OIL PUMP INSTALLATION


  1. INSTALL OIL PUMP RELIEF VALVE


    1. Coat the oil pump relief valve with engine oil.

    2. Insert the oil pump relief valve and relief valve spring into the timing chain cover hole.

    3. Install a new gasket to the plug.

    4. A003F98

      Using a 27 mm socket wrench, install the plug.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  2. INSTALL TIMING CHAIN CASE OIL SEAL


    1. Apply MP grease to the lip of a new timing chain case oil seal.

      Note


      • Do not allow foreign matter to contact the lip of the timing chain case oil seal.

      • Do not allow MP grease to contact the dust seal.

    2. Temporarily install the timing chain case oil seal to the timing chain or belt cover sub-assembly.

    3. Place the timing chain or belt cover sub-assembly on the wooden blocks.

    4. A003B8LE02
      Text in Illustration
      *a Wooden Block

      Using SST and a hammer, tap in the timing chain case oil seal until its surface is flush with the chain cover edge.

      SST
      09223-75010
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  3. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install a new gasket and the engine water pump assembly with the 8 bolts.

      Torque:
      8.9 N*m  { 91 kgf*cm, 79 in.*lbf }

  4. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. A003EA5E01
      Text in Illustration
      *1 Timing Chain Cover O-ring
      *2 Water Pump O-ring
      *3 Oil Pump O-ring

      Install 3 new O-rings to the timing chain or belt cover sub-assembly as shown in the illustration.

    2. Apply adhesive to the timing chain cover plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a 10 mm socket hexagon wrench, install the timing chain cover plug.

      Torque:
      17 N*m  { 170 kgf*cm, 12 ft.*lbf }

    4. Apply seal packing in a continuous bead to the timing chain or belt cover sub-assembly as shown in the following illustration.

      A003EG3E01
      Text in Illustration
      *1 Cylinder Head *2 Cylinder Block
      *3 Seal Packing - -
      *a Seal Packing Thickness *b Seal Packing Width
      *c Protrusion - -
      Application Specification
      Area Seal Packing Diameter Distance from Edge of Cover to Center of Seal Packing Seal Packing Application Length Protrusion from Cylinder Head

      A - A

      (Dashed line)

      		 2.5 to 4.0 mm (0.0984 to 0.157 in.) 2.0 mm (0.0787 in.) - -

      B - B

      (Continuous line)

      		 10 to 14 mm (0.394 to 0.551 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick 6.0 mm (0.236 in.) 40 mm (1.57 in.) from top of bolt hole -

      C - C

      (Continuous line)

      		 10 to 14 mm (0.394 to 0.551 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick 6.0 mm (0.236 in.) 49 mm (1.93 in.) from top of bolt hole -

      D - D

      (Continuous line)

      		 9.0 to 13 mm (0.354 to 0.512 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick - 13 mm (0.512 in.) from top of bolt hole -

      E - E

      (Continuous line)

      		 9.0 to 13 mm (0.354 to 0.512 in.) wide and 2.5 to 4.0 mm (0.0984 to 0.157 in.) thick - 13 mm (0.512 in.) from top of bolt hole -

      I - I

      (Continuous line)

      		 8.0 mm (0.315 in.) - 56.5 mm (2.22 in.) from bottom of cylinder head 5.0 to 6.0 mm (0.0197 to 0.236 in.)
      J 10 mm (0.394 in.) - 20 mm (0.787 in.) -
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after the installation.

    5. A003IF4E02
      Text in Illustration
      *1 Drive Rotor Spline
      *2 Crankshaft Timing Gear

      Align the drive rotor spline of the oil pump and the crankshaft timing gear as shown in the illustration.

    6. Install the timing chain or belt cover sub-assembly.


      1. Loosely install the timing chain or belt cover sub-assembly with the 16 bolts and nut but do not tighten the bolts and nuts yet.

