ENGINE ASSEMBLY (w/o DPF) INSTALLATION

INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

Text in Illustration

*a

Matchmark

1. Align the matchmarks on the clutch cover and flywheel.

2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

   SST

   09301-00110

   Torque:

   19 N*m  { 194 kgf*cm, 14 ft.*lbf }

   Tech Tips

   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.

INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

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

   SST

   09333-00013

   Maximum non-alignment
   0.5 mm (0.0196 in.)

   
   

   • If the is alignment is more than the maximum, use SST to adjust the diaphragm spring tip alignment.

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

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

   Torque:

   48 N*m  { 489 kgf*cm, 35 ft.*lbf }

   Tech Tips

   If it is difficult to reach the setting bolts with the wrench, raise or lower the transmission jack until there is sufficient space for the wrench.

   Note

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

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.

   Torque:

   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.

   Torque:

   88 N*m  { 899 kgf*cm, 65 ft.*lbf }

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.

   Torque:

   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.

   Torque:

   88 N*m  { 899 kgf*cm, 65 ft.*lbf }

INSTALL FRONT EXHAUST PIPE ASSEMBLY

1. Install a new gasket and the front exhaust pipe to the exhaust manifold with 3 new nuts.

   Torque:

   54 N*m  { 554 kgf*cm, 40 ft.*lbf }

INSTALL STARTER ASSEMBLY (for 2.2 kW Type)

1. for Manual Transmission:

   Install the starter assembly with the bolt and nut.

   Torque:

   68 N*m  { 693 kgf*cm, 50 ft.*lbf }

2. for Automatic Transmission:

   Install the starter assembly with the bolt and 2 nuts.

   Torque:

   68 N*m  { 693 kgf*cm, 50 ft.*lbf }

3. Connect the starter wire with the nut.

   Torque:

   9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

4. Connect the starter connector.

5. Install the terminal cap.

INSTALL STARTER ASSEMBLY (for 2.7 kW Type)

1. for Manual Transmission:

   Install the starter assembly with the bolt and nut.

   Torque:

   68 N*m  { 693 kgf*cm, 50 ft.*lbf }

2. for Automatic Transmission:

   Install the starter assembly with the bolt and 2 nuts.

   Torque:

   68 N*m  { 693 kgf*cm, 50 ft.*lbf }

3. Connect the starter wire with the nut.

   Torque:

   21 N*m  { 215 kgf*cm, 16 ft.*lbf }

4. Connect the starter connector.

5. Install the terminal cap.

INSTALL STARTER ASSEMBLY (for 3.0 kW Type)

1. Install the starter assembly with the bolt and 2 nuts.

   Torque:

   68 N*m  { 693 kgf*cm, 50 ft.*lbf }

2. Connect the starter wire with the nut.

   Torque:

   21 N*m  { 215 kgf*cm, 16 ft.*lbf }

3. Connect the starter connector.

4. Install the terminal cap.

CONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY

INSTALL COMPRESSOR OUTLET ELBOW

1. Install the compressor outlet elbow with the 2 bolts and tighten the hose clamp.

   Torque:

   for bolt

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   for hose clamp

   6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

2. Install the wire harness bracket with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

3. Attach the 3 wire harness clamps.

INSTALL AIR CLEANER CASE SUB-ASSEMBLY

1. Install the air cleaner case sub-assembly with the 3 bolts.

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

1. Attach the 4 clamps to install the air cleaner cap sub-assembly.

2. except Cold Area Specification Vehicles:

   Attach the 2 clamps and connect the mass air flow meter connector.

3. for Cold Area Specification Vehicles:

   Attach the 3 clamps and connect the mass air flow meter connector.

INSTALL NO. 1 AIR CLEANER HOSE

Text in Illustration

*1	No. 1 Air Cleaner Hose	*2	Compressor Inlet Elbow
*3	Air Cleaner Cap	-	-
*a	Upper Side	*b	Front Side of Vehicle
*c	Protrusion	*d	Groove

1. Install the No. 1 air cleaner hose with the 2 hose clamps.

   Note

   
   

   • When installing the No. 1 air cleaner hose, align the protrusion of the No. 1 air cleaner hose with the protrusion of the compressor inlet elbow as shown in the illustration.

