ENGINE ASSEMBLY INSTALLATION

for Front Differential:

1. 

   Add differential oil so that the oil level is between 0 to 5 mm (0 to 0.197 in.) from the bottom lip of the differential filler plug hole.

   Note

   
   

   • Too much or too little oil will lead to differential problems.

   • After changing the oil, drive the vehicle and then check the oil level again.

   Oil type
   Toyota Genuine Differential Gear Oil LT 75W-85 GL-5 or equivalent.

   Capacity
   0.7 to 0.8 liters (0.74 to 0.84 US qts., 0.62 to 0.70 Imp. qts.)

2. 

   Using a 10 mm hexagon wrench, install a new gasket and the filler plug.

   Torque:

   39 N*m  { 398 kgf*cm, 29 ft.*lbf }

Bleed air from the cooling system.

1. Put the engine in inspection mode Click here.

2. While idling the engine for approximately 10 minutes, make sure the coolant remains at the FULL line by adding coolant as necessary.

3. 

   After idling the engine for 10 minutes, add coolant until it reaches the B line.

   Capacity
   2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp. qts)

   Text in Illustration

   B Line

   Tech Tips

   The B line is the lower edge of the inner wall of the filler neck.

4. Close the radiator reservoir cap, and run the engine at 1500 to 2000 rpm for 5 minutes.

   CAUTION:

   
   

   • Wear protective gloves.

   • Be careful as the radiator hose is hot.

   • Keep your hands away from the radiator fan.

   Tech Tips

   The thermostat open timing can be confirmed by pressing the No. 1 radiator hose by hand, and checking when the SLLC starts to flow inside the hose.

for Vehicles used in Middle East and China:

1. Turn the power switch on (READY).

2. Move the shift lever to P, depress the accelerator pedal and start the engine.

   Tech Tips

   Depending on the amount of battery charge, the engine may already be running.

   Note

   Check State of Charge in the Data List. If the Battery State of Charge value is less than 50%, return to the Check SOC procedure and perform charging again.

3. Release the accelerator pedal, depress the brake pedal, and move the shift lever to N while the engine is running.

4. Check Engine Spd in the Data List. Check that the engine speed is 950 to 1050 rpm.

5. In order to be able to check the Data List, take the intelligent tester out of the vehicle while it is still connected and lift the vehicle up while keeping the vehicle level.

6. 

   Remove the overflow plug and gasket.

7. When the fluid overflowing from the overflow tube slows to a trickle, check T/M Oil Temperature in the Data List. When the value reaches 50°C (122°F), install a new gasket and the overflow plug.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   Note

   If the Battery State of Charge value is 30% or less at this time, stop work, return to the Check SOC procedure and start the procedure again from the step in which the battery is charged.

When not using the intelligent tester:

1. Remove the V-bank cover.

2. Remove the 5 clips and air cleaner inlet cover.

3. Remove the engine room side cover LH Click here.

4. Remove the 2 bolts and No. 1 air cleaner inlet.

5. Disconnect the air cleaner cap sub-assembly LH.

6. Remove the air cleaner filter element, 2 nuts and air cleaner case LH.

7. 

   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.

8. Put the engine in inspection mode Click here.

9. Start the engine and idle it.

10. 

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

    SST

    09843-18040

    Note

    
    

    • Confirm the terminal numbers before connecting the probes. Connecting the probe to the wrong terminal can damage the engine.

    • When checking the ignition timing, the transmission should be in neutral.

11. 

    Using a timing light, check the ignition timing.

    Standard ignition timing
    8 to 12° BTDC @ idle (Transmission neutral position and A/C switch OFF)

12. Remove SST from the DLC3.

13. Check the ignition timing.

    Standard ignition timing
    5 to 15° BTDC @ idle (Transmission neutral position and A/C switch OFF)

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

15. Disconnect the timing light from the engine.

16. Install the air cleaner case LH with the 2 nuts.

    Torque:

    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

17. Install the air cleaner filter element.

18. Connect the air cleaner cap sub-assembly LH.

19. Install the No. 1 air cleaner inlet with the 2 bolts.

    Torque:

    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

20. Install the engine room side cover LH Click here.

21. Install the air cleaner inlet cover with the 5 clips.

22. Install the V-bank cover.

When not using the intelligent tester:

1. 

   Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

   SST

   09843-18030

   Note

   Confirm the terminal number before connecting the probe. Connecting the probe to the wrong terminal can damage the engine.

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

3. Check the idle speed.

   Standard Idle Speed
   Condition Specified Condition Shift lever on P 800 to 900 rpm Shift lever on N 950 to 1050 rpm

   If the speed is not as specified, check the air intake system.

4. Disconnect the tachometer from the DLC3.

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.

   

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.