        A003ADCE01
        Text in Illustration
        *1 Nut - -
        *a Area 1 *b Area 2
        *c Area 3 *d Area 4

      2. Excluding the bolts labeled A and F, tighten the bolts and nuts in this order: Area 1, Area 3, Area 2.

        Torque:
        for bolt C
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }
        for bolt A, D and nut
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
        Bolt Length
        Item Length Thread Diameter
        Bolt A 75 mm (2.95 in.) 10 mm (0.394 in.)
        Bolt B 75 mm (2.95 in.) 8 mm (0.315 in.)
        Bolt C 90 mm (3.54 in.) 8 mm (0.315 in.)
        Bolt D 95 mm (3.74 in.) 8 mm (0.315 in.)
        Bolt E 35 mm (1.38 in.) 8 mm (0.315 in.)
        Bolt F 75 mm (2.95 in.) 10 mm (0.394 in.)

      3. Tighten the bolts labeled B in this order: Area 2 and Area 3.

        Torque:
        60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      4. Tighten the bolts labeled F.

        Torque:
        46 N*m  { 469 kgf*cm, 34 ft.*lbf }

      5. Tighten the bolts labeled E in area 4.

        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      6. A003B75

        Remove the seal packing from the 2 bolt holes for the No. 1 compressor mounting bracket.

        Note

        Do not use any cleaners to remove the seal packing.

  5. INSTALL OIL PAN SUB-ASSEMBLY

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. Install the stud bolt.


      1. Using an E5 "TORX" socket wrench, install the stud bolts labeled A for the oil pan sub-assembly as shown in the illustration.

      2. Using an E8 "TORX" socket wrench, install the stud bolts labeled B for the oil strainer sub-assembly as shown in the illustration.

        A003FONE07
        Text in Illustration
        *1

        Stud Bolt A

        (Oil Strainer)

        		 *2

        Stud Bolt B

        (Oil Pan)
        *a 20.0 mm (0.787 in.) *b 13.0 mm (0.512 in.)
        *c 8.0 mm (0.315 in.) *d 35.0 mm (1.38 in.)
        *e 18.0 mm (0.709 in.) *f 8.5 mm (0.335 in.)
        Torque:
        for stud bolt A
        7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
        for stud bolt B
        3.0 N*m  { 31 kgf*cm, 27 in.*lbf }
    2. A003AXPE06
      Text in Illustration
      *a 8.0 mm (0.315 in.)
      *b 6.5 mm (0.256 in.)
      *c Seal Packing
      *d Seal Width

      Apply seal packing in a continuous bead as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal width
      2.0 to 3.0 mm (0.0787 to 0.118 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    3. Install a new O-ring to the timing chain cover sub-assembly.

    4. A003H85E03
      Text in Illustration
      *1 Nut

      Temporarily install the oil pan sub-assembly with the 16 bolts and 2 nuts.

      Bolt Length
      Item Length
      Bolt A 20 mm (0.787 in.)
      Bolt B 40 mm (1.57 in.)

    5. Uniformly tighten the 16 bolts and 2 nuts in the sequence shown in the illustration.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  6. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer sub-assembly with the bolt and 2 nuts to the oil pan sub-assembly.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  7. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. A003D1WE04
      Text in Illustration
      *a 6.0 mm (0.236 in.)
      *b Seal Packing
      *c Seal Width

      Apply seal packing in a continuous bead as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal width
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    2. A003EDGE02

      Temporarily install the No. 2 oil pan sub-assembly with the 18 bolts and 2 nuts.

    3. Uniformly tighten the 18 bolts and 2 nuts in the sequence shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      38 N*m  { 382 kgf*cm, 28 ft.*lbf }

  8. INSTALL CRANKSHAFT PULLEY


    1. Align the key groove of the pulley with the pulley set key and slide on the crankshaft pulley.

    2. A003GR4E01

      Using SST, install a new crankshaft pulley bolt.

      Torque:
      260 N*m  { 2650 kgf*cm, 192 ft.*lbf }
      SST
      09213-54015   ( 91651-60855 )
      09330-00021

      Note

      Do not reuse the crankshaft pulley bolt.

  9. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

    2. Install the crankshaft position sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note


      • When reusing the crankshaft position sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the crankshaft position sensor.

