INSTALL ENGINE HANGERS
| *1 | No. 1 Engine Hanger |
| *2 | No. 2 Engine Hanger |
Install the 2 engine hangers with the 2 bolts as shown in the illustration.
| Item | Part No. |
|---|---|
| No. 1 engine hanger | 12281-36020 |
| No. 2 engine hanger | 12282-36020 |
| Bolt | 91552-81040, 91552-81025 |
Tech Tips
Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.
Attach the engine sling device and hang the engine with the chain block.
REMOVE ENGINE STAND
Remove the engine stand.
INSTALL ENGINE WIRE
Install the engine wire.
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft.
Tech Tips
SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)
Clean the bolts and their installation holes.
Install the front drive plate spacer.
Tech Tips
Align the pin of the front drive plate spacer with the pin hole of the crankshaft.
Install the drive plate and rear drive plate spacer to the crankshaft.
Apply a few drops of adhesive to 2 or 3 threads of the bolt end.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.
Note
Do not strike or damage the drive plate installation bolts. Be sure to handle them carefully.
INSTALL REAR ENGINE MOUNTING BRACKET (for AWD)
Install the rear engine mounting bracket with the 3 bolts.
INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)
Install the drive shaft bearing bracket with the 3 bolts.
INSTALL ENGINE MOUNTING BRACKET RH
Install the engine mounting bracket RH with the 3 bolts.
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before the transaxle installation.
| *1 | Drive Plate |
| *2 | Crankshaft |
| *3 | Torque Converter Assembly Centerpiece |
Apply clutch spline grease to the circumference of the crankshaft contact surface with the torque converter assembly centerpiece.
| Clutch spline grease |
|---|
| Toyota Genuine Clutch Splice Grease or equivalent |
| Maximum spread |
|---|
| About 1 g (0.0353 oz.) |
While keeping the engine and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the 9 bolts shown in the illustration.
Note
Do not forcibly pry on the automatic transaxle assembly.
Check that the torque converter assembly rotates.
Tech Tips
Bolt length:
Bolt A: 55 mm (2.17 in.)
Bolt B: 50 mm (1.97 in.)
Bolt C: 32 or 33 mm (1.26 or 1.30 in.)
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD)
Confirm that the 2 knock pins are on the transaxle contact surface of the engine block before the transaxle installation.
| *1 | Drive Plate |
| *2 | Crankshaft |
| *3 | Torque Converter Assembly Centerpiece |
Apply clutch spline grease to the circumference of the crankshaft contact surface with the torque converter assembly centerpiece.
| Clutch splice grease |
|---|
| Toyota Genuine Clutch Spline Grease or equivalent |
| Maximum spread |
|---|
| About 1 g (0.0353 oz.) |
While keeping the engine and automatic transaxle assembly horizontal, align the knock pins with each the holes in the automatic transaxle assembly and install the 9 bolts shown in the illustration.
Note
Do not forcibly pry on the automatic transaxle assembly.
Check that the torque converter assembly rotates.
Tech Tips
Bolt length:
Bolt A: 55 mm (2.17 in.)
Bolt B: 50 mm (1.97 in.)
Bolt C: 32 or 33 mm (1.26 or 1.30 in.)
INSTALL TRANSFER STIFFENER PLATE RH (for AWD)
Temporarily install the transfer stiffener plate RH.
Tighten the transfer stiffener plate RH with the 4 bolts to the transfer and rear engine mounting bracket.
TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR ASSEMBLY
Temporarily install the front engine mounting insulator assembly with the 3 nuts.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR LH
Temporarily install the engine mounting insulator LH with the 3 nuts.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR RH
Temporarily install the engine mounting insulator RH with the 3 nuts.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for AWD)
Temporarily install the rear engine mounting insulator with the 2 nuts.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
INSTALL FRONT FRAME ASSEMBLY
Set the engine assembly with transaxle to the front frame assembly.
Install the engine mounting insulators RH and LH with the 2 nuts.
Install the front engine mounting insulator with the bolt.
Connect the 2 clamps with the engine wire.
INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for AWD)
Install the rear engine mounting insulator assembly with the 2 bolts to the engine mounting bracket.
FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR ASSEMBLY
Fully tighten the front engine mounting insulator with the 3 nuts.
