *2 Rib
      *a Upper
      *b LH Side
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Install the 3 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
  42. Click here

    INSTALL RADIATOR ASSEMBLY


    1. A01DR7J

      Insert the radiator bracket hooks into the radiator support holes.

    2. Install the radiator with the 4 bolts.

      18 N*m 184 kgf*cm 13 ft.*lbf
    3. A01DO04E01

      for Automatic Transmission:

      Connect the 2 oil cooler hoses.

      Table 22. Text in Illustration
      *A w/ Warmer
      *B w/ Air Cooled Transmission Oil Cooler
      *a Upper
      Tip:

      Make sure the direction of the hose clamp is as shown in the illustration.

  43. Click here

    INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Place the shroud together with the coupling fan between the radiator and engine.

      Note:

      Be careful not to damage the radiator core.

    3. A01DMZAE01

      Align the paint marks on the heads of the water pump stud bolts with the paint marks of the same color on the outer edge of the fluid coupling flange and install the fluid coupling to the water pump.

      Table 23. Text in Illustration
      *1 Paint Mark

    4. Temporarily install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

    5. A01DQ2X

      Attach the claws of the shroud to the radiator as shown in the illustration.

    6. Install the shroud with the 2 bolts.

      5.0 N*m 51 kgf*cm 44 in.*lbf

    7. Install the fan and generator V-belt (Click here).

    8. Tighten the 4 nuts of the fluid coupling fan.

      21 N*m 214 kgf*cm 15 ft.*lbf
  44. Click here

    CONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)


    1. A01DUNE

      Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

      5.5 N*m 56 kgf*cm 49 in.*lbf
  45. Click here

    CONNECT OIL COOLER TUBE (w/ Warmer)


    1. A01DN6Y

      Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

      5.5 N*m 56 kgf*cm 49 in.*lbf
  46. Click here

    INSTALL RADIATOR RESERVOIR


    1. Install the radiator reservoir with the 3 bolts.

      5.0 N*m 51 kgf*cm 44 in.*lbf

    2. Connect the reservoir hose to upper side of the radiator tank upper.

  47. Click here

    INSTALL NO. 2 RADIATOR HOSE


    1. A01DMV1E01

      Connect the No. 2 radiator hose so that its paint mark aligns with the radiator protrusion as shown in the illustration.

      Table 24. Text in Illustration
      *1 Paint Mark
      *2 Protrusion
      *a Upper
      Tip:

      • Make sure the paint mark of the No. 1 air injection system hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

    2. A01DSA8E01

      Connect the No. 2 radiator hose so that its paint mark aligns with the water inlet housing protrusion as shown in the illustration.

      Table 25. Text in Illustration
      *1 Paint Mark
      *2 Protrusion
      *a Front
      *b Upper
      Tip:

      • Make sure the paint mark of the No. 1 air injection system hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

  48. Click here

    INSTALL NO. 1 RADIATOR HOSE


    1. A01DP53E01

      Connect the No. 1 radiator hose to the water inlet housing shown in the illustration labeled A.

      Table 26. Text in Illustration
      *1 Paint Mark
      *2 Protrusion
      *a Front
      *b Upper
      Tip:

      • Make sure the paint mark of the No. 1 radiator hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

    2. Connect the No. 1 radiator hose so that its paint mark aligns with the radiator protrusion as shown in the illustration labeled B.

      Tip:

      • Make sure the paint mark of the No. 1 radiator hose is facing upward.

      • Make sure the direction of the hose clamp is as shown in the illustration.

  49. Click here

    INSTALL RADIATOR SIDE DEFLECTOR LH


    1. Attach the 3 claws.

    2. Install the deflector with the clip.

  50. Click here

    INSTALL RADIATOR SIDE DEFLECTOR RH


    1. Attach the 3 claws.

    2. Install the deflector with the clip.

  51. Click here

    INSTALL UPPER FRONT BUMPER RETAINER


    1. Install the retainer with the 3 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  52. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

      12 N*m 122 kgf*cm 9 ft.*lbf

    2. Attach the wire harness clamp.

    3. Install the air cleaner filter element.

  53. Click here

    INSTALL AIR CLEANER CAP AND HOSE


    1. A01DTUYE01

      Install the air cleaner cap and hose.