    3. Connect the crankshaft position sensor connector and attach the 2 wire harness clamps.

  10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install a new cylinder head cover gasket and new No. 2 cylinder head cover gasket to the cylinder head cover sub-assembly.

    2. A003EWKE04
      Text in Illustration
      *a Seal Packing

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover sub-assembly within 3 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installing.

    3. Temporarily install the cylinder head cover sub-assembly with the 19 bolts and 2 nuts.

    4. A003CU7E03
      Text in Illustration
      *1 Nut

      Tighten the bolts (A) shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    5. Tighten the bolts (B) shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

      Tech Tips

      Make sure the tightening torque of bolts (A).

  11. INSTALL IGNITION COIL ASSEMBLY


    1. Install the ignition coils with the bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  12. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A003HZ2E01

      Temporarily install the V-ribbed belt tensioner assembly with the 2 bolts.

      Tech Tips


      • Make sure that the V-ribbed belt tensioner assembly is in contact with the engine block.

      • Check that the bolt holes of the V-ribbed belt tensioner assembly and timing chain cover are aligned.

    2. Install the V-ribbed belt tensioner assembly by tightening the 2 bolts in the order shown in the illustration.

      Torque:
      for bolt 1
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      for bolt 2
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  13. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 1 idler pulley sub-assembly, collar and pulley plate with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note

      Check that the pulley plate and collar are assembled properly to the No. 1 idler pulley sub-assembly.

  14. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

    Note

    Install the No. 1 compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.


    1. A003DXP

      Temporarily install the No. 1 compressor mounting bracket with the 3 bolts.

      Tech Tips

      Temporarily install the No. 1 compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

    2. Push the No. 1 compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

      A003BIHE02
      Text in Illustration
      *a Front *b No Clearance
      *c Push - -
      Torque:
      Bolt B
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      Tech Tips

      Make sure there is no clearance between the cylinder block and No. 1 compressor mounting bracket as shown in the illustration.

    3. A003FGFE01

      Uniformly tighten the 4 bolts in the order shown in the illustration.

      Text in Illustration
      A003DCD Bolt A
      A003GWQ Bolt C
      Torque:
      Bolt A
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      Bolt C
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  15. INSTALL GENERATOR ASSEMBLY


    1. Install the generator assembly with the 3 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    2. Connect the wire harness clamp with the bolt.

    3. Connect the wire harness to terminal B with the nut.

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

    4. Install the terminal cap.

    5. Connect the generator connector.

  16. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A003EJLE01

      Install the thermostat with the jiggle valve upward.

      Tech Tips

      The jiggle valve may be set within 10° of either side of the prescribed position.

  17. INSTALL WATER INLET


    1. Install a new gasket and connect the water inlet with the bolt and 2 nuts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  18. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

  19. INSTALL FAN PULLEY


    1. Install the fan spacer and fan pulley with the 4 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  20. INSTALL INTAKE MANIFOLD


    1. Install a new gasket onto the intake manifold.

    2. Install the intake manifold with the 5 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    3. Install the bolt and wire harness bracket to the intake manifold.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Connect the vacuum hose to the intake manifold, and slide the clamp to secure the hose.

    5. Connect the No. 3 PCV hose to the intake manifold, and slide the clamp to secure the hose.

    6. Attach the 2 wire harness clamps to the wire harness bracket.

    7. Connect the purge line hose to the vacuum switching valve, and slide the clamp to secure the hose.

    8. Connect the vacuum switching valve connector.

  21. INSTALL INJECTOR ASSEMBLY


    1. Apply a light coat of gasoline or spindle oil to new O-rings and install them to the injector spacers.

      Note

      Make sure that the O-rings are installed between the parts correctly.

    2. Install the 4 injector spacers to the cylinder head sub-assembly.

    3. Apply a light coat of gasoline or spindle oil to new O-rings, and then install one onto each fuel injector assembly.

    4. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe sub-assembly and the O-ring of the fuel injector assembly.