Install the hole plug.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
FULLY TIGHTEN ENGINE MOUNTING INSULATOR LH
Fully tighten the engine mounting insulator LH with the 3 nuts.
Install the 2 hole plugs.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
FULLY TIGHTEN ENGINE MOUNTING INSULATOR RH
Fully tighten the engine mounting insulator RH with the 3 nuts.
Install the 2 hole plugs.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for AWD)
Fully tighten the rear engine mounting insulator with the 2 nuts.
Install the 2 hole plugs.
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
INSTALL STEERING LINK ASSEMBLY (for AWD)
Install the steering link assembly with the 2 bolts and 2 nuts.
Note
Make sure to tighten the bolts starting from the left side of the vehicle.
Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
INSTALL FRONT STABILIZER BAR (for AWD)
Install the front stabilizer bar.
INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD)
Install the front No. 1 stabilizer bracket LH to the front frame assembly with the 2 bolts.
INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD)
Tech Tips
Use the same procedure described for the LH side.
INSTALL STARTER ASSEMBLY
Install the starter with the 2 bolts.
Connect the starter connector.
Install the terminal nut and cover the nut with the cap.
INSTALL COMPRESSOR ASSEMBLY WITH PULLEY
Using an E8 "TORX" socket wrench, install the 2 stud bolts.
Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
Note
Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.
INSTALL GENERATOR ASSEMBLY
Install the generator with the 2 bolts.
Install the wire harness clamp bracket with the bolt.
Connect the generator wire with the nut.
Install the terminal cap.
Connect the generator connector.
INSTALL V-RIBBED BELT
| *1 | Generator |
| *2 | Tensioner |
| *3 | Crankshaft |
| *4 | Water Pump |
| *5 | Cooler Compressor |
Set the V-ribbed belt onto each part as shown in the illustration except the water pump pulley.
Loosen the V-ribbed belt by turning the belt tensioner clockwise.
Set the V-ribbed belt onto the water pump pulley.
Note
Make sure that the belt is attached to each pulley. In particular, make sure that the belt is securely fitted into the grooves of the crankshaft pulley.
REMOVE ENGINE HANGERS
| *1 | No. 1 Engine Hanger |
| *2 | No. 2 Engine Hanger |
Remove the 2 bolts and No. 1 and No. 2 engine hangers.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Set the engine assembly with transaxle on the engine lifter.
Install the engine assembly to the vehicle.
Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.
Install the front suspension member rear braces RH and LH with the 4 bolts and 2 nuts.
INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT
Using SST, hold the crankshaft pulley.
Tech Tips
SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)
Apply a few drops of adhesive to the first 2 or 3 threads of the 6 drive plate and torque converter assembly setting bolts.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Install the 6 drive plate and torque converter assembly setting bolts.
Note
Install the black colored bolt first, and then the 5 silver colored bolts.
INSTALL FLYWHEEL HOUSING UNDER COVER
Install the flywheel housing under cover.
INSTALL FRONT FLOOR BRACE
Install the front floor brace with the 4 nuts.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING (for LH Side)
Install a new front drive shaft hole snap ring.
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
Align the splines of the shaft and install the drive shaft assembly LH using a brass bar and a hammer.
Note
Set the shaft snap ring with the opening facing down.
Be careful not to damage the drive shaft dust cover, boot or oil seal.
Move the drive shaft assembly while keeping it level.
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
Install the front drive shaft assembly RH.
Install the bearing bracket hole snap ring and a new bolt.
Note
Do not damage the boot or oil seal.
Move the drive shaft assembly while keeping it level.
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for AWD)
Install the front drive shaft assembly RH.
Install the bearing bracket hole snap ring and a new bolt.
Note
Do not damage the boot or oil seal.
Move the drive shaft assembly while keeping it level.
INSTALL FRONT AXLE ASSEMBLY LH
| *1 | Matchmark |
Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.
INSTALL FRONT AXLE ASSEMBLY RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL FRONT LOWER SUSPENSION ARM LH
Install the front lower suspension arm to the front lower ball joint with the bolt and 2 nuts.
INSTALL FRONT LOWER SUSPENSION ARM RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL FRONT STABILIZER LINK ASSEMBLY LH
Install the front stabilizer link assembly LH with the 2 nuts.
Tech Tips
If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.
INSTALL FRONT STABILIZER LINK ASSEMBLY RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL TIE ROD ASSEMBLY LH
Connect the tie rod assembly LH to the steering knuckle with the nut.