      Table 27. Text in Illustration
      *a Top
      *b Front
      *c RH
      *d Align cutout portion of hose with protrusion of throttle
      *e Paint Mark

      1. Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.

        5.0 N*m 51 kgf*cm 44 in.*lbf

      2. Tighten the clamp.

        5.0 N*m 51 kgf*cm 44 in.*lbf

      3. Attach the 4 clamps and connect the ventilation hose, vacuum hose and mass air flow meter connector.

        Tip:

        The direction of the hose clamp is indicated in the illustration.

  54. Click here

    INSTALL FRONT BUMPER COVER


    1. Install the front bumper cover (Click here).

  55. Click here

    INSTALL V-BANK COVER


    1. A01DQA1E01

      Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

      Table 28. Text in Illustration
      *1 Pin
      *2 Hook
  56. Click here

    INSTALL BATTERY TRAY

  57. Click here

    INSTALL BATTERY

  58. Click here

    INSTALL BATTERY HOLD DOWN CLAMP


    1. Install the battery hold down clamp with the 2 nuts.

      6.0 N*m 61 kgf*cm 53 in.*lbf
  59. Click here

    CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  60. Click here

    ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

      13 N*m 130 kgf*cm 9 ft.*lbf

    2. Tighten the radiator drain cock plug by hand.

    3. Add engine coolant.

      Standard Capacity
      Item Specified Condition
      for Automatic Transmission w/o Warmer w/o Rear Heater 10.5 liters (11.1 US qts, 9.2 Imp. qts)
      w/ Rear Heater 12.3 liters (13.0 US qts, 10.8 Imp. qts)
      w/ Warmer w/o Rear Heater 11.0 liters (11.6 US qts, 9.7 Imp. qts)
      w/ Rear Heater 12.8 liters (13.5 US qts, 11.3 Imp. qts)
      for Manual Transmission w/o Rear Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Rear Heater 12.5 liters (13.2 US qts, 11.0 Imp. qts)
      Note:

      Do not substitute plain water 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 consists of a combination of low phosphates and organic acids).

      • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

    4. Slowly pour coolant into the radiator reservoir until it reaches the F line.

    5. Install the reservoir cap.

    6. Install the radiator cap.*1

    7. Start the engine and stop it immediately.*2

    8. Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

    9. Repeat steps *1, *2 and *3 until the coolant level does not decrease.

      Tip:

      Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

    10. Install the radiator cap.*4

    11. Set the air conditioning as follows.*5

      Item Condition
      Fan speed Any setting except off
      Temperature Toward WARM
      Air conditioning switch Off

    12. Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

      CAUTION:

      • Wear protective gloves. Hot areas on the parts may injure your hands.

      • Be careful of the fan.

      • Be careful as the engine, radiator and radiator hoses are hot and can cause burns.

      Note:

      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Do not start the engine when there is no coolant in the radiator reservoir.

      • Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      Tip:

      • Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.

      • The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.

    13. Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

      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.

    14. If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

    15. If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

      If the coolant level is below the F line, repeat steps *4 through *8.

      If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

  61. Click here

    ADD ENGINE OIL


    1. Add fresh oil.

      Standard Engine Oil
      Oil Grade Oil Viscosity (SAE)
      API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil

      0W-20

      5W-20

      5W-30

      10W-30
      API grade SL, SM or SN multigrade engine oil

      15W-40

      20W-50
      Standard Oil Capacity (w/o Oil Cooler)
      Item Specified Condition
      Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 Imp. qts)
      Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 Imp. qts)
      Dry fill 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Standard Oil Capacity (w/ Oil Cooler)
      Item Specified Condition
      Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 Imp. qts)
      Drain and refill with oil filter change 6.2 liters (6.6 US qts, 5.5 Imp. qts)
      Dry fill 7.1 liters (7.5 US qts, 6.2 Imp. qts)
  62. Click here

    INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Install the cowl top ventilator louver (Click here).

