ENGINE ASSEMBLY INSTALLATION

INSTALL ENGINE HANGER

INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

INSTALL STARTER HOLE INSULATOR

INSTALL OIL COOLER TUBE SUB-ASSEMBLY

INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

1. Install the clamp to the steering column hole cover sub-assembly.

2. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering column.

3. Install the bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

4. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks on the No. 2 steering intermediate shaft assembly and power steering link.

5. Install the bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

INSTALL WATER PUMP ASSEMBLY WITH MOTOR AND BRACKET

CONNECT GENERATOR CABLE (for LHD)

CONNECT MOTOR CABLE (for LHD)

INSTALL INVERTER TERMINAL COVER (for LHD)

CONNECT GENERATOR CABLE (for RHD)

CONNECT MOTOR CABLE (for RHD)

INSTALL INVERTER TERMINAL COVER (for RHD)

CONNECT NO. 3 FUEL HOSE

1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.

2. Install the fuel pipe clamp.

   Note

   
   

   • Check that there is no damage or foreign objects on the connected part of the fuel pipe.

   • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

CONNECT NO. 1 FUEL HOSE

1. Push in the tube connector to the pipe until the tube connector makes a "click" sound.

2. Push down on the retainer to lock it in place.

   Note

   
   

   • Check that there is no damage or foreign objects on the connected part of the fuel pipe.

   • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

INSTALL RESONATOR BRACKET SUB-ASSEMBLY

INSTALL RADIATOR RESERVOIR ASSEMBLY

1. Install the radiator reservoir assembly with the 2 bolts.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

2. 

   Text in Illustration

   *a

   Upper

   Connect the 2 reservoir hoses.

   Tech Tips

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

INSTALL AIR CLEANER ASSEMBLY RH

INSTALL AIR CLEANER ASSEMBLY LH

INSTALL INTAKE AIR CONNECTOR PIPE

1. Align the protrusion of the intake air resonator with the cutout of the bracket and insert the protrusion.

2. Install the intake air connector pipe with the 3 hose clamps.

   Torque:

   for intake air connector pipe and throttle body

   4.8 N*m  { 49 kgf*cm, 42 in.*lbf }

   for intake air connector pipe and intake air resonator

   3.8 N*m  { 39 kgf*cm, 34 in.*lbf }

   Note

   Insert the protrusion of the intake air connector pipe into the hole of the hose clamp.

   Tech Tips

   
   

   • The intake air connector pipe and throttle body clamp can be tightened within the range of 4.0 N*m (41 kgf*cm, 35 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf), and the intake air connector pipe and intake air resonator clamp can be tightened within the range of 2.0 N*m (20 kgf*cm, 18 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf).

   • When tightening the hose clamp, make sure the hose clamp's end is within the painted white line (width: 2 mm (0.0787 in.)).

3. Attach the 2 wire harness clamps.

4. 

   Connect the No. 1 ventilation hose and No. 2 ventilation hose to the intake air connector pipe.

   Tech Tips

   
   

   • Position the claws of the clamps as shown in the illustration.

   • Install the clamps so that they are within the hose's paint marks.

CONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR CONNECTOR (w/ Active Stabilizer System)

INSTALL INLET ENGINE ROOM ECM DUCT (w/ Active Stabilizer System)

INSTALL NO. 3 COOL AIR INTAKE DUCT SUB-ASSEMBLY (w/ Active Stabilizer System)

CONNECT FRONT FENDER LINER LH (w/ Active Stabilizer System)

CONNECT OUTLET OIL COOLER HOSE

1. Connect the No. 2 oil cooler outlet hose to the radiator assembly.

CONNECT INLET OIL COOLER HOSE

1. Connect the No. 2 oil cooler inlet hose to the radiator assembly.

ADD FRONT DIFFERENTIAL OIL

ADD ENGINE COOLANT

ADD ENGINE OIL

ADD COOLANT (for Inverter)

INSPECT FOR COOLANT LEAK (for Inverter)

CHARGE REFRIGERANT

CHECK TRANSMISSION FLUID LEVEL

INSPECT FOR SHIFT LEVER POSITION

1. When moving the shift lever from the P position to the R position with the power switch on (IG) and the brake pedal depressed, make sure that it moves smoothly and correctly into position.

2. Turn the power switch on (READY) and make sure that the vehicle moves forward when the shift lever is moved from the N position to the D position and moves rearward when the shift lever is moved to the R position. If the operation cannot be performed as specified, inspect the shift lever position sensor and check the shift lever assembly installation condition.