Install a new cotter pin.
Note
Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.
INSTALL TIE ROD ASSEMBLY RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL FRONT SPEED SENSOR LH
Install the front speed sensor and front flexible hose with the bolt.
Note
Do not twist the front speed sensor when installing it.
First install the speed sensor harness bracket, and then install the flexible hose bracket.
Install the front speed sensor to the steering knuckle with the bolt.
Note
Prevent foreign matter from attaching to the front speed sensor tip.
Firmly insert the front speed sensor body into the steering knuckle before tightening the bolt.
After installing the front speed sensor to the steering knuckle, make sure that there is no clearance between the front speed sensor stay and steering knuckle. Also make sure that no foreign matter is stuck between the parts.
To prevent interference between the front speed sensor and magnetic rotor, do not rotate the front speed sensor body during or after the insertion of the front speed sensor body to the steering knuckle.
INSTALL FRONT SPEED SENSOR RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH
Clean the threaded parts on the front drive shaft and a new front axle shaft nut using a non-residue solvent.
Tech Tips
Be sure to perform this work for a new drive shaft.
Keep the threaded parts free of oil and foreign matter.
Install the new front axle shaft nut.
Using a chisel and hammer, stake the front axle shaft nut.
INSTALL FRONT AXLE SHAFT NUT RH
Tech Tips
Use the same procedure described for the LH side.
INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
| *1 | Matchmark |
Align the matchmarks on the steering intermediate shaft assembly and steering link assembly.
Install the bolt.
TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
Remove SST from the transfer.
Install the propeller with center bearing shaft assembly.
Note
Be careful not to damage the oil seal.
Be careful not to damage the universal joint boot when installing the propeller shaft.
| *1 | Matchmark |
Align the matchmarks on the rear propeller shaft and electromagnetic control coupling assembly and install the 4 nuts and 4 washers temporarily.
Note
Do not allow grease to adhere to be bolts or washers.
Temporarily install the propeller with center bearing shaft assembly with the 4 bolts, 2 No. 1 center support bearing washers and 2 No. 2 center support bearing washers.
Note
Reuse the washers.
Do not allow grease to adhere to be bolts or washers.
Fully tighten the 4 nuts.
FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
Remove the piece of cloth or equivalent from the universal joint.
Depress the brake pedal and hold it.
Using a hexagon wrench (6 mm), tighten the 6 bolts.
With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft as shown in the illustration.
| Length A |
|---|
| 65.5 to 70.5 mm (2.579 to 2.776 in.) |
| *1 | No. 1 Center Support Bearing Assembly |
| *2 | No. 2 Center Support Bearing Assembly |
With the vehicle unloaded, 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 in the illustration, and then tighten the bolts.
| Length A |
|---|
| 11.5 to 13.5 mm (0.453 to 0.532 in.) |
Check that the center line of the bracket is at a right angle to the shaft axial direction.
Fully tighten the 4 bolts.
INSTALL CENTER EXHAUST PIPE ASSEMBLY (for AWD)
Install a new gasket to the center exhaust pipe assembly.
Connect the center exhaust pipe assembly to the 2 exhaust pipe supports.
Install the center exhaust pipe assembly with the 2 bolts.
INSTALL TAIL EXHAUST PIPE ASSEMBLY (for AWD)
Using a vernier caliper, measure the free length of the compression springs.
| Minimum length |
|---|
| 38.5 mm (1.52 in.) |
If the free length is less than the minimum, replace the compression spring.
Fully insert a new gasket to the center exhaust pipe assembly.
| *1 | Center Exhaust Pipe Assembly |
| *2 | Gasket |
| *3 | Wooden Block |
Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly.
Note
Be sure to install the gasket in the correct direction.
Do not reuse the gasket.
Do not damage the gasket.
Do not push in the gasket by using the exhaust pipe when connecting it.
Connect the tail exhaust pipe assembly to the 4 exhaust pipe supports.
Install the tail exhaust pipe assembly with the 2 bolts and 2 compression springs.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
Using a vernier caliper, measure the free length of the compression springs.
| Minimum length |
|---|
| 41.5 mm (1.64 in.) |
If the free length is less than the minimum, replace the compression spring.
Fully insert a new gasket to the exhaust manifold converter sub-assembly.
| *1 | Exhaust Manifold Converter Sub-assembly |
| *2 | Gasket |
| *3 | Wooden Block |
Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.