  63. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  64. Click here

    INSPECT FOR FUEL LEAK


    1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON and turn the intelligent tester on.

        Note:

        Do not start the engine.

      3. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

      4. Check that there are no leaks from the fuel system.

        If there are fuel leaks, repair or replace parts as necessary.

      5. Turn the ignition switch off.

      6. Disconnect the intelligent tester from the DLC3.

  65. Click here

    INSPECT FOR ENGINE OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the area that was worked on.

  66. Click here

    INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  67. Click here

    CHECK ENGINE OIL LEVEL


    1. Warm up the engine, and then stop the engine and wait for 5 minutes.

    2. Check that the engine oil level is between the low level and full level marks on the dipstick.

      If low, check for leakage and add oil up to the full level mark.

      Note:

      Do not fill engine oil above the full level mark.

  68. Click here

    INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  69. Click here

    INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Install the front No. 1 fender apron to frame seal with the 5 clips.

  70. Click here

    INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH


    1. Install the front No. 1 fender apron to frame seal with the 5 clips.

  71. Click here

    INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal with the 5 clips.

  72. Click here

    INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal with the 5 clips.

  73. Click here

    INSTALL REAR ENGINE UNDER COVER ASSEMBLY


    1. Install the rear engine under cover with the 4 bolts.

      29 N*m 296 kgf*cm 21 ft.*lbf
  74. Click here

    INSTALL TRANSMISSION UNDER COVER


    1. Install the transmission under cover with the 2 bolts.

      29 N*m 296 kgf*cm 21 ft.*lbf
  75. Click here

    INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A01DQWQ

      Hook the engine under cover to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

      29 N*m 296 kgf*cm 21 ft.*lbf
  76. Click here

    INSTALL FRONT BUMPER COVER LOWER


    1. Install the front bumper cover lower with the 5 bolts and clip.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  77. Click here

    PERFORM RESET MEMORY (for Automatic Transmission)


    1. Perform the Reset Memory procedures (Click here).

  78. Click here

    INSPECT IGNITION TIMING

    Note:

    • Turn all electrical systems off.


    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Check that the ignition timing advances immediately when the engine speed is increased.

    3. A01DR2AE05

      When not using the intelligent tester:


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

        09843-18040
        Table 29. Text in Illustration
        *a Front view of DLC3
        Note:

        Be sure not to improperly connect the terminals. This may damage the engine.

      2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

        Note:

        • Use a timing light that detects primary signals.


        • After the inspection, be sure to wrap the wire harness with tape.

      3. A01DQOIE01

        Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Remove SST from the DLC3.

      5. Inspect the ignition timing during idling.

        Standard ignition timing
        7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

      6. Disconnect the timing light from the engine.

  79. Click here

    INSPECT ENGINE IDLE SPEED

    Note:

    • Turn all the electrical systems off.


    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Engine Speed.

      3. Inspect the engine idle speed.

        Standard idle speed
        690 to 790 rpm (transmission in neutral and A/C switch off)
    3. A01DR2AE06

      When not using the intelligent tester:


      1. Connect SST to terminal 9 (TAC) of the DLC3.

        09843-18040
        Table 30. Text in Illustration
        *a Front view of DLC3

      2. Race the engine at 2500 rpm for approximately 90 seconds.

      3. Inspect the engine idle speed.

        Standard idle speed
        690 to 790 rpm (transmission in neutral and A/C switch off)
  80. Click here

    INSPECT CO/HC

    Tip:

    This check is to determine whether or not the idle CO/HC concentration complies with regulations.


    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 (1.31 ft) into the tailpipe during idling.

    4. Immediately check the CO/HC concentration during idling and/or at 2500 rpm.

      Tip:

      When carrying out the 2 tests (idling and 2500 rpm), the measurement orders are prescribed by the applicable local regulations.