INSPECT FOR OIL LEAK

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

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 engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

INSPECT FOR FUEL LEAK

1. Connect the intelligent tester to the DLC3.

2. Turn the power switch on (IG).

   Note

   Do not start the engine.

3. Turn the intelligent tester on.

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

5. Check the fuel pump operation.

   
   

   1. Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing in the fuel tank can be heard.

      If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.

6. Check for fuel leaks.

   
   

   1. Check that there are no fuel leaks anywhere on the system after performing maintenance.

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

INSPECT FOR REFRIGERANT LEAK

1. After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.

2. Carry out the test under the following conditions:

   
   

   • Power switch off.

   • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).

   • Repeat the inspection 2 or 3 times.

   • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system (pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)).

3. 

   Text in Illustration

   *1	Halogen Leak Detector
   *a	Check for Leak

   Using a halogen leak detector, check for refrigerant leaks from the air conditioning system.

4. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

5. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

   Tech Tips

   When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

INSPECT FOR EXHAUST GAS LEAK

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

INSPECT IGNITION TIMING

INSPECT ENGINE IDLE SPEED

INSPECT CO/HC

1. Put the engine in inspection mode Click here.

2. Warm up the engine.

   Tech Tips

   A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.

3. Keep the engine speed at 2500 rpm for approximately 180 seconds.

4. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling.

5. Immediately check CO/HC concentration at idle and 2500 rpm.

   Tech Tips

   
   

   • When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.

   • If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

   
   

   1. Check the air fuel ratio sensor Click here and heated oxygen sensor Click here operation.

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

      CO	HC	Symptom	Causes
      Normal	High	Rough idle	1. Faulty ignitions Incorrect timing Plugs (contaminated, shorted, or gaps are defective) 2. Leaky intake and exhaust valves 3. Leaky cylinder
      Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks PCV hose Intake manifold Throttle body 2. Lean mixture causing misfire
      High	High	Rough idle (Black smoke from exhaust)	1. Restricted air filter 2. Faulty SFI system Faulty pressure Defective engine coolant temperature sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty mass air flow meter

MEASURE VEHICLE HEIGHT

1. Bounce the vehicle at the corners up and down to stabilize the suspension and inspect the vehicle height.

   Standard vehicle height (unloaded)
   Item Front (A - B) Rear (C - D) except Sports Package 146 mm (5.75 in.) 83 mm (3.27 in.) Sports Package 156 mm (6.14 in.) 93 mm (3.66 in.)

   Measuring points
   A
   Ground clearance of front wheel center
   B
   Ground clearance of head center of bolt used to install the front No. 1 suspension lower arm to the front suspension member
   C
   Ground clearance of rear wheel center
   D
   Ground clearance of pit center of the attachment rear suspension arm

   Note

   
   

   • Before inspecting the wheel alignment, adjust the vehicle height to the specified value.

   • The standard value shown here is a value that is used for adjusting the wheel alignment and does not indicate the height of an actual vehicle.

   If the vehicle height is not as specified, adjust the height by pressing down on the vehicle several times to stabilize the suspension.

ADJUST OBJECT RECOGNITION CAMERA

Note

• Make sure there are no black and white patterned objects in front of the vehicle.

• Perform the measurement in a place with no wind, and make sure there is a distance of 1.5 m (4.92 ft.) or more in front of the vehicle and that the surface is level with no obstacles.

• Make sure that there is no wind when performing the measurement.

• Check that there are no reflective materials in the surroundings or on the ground within a 3 m (9.84 ft.) or more x 3 m (9.84 ft.) or more area in front of the vehicle.

• Perform the inspection in a bright area.

1. Beam axis learning preparation

   
   

   1. Move the vehicle to a level surface.

   2. Make sure the engine oil in the vehicle is at the specified amount.

   3. Make sure the engine coolant in the vehicle is at the specified amount.

   4. Make sure the fuel tank is full.

   5. Make sure the spare tire is in the vehicle. (w/ Spare Tire)

   6. Make sure the standard tools are in the vehicle.

   7. Make sure nobody is in the vehicle.

   8. Make sure no extra loads are in the vehicle.

   9. Adjust the tire pressures to the specified pressure.

   10. Clean the front glass.

   11. If the lens of the object recognition camera sensor is dirty, apply a small amount of lens cleaner to a clean, soft cloth and clean the lens.

2. Perform height control sensor adjustment

   
   

   1. Perform the height control sensor adjustment Click here.

      Note

      Perform this procedure as accurately as possible.