Note
Be sure to install the gasket in the correct direction.
Do not reuse the gasket.
Do not damage the gasket.
Do not push in the gasket by using the exhaust pipe when connecting it.
Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.
CONNECT COOLER REFRIGERANT DISCHARGE HOSE
Remove the attached vinyl tape from the hose.
Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.
| Compressor oil |
|---|
| ND-OIL 8 or equivalent |
Install the O-ring onto the discharge hose.
Note
Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.
Install the cooler refrigerant discharge hose onto the compressor assembly with pulley with the bolt.
Using pliers, grip the claws of the clip and slide the clip to install the No. 2 radiator hose.
Engage each clamp.
Connect each connector.
CONNECT SUCTION HOSE SUB-ASSEMBLY
Remove the attached vinyl tape from the hose.
Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.
| Compressor oil |
|---|
| ND-OIL 8 or equivalent |
Install the O-ring onto the suction hose sub-assembly.
Note
Keep the O-ring and O-ring fitting surfaces free from dirt or any foreign objects.
Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.
CONNECT UNION TO CHECK VALVE HOSE
Using pliers, grip the claws of the clip and slide the clip to connect the union to check valve hose to the intake air surge tank assembly.
INSTALL ENGINE MOVING CONTROL ROD
Temporarily install the engine moving control rod with the 4 bolts.
Temporarily install the No. 2 engine mounting stay with the 2 bolts
Tighten the 6 bolts.
CONNECT ENGINE WIRE
Connect the connector to the ECM with the lock lever.
Connect the engine wire with the 2 clamps.
Install the ground cable with the bolt.
Install the ground cable with the 2 bolts.
Connect the ground cable clamp.
Connect the positive (+) cable with the nut and 2 clamps.
Install the ground cable with the bolt.
Connect the 2 engine wire clamps.
Connect the engine wire to the engine room relay block. Then, install it with the nut and 2 connectors.
Install the No. 1 relay block cover.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
Connect the transmission control cable assembly to the control shaft lever with a new clip and the nut.
Note
Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.
CONNECT OUTLET NO. 1 OIL COOLER HOSE
Connect the outlet No. 1 oil cooler hose.
CONNECT INLET NO. 1 OIL COOLER HOSE
Connect the inlet No. 1 oil cooler hose.
CONNECT FUEL TUBE SUB-ASSEMBLY
Push in the fuel tube connector to the fuel pipe until the fuel tube makes a "click" sound.
Note
Check for damage or dirt and foreign objects on the connecting part of the pipe.
Check if the pipe and the connector are securely connected by trying to pull them apart.
Install the No. 1 fuel pipe clamp.
CONNECT OUTLET HEATER WATER HOSE
Connect the outlet heater water hose.
CONNECT INLET HEATER WATER HOSE
Connect the inlet heater water hose.
CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose.
Connect the wire harness clamp.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator outlet hose.
INSTALL AIR CLEANER BRACKET
Install the air cleaner bracket with the 2 bolts.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
Install the air cleaner case sub-assembly with the 3 bolts.
connect the wire harness clamp.
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
Install the air cleaner filter element sub-assembly.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
Connect the air-cleaner cap sub-assembly to the throttle body assembly and lock the hose band.
Install the air cleaner cap sub-assembly with the 2 bolts.
Connect the ventilation hose to the cylinder head cover.
Connect the mass air flow meter connector and install the wire harness clamp to the air cleaner cap.
Install the hose to the hose clamp.
INSTALL INLET AIR CLEANER ASSEMBLY
Install the inlet air cleaner assembly with the 2 bolts.
INSTALL BATTERY
Install the battery tray and battery.
Install the battery clamp with the bolt and nut.
Install the positive (+) battery terminal with the nut.
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
| *1 | Bolt |
| *2 | Nut |
Install the outer cowl top panel with the 4 bolts and 4 nuts.
Engage the 2 wire harness clamps to the outer cowl top panel.
Engage the 2 wire harness clamps to the outer cowl top panel and connect the connector (w/ Windshield Deicer).
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Install the windshield wiper motor and link assembly with the 3 bolts as shown in the illustration.
Connect the connector.
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
Engage the 13 claws and install the cowl top ventilator louver sub-assembly as shown in the illustration.
Install the 2 clips.