    5. A003GN6

      Apply a light coat of gasoline or spindle oil to the O-ring again, and then install the fuel injector assembly into the fuel delivery pipe sub-assembly by turning it right and left.

      Text in Illustration
      A003DCD Turn
      A003GWQ Push

      Note


      • Be careful not to twist the O-ring.

      • After installing the fuel injector assembly, check that it turns smoothly. If not, reinstall it with a new O-ring.

  22. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Install 4 new injector vibration insulators to the cylinder head sub-assembly.

    2. Install the 2 No. 1 delivery pipe spacers to the cylinder head sub-assembly.

    3. A003F5N

      Temporarily install the fuel delivery pipe sub-assembly together with the 4 fuel injector assemblies with the 2 bolts.

      Note


      • Do not drop the fuel injector assembly when installing the fuel delivery pipe sub-assembly.

      • Make sure that the fuel injector assembly turns smoothly.

    4. Tighten the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    5. Apply a light coat of gasoline or spindle oil to a new O-ring.

    6. Install the fuel pressure pulsation damper assembly with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    7. Connect the 4 fuel injector connectors.

    8. Connect the No. 2 fuel hose to the fuel pressure regulator assembly, and slide the clamp to secure the hose.

    9. Connect the vacuum hose to the fuel pressure regulator assembly.

  23. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


    1. Install a new gasket onto the intake manifold.

      Tech Tips

      Align the protrusion of the gasket with the groove of the intake manifold.

      A003BB2E01
      Text in Illustration
      *a Protrusion
      *b Groove

    2. Install the throttle body assembly with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    3. Connect the No. 2 water by-pass hose to the throttle body assembly, and slide the clamp to secure the hose.

    4. Connect the water by-pass hose to the throttle body assembly, and slide the clamp to secure the hose.

    5. Connect the throttle motor connector.

  24. CONNECT ENGINE WIRE


    1. A003HGCE05
      Text in Illustration
      *1 Nut

      Install the nut and connect the 4 connectors as shown in the illustration.

    2. Connect the starter connector Click here.

    3. Connect the generator connector Click here.

    4. Connect the clamps of the engine wire and ground cable.

    5. Connect the connectors of the ECM.

    6. Connect the wire harness support of the ECM.

  25. INSTALL COMPRESSOR AND MAGNETIC CLUTCH


    1. A003DDVE01

      Temporarily install the bolt A to connect the compressor and magnetic clutch.

    2. Connect the compressor and magnetic clutch completely by tightening the 4 bolts in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      In order to prevent misalignment, which causes belt rattle, tightening of the bolts must be performed in the order shown.

    3. Connect the compressor and magnetic clutch connector.

  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring and the engine oil level dipstick guide with the bolt to the front No. 1 engine mounting bracket LH.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  27. INSTALL ENGINE OIL LEVEL DIPSTICK

  28. INSTALL VANE PUMP ASSEMBLY


    1. Connect the vane pump assembly with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Connect the oil pressure switch connector.

  29. CONNECT NO. 2 FUEL HOSE


    1. Connect the No. 2 fuel hose to the fuel delivery pipe sub-assembly Click here.

  30. CONNECT NO. 1 FUEL HOSE


    1. Connect the No. 1 fuel hose to the fuel pressure pulsation damper assembly Click here.

  31. INSTALL INTAKE AIR CONNECTOR


    1. Temporarily install the intake air connector to the throttle body assembly.

    2. Connect the vacuum hose to the intake air connector.

    3. Connect the No. 2 PCV hose to the cylinder head cover sub-assembly, and slide the clamp to secure the hose.

    4. Install the intake air connector with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A003COPE01

      Tighten the 2 hose clamps.

      Torque:
      for clamp A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  32. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the intake manifold, and slide the clamp to secure the hose.

  33. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. Connect the fuel vapor feed hose assembly to the purge VSV, and slide the clamp to secure the hose.

  34. CONNECT NO. 4 RADIATOR HOSE


    1. Connect the No. 4 radiator hose to the engine, and slide the clamp to secure the hose.

  35. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the No. 1 radiator pipe, and slide the clamp to secure the hose.