3. Perform the front wheel alignment adjustment

   
   

   1. Perform the front wheel alignment adjustment Click here.

      Note

      Perform this procedure as accurately as possible.

4. Perform the rear wheel alignment adjustment

   
   

   1. Perform the rear wheel alignment adjustment Click here.

      Note

      
      

      • Perform this procedure as accurately as possible.

      • Press the height control switch and change the vehicle height to HIGH and return it to NORM. Then repeat.

5. Target sheet creation

   
   

   1. 

      Print or copy the illustration below. Check that the dimensions are +/-5 mm (0.197 in.) of the ones in the table below.

      Dimension
      Area Specification A 160 mm (6.30 in.) B 80 mm (3.15 in.) C 16 mm (0.630 in.)

      Note

      
      

      • Make sure that the black areas of the target sheets are not glossy.

      • Make sure that the borders of the black and white areas on the target sheets are straight, and are not warped or blurry.

      If the print or copy's dimensions are not as specified, adjust settings and reprint or recopy so that the print or copy's dimensions are as specified.

      
6. 

   Target sheet attachment

   
   

   1. Place the prepared target sheet on a piece of cardboard of the same size with the black area on the top right, as shown in the illustration. Then use double-sided tape to fix the target sheet in place.

      Note

      Do not attach reflective tape, such as scotch tape, etc. to the target face as this may affect target recognition.

   2. 

      Hang a weight with a pointed tip from the center of the target sheet. Then, with double-sided tape, attach the target sheet to the reflector so that the weight aligns with the mark-off line of SST (laser radar adjusting reflector).

      SST

      09870-60000   ( 09870-60010, 09870-60020 )

      Note

      
      

      • Perform this procedure as accurately as possible.

      • Attach the target sheet so that it is horizontal with the ground.

   3. 

      Move the reflector up and down to position the center of the target at the height shown in the illustration, and fix it in place.

      Dimension A
      1270 mm (4.17ft.)

      SST

      09870-60000   ( 09870-60010, 09870-60020 )

      Note

      Perform this procedure as accurately as possible.

7. Target placement point measurement

   Note

   
   

   • Perform this procedure as accurately as possible.

   • Do not place reflective materials in the area behind the target.

   • Make sure there are no patterns on the wall behind the target.

   • Make sure the distance between the target and wall is within 3 m (9.84 ft.).

   • Do not place black and white patterned objects near the target.

   • Make sure the target's shadow is not on the wall, as the camera may have a recognition error.

   
   

   1. From the center of the front bumper (center of the emblem), hang a weight with a pointed tip, and mark point B on the ground.

      

   2. From the center of the rear bumper (center of the emblem), hang a weight with a pointed tip, and mark point A on the ground.

      

   3. Using a piece of string that uses point A as a starting point and that passes through point B, make a straight line on the ground ahead of the vehicle 2 m (6.56 ft.) or more from point B.

      Tech Tips

      
      

      • Make sure to secure the string (using tape, etc.) when it is taut.

      • Lightly flick the string with your fingers several times to confirm that the string is aligned above point B.

   4. Mark point C at a position 340 mm (1.12 ft.) from point B.

      

   5. Mark point D at a position 1660 mm (5.44 ft.) from point B.

   6. Using the string, mark line E at a position 1000 mm (3.28 ft.) from point C.

   7. Using the string, mark line H at a position 1000 mm (3.28 ft.) from point C.

   8. Using the string, mark line F at a position 1000 mm (3.28 ft.) from point D.

   9. Using the string, mark line I at a position 1000 mm (3.28 ft.) from point D.

   10. Mark point G at the point where line E and line F intersect (placement point 2).

   11. Mark point J at the point where line H and line I intersect (placement point 3).

   12. Secure a string that connects point G and point J to the ground (target placement line).

       

   13. Mark point K at the intersection between the string connecting points C and D and the string connecting points G and J (placement point 1).

   14. Confirm the distance measurements for points K, G, and J (placement points 1, 2, and 3) again.

       

8. Object recognition camera sensor height measurement

   Note

   
   

   • Do not place black and white patterned objects near the target.

   • Face the vehicle toward a wall with no patterns, or make sure the background behind the target has no patterns.

   • Perform this procedure as accurately as possible.

   • Do not place reflective materials in the area behind the target.

   • Make sure there are no patterns on the wall behind the target.

   • Make sure the distance between the target and wall is within 3 m (9.84 ft.).