INSTALL FRONT FENDER TO COWL SIDE SEAL LH
Engage the claw and 2 guides to install the front fender to cowl side seal LH.
INSTALL FRONT FENDER TO COWL SIDE SEAL RH
Tech Tips
Use the same procedure for the RH side and LH side.
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
When reusing the front wiper arm and blade assembly LH:
| *1 | Wiper Arm Serration |
Clean the wiper arm serrations.
When reusing the windshield wiper link assembly:
| *1 | Wire Brush |
| *2 | Wiper Pivot Serration |
Clean the wiper pivot serrations with a wire brush.
| *1 | Ceramic Notch |
Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.
Operate the front wipers while spraying washer fluid onto the windshield. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.
INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
Operate the wiper and stop the windshield wiper motor at the automatic stop position.
When reusing the front wiper arm and blade assembly RH:
| *1 | Wiper Arm Serration |
Clean the wiper arm serrations.
When reusing the windshield wiper link assembly:
| *1 | Wire Brush |
| *2 | Wiper Pivot Serration |
Clean the wiper pivot serrations with a wire brush.
| *1 | Ceramic Notch |
Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.
INSTALL FRONT WIPER ARM HEAD CAP
Install the 2 front wiper arm head caps.
INSTALL FRONT WHEELS
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD ENGINE OIL
Add new engine oil and install the oil filler cap.
| Standard Oil Grade | ||||||
|---|---|---|---|---|---|---|
|
| Standard Capacity | ||||||||
|---|---|---|---|---|---|---|---|---|
|
ADD ENGINE COOLANT
Tighten the radiator drain cock plug by hand.
Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).
| Standard Capacity |
|---|
| 7.1 liters (7.5 US qts, 6.2 lmp. 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 is a combination of low phosphates and organic acids).
Note
Never use water as a substitute for engine coolant.
| *1 | Full Line |
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.
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 No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.
Maintain the engine speed at 2500 to 3000 rpm.
Squeeze the inlet and No. 1 and No. 2 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 cooling fans.
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 AUTOMATIC TRANSAXLE FLUID (for 2WD)
Tech Tips
ADD AUTOMATIC TRANSAXLE FLUID (for AWD)
Tech Tips
ADD TRANSFER OIL (for AWD)
Remove the No. 1 transfer case plug and gasket.
Add oil until the oil level is between 0 and 5 mm (0 and 0.197 in.) from the bottom lip of the case plug hole.
Note
When adding transfer oil, make sure the vehicle is level.
Add oil slowly, waiting several minutes between each addition.
An excessively large or small amount of oil may cause damage.
After adding oil, drive the vehicle and recheck the oil level.
Tech Tips
| Oil grade |
|---|
| API GL-5 |
| Viscosity |
|---|
| Above 0°F(-18°C): SAE 90 |
| Below 0°F(-18°C): SAE 80W or 80W-90 |
| Capacity |
|---|
| 0.8 liters (0.84 US qts, 0.70 lmp.qts) |
After waiting for approximately 5 minutes, recheck the oil level.
Install a new gasket onto the No. 1 transfer case plug and then tighten the plug.
CHARGE REFRIGERANT
Perform vacuum purging using a vacuum pump.
Charge with refrigerant HFC-134a (R134a).
| Standard |
|---|
| 450 to 550 g (15.9 to 19.4 oz.) |
Note
Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.
Tech Tips
Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.
INSPECT FOR FUEL LEAK
Check fuel pump operation.
Connect the GTS to the DLC3.
Turn the ignition switch to ON and turn the GTS on.
Note
Do not start the engine.
Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.
Check for pressure in the fuel inlet tube from the fuel line. Check that the sound of fuel flowing from the fuel tank can be heard. If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connectors.
Inspect for fuel leaks.
Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.
Turn the ignition switch off.
Disconnect the GTS from the DLC3.
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
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.
Note
Before performing each inspection, turn the A/C switch off.
Fill the radiator with coolant and attach a radiator cap tester.
Warm up the engine.
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 water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
INSPECT FOR EXHAUST GAS LEAK
INSPECT FOR REFRIGERANT LEAK
After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.
Carry out the test under the following conditions:
Turn the ignition switch off.
Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining in the refrigeration system.
When the compressor is off: approx. 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi)
| *1 | Halogen Leak Detector |
Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.
| *1 | Halogen Leak Detector |
| *2 | Drain Hose |
Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.