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


      1. Check the A/F sensor operation (Click here) and heated oxygen sensor operation (Click here).

      2. See the table below for possible causes, and then inspect and correct the corresponding causes if necessary.

        CO HC Symptom Causes
        Normal High Rough idling

        1. Faulty ignition:


          • Incorrect timing

          • Plugs are contaminated or shorted, or plug gaps are incorrect

        3. Incorrect valve clearance

        4. Leaky intake and exhaust valves

        5. Leaky cylinders
        Low High

        Rough idling

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • Ventilation hoses

          • Intake manifold

          • Throttle body

        3. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air filter

        2. Plugged PCV valve

        3. Faulty SFI system:


          • Faulty pressure regulator

          • Defective engine coolant temperature sensor

          • Faulty mass air flow meter

          • Faulty ECM

          • Faulty injectors

          • Faulty throttle position sensor
  81. Click here

    INSTALL HOOD SUB-ASSEMBLY


    1. A01DMB9

      Install the hood with the 8 bolts.

      for bolt A
      13 N*m 133 kgf*cm 10 ft.*lbf
      for bolt B
      18 N*m 184 kgf*cm 13 ft.*lbf
      Table 31. Text in Illustration
      A01DQPB Bolt A
      A01DMKT Bolt B

    2. Connect the washer nozzle hose.

  82. Click here

    ADJUST HOOD SUB-ASSEMBLY


    1. Adjust the hood position.


      1. A01DQ0Z

        Loosen the 4 hinge bolts on the hood.

      2. Move the hood and adjust the clearance between the hood and front fender.

      3. Tighten the 4 hinge bolts on the hood.

        13 N*m 133 kgf*cm 10 ft.*lbf

    2. Adjust the height of the front end of the hood using the cushion rubbers.


      1. A01DQ6D

        Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.

        Tip:

        Raise or lower the front end of the hood by turning the 2 cushion rubbers.

    3. Adjust the hood lock.


      1. A01DP94

        Loosen the 3 bolts.

      2. Adjust the hood lock and tighten the 3 bolts.

        7.5 N*m 76 kgf*cm 66 in.*lbf

      3. Check that the striker can smoothly engage with the hood lock.

  83. Click here

    CHARGE REFRIGERANT (w/ Air Conditioning System)

    09985-20010 09985-02130 09985-02150 09985-02090 09985-02110 09985-02010 09985-02050 09985-02060 09985-02070

    1. Perform vacuum purging using a vacuum pump.

    2. A01DN0ZE19

      Charge refrigerant HFC-134a (R134a).

      Table 32. Standard
      Model Code Air Conditioning Type Cool Box Refrigerant Charging Amount
      Except the model codes below w/o Rear Cooler w/ Cool Box 600 +/-30 g (21.2 +/-1.1 oz.)
      w/o Cool Box 550 +/-30 g (19.3 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 800 +/-30 g (28.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)

      w/ Rear Cooler

      for Cold Area Specification Vehicles

      		 w/o Cool Box 720 +/-30 g (25.3 +/-1.1 oz.)

      TRJ150L-GKMEKV

      TRJ150L-GKPEKV

      TRJ155L-GJPEKV

      GRJ150L-GKFEKV

      GRJ150L-GKAEKV

      KDJ150L-GKFEYV

      KDJ150L-GKAEYV

      		 w/o Rear Cooler w/ Cool Box 600 +/-30 g (21.2 +/-1.1 oz.)
      w/o Cool Box 550 +/-30 g (19.3 +/-1.1 oz.) or 600 +/-30 g (21.2 +/-1.1 oz.) *1
      w/ Rear Cooler w/ Cool Box 800 +/-30 g (28.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)

      *1: For vehicles with the 2TR-FE engine which have neither the rear cooler nor cool box, the refrigerant charging amount changes based on region.

      Note:

      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  84. Click here

    WARM UP ENGINE (w/ Air Conditioning System)


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note:

      Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  85. Click here

    CHECK FOR REFRIGERANT GAS LEAK (w/ Air Conditioning System)


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A01DM2DE34

      Using a halogen leak detector, check the refrigerant line for leakage.

      Table 33. Text in Illustration
      *1 Halogen Leak Detector
      *a Check for Leakage

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.