   • When installing the No. 1 air cleaner hose, align the groove of the No. 1 air cleaner hose with the protrusion of the air cleaner cap as shown in the illustration.

2. Tighten the 2 hose clamps.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

   Note

   When tightening the 2 hose clamps, make sure that they are positioned as shown in the illustration.

INSPECT MANUAL TRANSMISSION OIL (for Manual Transmission)

ADD ENGINE OIL

1. Add new engine oil.

   Standard Oil Grade
   Item Oil Grade Oil Viscosity (SAE) w/ DPF ACEA C2 (Using engine oil other than ACEA C2 may damage catalytic converter) - 0W-30 - 5W-30 (0W-30 is best choice for fuel economy and good starting in cold weather) w/o DPF G-DLD1, API CF-4, CF or ACEA B1 (You may also use API CE or CD) - 5W-30 - 10W-30 - 15W-40 - 20W-50

   Standard Capacity
   Item Specified Condition Drain and refill without oil filter change 6.7 liters (7.1 US qts, 5.9 Imp. qts) Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 Imp. qts) Dry fill 7.5 liters (7.9 US qts, 6.6 Imp. qts)

2. Install the oil filler cap.

BLEED AIR FROM FUEL SYSTEM

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Tighten the cylinder block drain cock plug.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

3. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

   Standard Capacity
   Item Specified Condition for Automatic Transmission w/ Rear Heater 14.9 liters (15.7 US qts, 13.1 Imp. qts) w/o Rear Heater 13.1 liters (13.8 US qts, 11.5 Imp. qts) for Manual Transmission w/ Rear Heater 15.0 liters (15.8 US qts, 13.2 Imp. qts) w/o Rear Heater 13.2 liters (13.9 US qts, 11.6 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).

   • Please contact your TOYOTA dealer for further details.

   • for Cold Area Specification Vehicles:

     Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

   Note

   Never use water as a substitute for engine coolant.

4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

   If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

5. Install the radiator reservoir cap.

6. Using a wrench, install the vent plug.

   Torque:

   2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

7. 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.

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

   3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

      CAUTION:

      When pressing the radiator hoses:

      
      

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fan.

   4. Stop the engine and wait until the coolant cools down to ambient temperature.

      CAUTION:

      Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

8. After the coolant cools down, check that the coolant level is at the FULL line.

   If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

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 123 kPa (1.3 kgf/cm², 18 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 head.

INSPECT FOR OIL LEAK

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

INSPECT FOR FUEL LEAK

1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

3. Disconnect the return hose from the common rail.

4. Start the engine and check for fuel leaks from the return pipe.

   If there is fuel leakage, replace the common rail.

5. Connect the intelligent tester to the DLC3.

6. Start the engine and turn the intelligent tester on.

7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

9. Check that there are no leaks from any part of the fuel system.

   Note

   A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

   If there is fuel leakage, repair or replace parts as necessary.

10. Reconnect the return hose to the common rail.

INSPECT FOR EXHAUST GAS LEAK

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

INSPECT ENGINE IDLE SPEED AND MAXIMUM SPEED

1. Connect the intelligent tester to the DLC3.

2. 

   Text in Illustration

   *a	Front view of DLC3

   If a tester is not available, connect the tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

   SST

   09843-18040

3. Inspect the idle speed.

   Tech Tips

   
   

   • Make sure that the engine is warmed up.

   • Make sure that the A/C switch is off.

   • w/ DPF:

     Make sure that PM regeneration is not being performed.

   
   

   1. Start the engine and measure the idle speed.

      Idle Speed
      Item Specified Condition for Automatic Transmission 650 to 750 rpm for Manual Transmission w/ DPF 650 to 750 rpm w/o DPF 610 to 710 rpm

4. Inspect the maximum speed.

   
   

   1. Start the engine.

   2. Fully depress the accelerator pedal.

   3. Measure the maximum speed.

      Maximum Speed
      Item Specified Condition w/ DPF 4500 to 4700 rpm w/o DPF 4450 to 4750 rpm

5. If the tester probe of a tachometer is connected to the DLC3, disconnect the tester probe together with SST from terminal 9 of the DLC3.

6. Disconnect the intelligent tester from the DLC3.

INSPECT ENGINE OIL LEVEL

1. Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.

   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.