Tech Tips
After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
Bring the halogen leak detector sensor under the drain hose.
When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.
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 perform the test.
Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.
INSPECT AND ADJUST SHIFT LEVER POSITION (for 2WD)
Tech Tips
INSPECT AND ADJUST SHIFT LEVER POSITION (for AWD)
Tech Tips
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Tech Tips
INSPECT IGNITION TIMING
Warm up and stop the engine.
When using the GTS:
Connect the GTS to the DLC3.
Start the engine and idle it.
Turn the GTS main switch on.
Enter the following menus: Powertrain / Engine / Data List / IGN Advance.
| Standard ignition timing |
|---|
| 5 to 15° BTDC at idle |
Tech Tips
Refer to the GTS operator's manual for further details.
If the ignition timing is not as specified, check the valve timing.
Check that the ignition timing advances immediately when the engine speed is increased.
Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1 / ON.
Monitor IGN Advance of the Data List.
| Standard ignition timing |
|---|
| 8 to 12° BTDC at idle |
Tech Tips
Refer to the GTS operator's manual for further details.
If the ignition timing is not as specified, check the valve timing.
Enter the following menus: Connect the TC and TE1 / OFF.
Turn the ignition switch off.
Disconnect the GTS from the DLC3.
When not using the GTS:
Remove the No. 1 engine cover sub-assembly.
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.
Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
Note
Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
When checking the ignition timing, the transmission should be in neutral.
Using a timing light, check the ignition timing.
| Standard ignition timing |
|---|
| 8 to 12° BTDC at idle |
Remove SST from the DLC3.
Check the ignition timing.
| Standard ignition timing |
|---|
| 5 to 15° BTDC at idle |
If the ignition timing is not as specified, check the valve timing.
Check that the ignition timing advances immediately when the engine speed is increased.
Disconnect the timing light from the engine.
Install the No. 1 engine cover sub-assembly.
INSPECT ENGINE IDLE SPEED
Warm up and stop the engine.
When using the GTS:
Connect the GTS to the DLC3.
Note
Switch off all accessories and the A/C before connecting the GTS.
Race the engine at 2500 rpm for approximately 90 seconds.
Turn the GTS on.
Enter the following menus: Powertrain / Engine / Data List / Engine Speed.
| Standard idle speed |
|---|
| 600 to 700 rpm |
Tech Tips
Refer to the GTS operator's manual for further details.
Note
When checking the idle speed, the transmission should be in neutral.
If the idle speed is not as specified, check the air intake system.
Disconnect the GTS from the DLC3.
When not using the GTS:
Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.
Note
Confirm the terminal number before connecting the probe. Connecting the wrong terminals can damage the engine.
Race the engine at 2500 rpm for approximately 90 seconds.
Check the idle speed.
| Standard idle speed |
|---|
| 600 to 700 rpm |
Note
Turn all electrical systems and the A/C off.
Inspect the idle speed with the cooling fans off.
When checking the idle speed, the transaxle should be in neutral.
If the speed is not as specified, check the air intake system.
Disconnect the tachometer probe from the DLC3.
INSPECT CO/HC
Tech Tips
This check determines whether or not the idle CO/HC complies with regulations.
Start the engine.
Keep the engine speed at 2500 rpm for approximately 180 seconds.
Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling.
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.
Check for DTCs Click here.
See the table below for possible causes, and then inspect and correct the applicable causes if necessary.
| CO | HC | Symptom | Causes |
|---|---|---|---|
| Normal | High | Rough idle |
|
| Low | High | Rough idle (Fluctuating HC reading) |
|
| High | High | Rough idle (Black smoke from exhaust) |
|
INSTALL FRONT FENDER APRON SEAL LH
Install the front fender apron seal LH with the 2 bolts and clip.
INSTALL FRONT FENDER APRON SEAL RH
Install the front fender apron seal RH with the 2 bolts and clip.
INSTALL FRONT FENDER LINER LH
INSTALL FRONT FENDER LINER RH
INSTALL NO. 2 ENGINE UNDER COVER
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
Fit the 3 retainers and install the No. 1 engine cover sub-assembly.
INSTALL COOL AIR INTAKE DUCT SEAL
Install the cool air intake duct seal with the 12 clips.
CHECK SPEED SENSOR SIGNAL
Tech Tips