   • Make sure the target's shadow is not on the wall, as the camera may have a recognition error.

   
   

   1. Measure the distance (X mm or in.) from the ground to point H for the front left wheel arch.

      

   2. Measure the distance (Y mm or in.) from the ground to point H for the front right wheel arch.

   3. The average of the 2 distances (X mm or in. Y mm or in.) plus 599 mm (23.6 in.) is the height of the object recognition camera sensor.

9. Memorize camera/target position

   Note

   
   

   • Close all doors.

   • Perform the procedure with no one in the vehicle.

   • During the procedure, do not lean on the vehicle.

   • Illuminate the clearance lights.

   • Do not illuminate the headlights.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the power switch ON (IG).*1

   3. Turn the intelligent tester main switch ON.

   4. Select "Auto" from the display screen and proceed to the next screen.

   5. Select each option for the vehicle being adjusted from the display screen.

   6. Select "Chassis" or "Body" from the display screen.

   7. Select "Lane Keeping Assist" or "Pre-Crash 2" and then "Utility" from the display screen

   8. Select "Camera/target position memory" from the display screen.

   9. Follow the tester display, and select "Next".

   10. Input the measured height of the object recognition camera sensor and the horizontal position of the camera "175 mm (6.89 in.)" into the input screen. Then press the "Next" button on the display screen.

   11. Input "3010 mm (119 in.)" for the distance from the camera to the target and "1270 mm (50.0 in.)" for the height of the target into the input screen. Then press the "Next" button on the display screen.

       Tech Tips

       When the "Next" button is pressed, a 70 second countdown begins.

   12. Press the "Exit" button to finish the camera/target position memory mode.

       Note

       If "Error Camera/target position memory" is displayed on the screen, press the "Try Again" button, and repeat the procedures from *1 again.

10. Beam axis learning

    
    

    1. Select "Camera axis adjust" from the display screen.*1

    2. Follow the tester display, and select "Next".

    3. 

       Align the target sheet with the target placement line, and align the mark-off line with placement point 1 (point K).

    4. Check that the screen displays beam axis learning for target 1, then press the "Next" button on the display screen.

       Tech Tips

       When the "Next" button is pressed, the buzzer sounds for 1 second.

    5. 

       Align the target sheet with the target placement line, and align the mark-off line with placement point 2 (point G).

    6. Check that the screen displays beam axis learning for target 2, then press the "Next" button on the display screen.

       Tech Tips

       When the "Next" button is pressed, a 180 second countdown begins.

       Note

       Within 3 minutes after the screen displays the beam axis learning for target 2, move the target and press the "Next" button on the display screen.

    7. 

       Align the target sheet with the target placement line, and align the mark-off line with placement point 3 (point J).

    8. Check that the screen displays beam axis learning for target 3, then press the "Next" button on the display screen.

       Tech Tips

       When the "Next" button is pressed, a 180 second countdown begins.

       Note

       Within 3 minutes after the screen displays the beam axis learning for target 3, move the target and press the "Next" button on the display screen.

    9. Press the "Exit" button to finish the beam axis learning mode.

       Note

       If "Error camera axis adjust" is displayed on the screen, press the "Exit" button. Then after checking the conditions below, turn the power switch ON (IG) and OFF, and repeat from procedure *1 again.

       
       

       • Height of the target.

       • Distance from object recognition camera sensor to target.

       • Orientation of target (black area positioned on top right).

       • If surrounding area is bright enough.

       • If black and white patterned objects are placed near the target.

INSTALL NO. 1 ENGINE UNDER COVER

1. Install the No. 1 engine under cover with the 13 screws and 7 clips.

INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

1. Install the front wheel opening extension pad LH with the 5 screws.

INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

INSTALL COWL TOP VENTILATOR LOUVER RH (for LHD)

INSTALL ENGINE ROOM SIDE COVER LH

1. Install the engine room side cover LH with the 5 clips.

INSTALL ENGINE ROOM SIDE COVER RH

1. Install the engine room side cover RH with the 5 clips.

CHECK ENGINE COOLANT LEVEL

1. Check that the engine coolant level is between the LOW and FULL lines when the engine is cold.

   If the engine coolant is below the LOW line, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the FULL line.

   Note

   Do not substitute plain water for engine coolant.

   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).

INSTALL BATTERY SERVICE HOLE COVER LH

1. 

   Text in Illustration

   *A	for Standard
   *B	for Ottoman

   Attach the battery service hole cover LH with the clip and fastening tape.

INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)

INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)