  36. INSTALL CAMSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

    2. Install the camshaft position sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note


      • When reusing the camshaft position sensor, inspect the O-ring.

      • Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  37. INSTALL FAN AND GENERATOR V BELT

    Click here

  38. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  39. ADD ENGINE OIL


    1. Add new engine oil.

      Standard Oil Grade
      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 Capacity
      Item Capacity
      Drain and refill without oil filter change 5.0 liters (5.3 US qts, 4.4 Imp. qts)
      Drain and refill with oil filter change 5.5 liters (5.8 US qts, 4.8 Imp. qts)
      Dry fill 6.0 liters (6.3 US qts, 5.3 Imp. qts)

    2. Install the oil filler cap.

  40. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block water drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

      Standard Capacity
      11.2 liters (11.8 US qts, 9.9 Imp. qts)

      Note

      Never use water as a substitute 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 is a combination of low phosphates and organic acids).

    4. Remove the 2-way that is located near the throttle body assembly.

    5. When air is bleed and the engine coolant drains out, install the 2-way.

    6. Add coolant through the radiator reservoir assembly filler opening until the coolant reaches the B line and install the radiator reservoir cap sub-assembly. [*1]

    7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fans.

      Note


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

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

      • Make sure that the needle does not show an abnormally high temperature.

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

      Tech Tips


      • Press the No. 2 and No. 3 radiator hoses several times by hand, and then check the level of the engine coolant.

      • The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

    9. Check the engine coolant level in the radiator reservoir assembly. [*4]

      Tech Tips


      • If the engine coolant level is below the LOW line, repeat steps *1 through *4.

      • If the engine coolant level is above the FULL line, drain engine coolant until the engine coolant level is between the FULL and LOW line.

  41. INSPECT FOR FUEL LEAK

    Click here

  42. INSPECT FOR OIL LEAK


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

  43. INSPECT FOR COOLANT LEAK

    CAUTION:

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


    1. Remove the radiator reservoir cap sub-assembly.

    2. Fill the radiator reservoir assembly with engine coolant, and then attach a radiator cap tester.

    3. Warm up the engine.

    4. Using the radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 20 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leakage.

      If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.

    5. Install the radiator reservoir cap sub-assembly.

  44. INSPECT CHECK IDLE SPEED AND IGNITION TIMING


    1. Warm up and stop the engine.

      Note

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

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine and idle it.

      3. Turn the intelligent tester main switch on.

      4. Enter the following menus:

        Powertrain / Engine and ECT / Data List / IGN Advance

        Standard ignition timing
        5 to 15° BTDC at idle

        Note

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

        Tech Tips

        Refer to the intelligent tester operator's manual for further detail.

    3. When not using the intelligent tester:


      1. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No.4 cylinder.

        Note


        • Use a timing light that detects primary signals.

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

      2. Start the engine and idle it.

      3. A003BJYE05

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

        SST
        09843-18040
        Text in Illustration
        *a Front view of 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 or park.

        Tech Tips


        • A003D9TE09

        • After connecting terminals (TC and CG), engine speed changes to approximately 1000 to 1500 rpm for 5 seconds, and then returns to idle speed. This is because the ECM checks that the ISC (idle speed control system) operates properly.

        • Perform the inspection of the ignition timing after engine speed is returned to idle speed.

        Text in Illustration
        *a Engine Speed
        *b Approx. 1000 to 1500 rpm
        *c 5 sec.
        *d Idle Speed
        *e Connect Terminals TC and CG

      4. Inspect the ignition timing

        Standard ignition timing
        3 to 7° BTDC at idle

      5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

      6. Inspect the ignition timing

        Standard ignition timing
        5 to 15° BTDC at idle

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

      8. Turn the ignition switch off.

      9. Remove the timing light.

  45. CHECK FUNCTION OF THROTTLE BODY

    Click here

  46. INSPECT ABS SENSOR SIGNAL

    Click here

  47. PERFORM INITIALIZATION

    Click here