ENGINE ASSEMBLY INSTALLATION


  1. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install the engine oil level sensor with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 52 in.*lbf }
  2. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH


    1. A003DAL

      Install the mounting bracket with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
  3. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH


    1. A003H9S

      Install the mounting bracket with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
  4. INSTALL WATER TEMPERATURE SENSOR


    1. A003I9K

      Using a 19 mm deep socket wrench, install a new gasket and the water temperature sensor.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
  5. INSTALL KNOCK CONTROL SENSOR

    Tech Tips

    w/ Dual VVT-i:

    Perform "Inspection After Repairs" after replacing the knock control sensor Click here.


    1. A003ESNE03
      Text in Illustration
      *a Front

      Install the knock control sensor with the bolt as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. Connect the knock control sensor connector.

  6. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A003F6ME01

      Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A003EP5

      Install the oil pressure switch.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after installation of the switch.

  7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A003HZ2E01

      Temporarily install the belt tensioner with the 2 bolts.

      Tech Tips


      • Make sure that the belt tensioner is in contact with the engine block.

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

    2. Install the tensioner by tightening the 2 bolts in the order shown in the illustration.

      Torque:
      Bolt 1
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      Bolt 2
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  8. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1


    1. A003CXV

      Install the idler pulley sub-assembly No.1, 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 idler pulley No.1.

  9. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (w/ Air Conditioning System)

    Note

    Install the compressor mounting bracket No. 1 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 compressor mounting bracket No. 1 with the 3 bolts.

      Tech Tips

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

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

      A003BIHE01
      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 compressor mounting bracket No. 1 as shown in the illustration.

    3. A003GLQE01

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

      Torque:
      Bolt A
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      Bolt C
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
  10. INSTALL IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Temporarily install the idle pulley assembly with the bolt.

      Note

      Do not use any tools.

    2. Tighten the bolt.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
  11. INSTALL GENERATOR ASSEMBLY


    1. A003H3NE01

      Install the generator assembly with the 3 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    2. Install the generator wire with the nut to terminal B.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. Install the terminal cap.

    4. Connect the generator connector.

  12. 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.

  13. INSTALL WATER INLET


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

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
  14. INSTALL WATER BY-PASS PIPE NO.1


    1. Install a new gasket and the water by-pass pipe with the 2 nuts and bolt.

      Torque:
      Nut
      18 N*m  { 180 kgf*cm, 13 ft.*lbf }
      Bolt
      8.0 N*m  { 80 kgf*cm, 71 in.*lbf }
  15. 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 }
  16. INSTALL EXHAUST MANIFOLD


    1. A003HEGE02

      w/o Secondary air injection system:


      1. Install a new gasket and the exhaust manifold with the new 6 nuts.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    2. w/ Secondary air injection system:


      1. Install a new gasket and the exhaust manifold with the new 8 nuts.

        Torque:
        36 N*m  { 367 kgf*cm, 27 ft.*lbf }
  17. INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)


    1. A003B3VE02

      Install the valve with the 2 new nuts.

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

    3. A003BX0E01

      w/ Manifold Absolute Pressure Sensor:

      Connect the vacuum hose to the air switching valve assembly.

  18. INSTALL INTAKE PIPE NO.4 (w/ Secondary Air Injection System)


    1. A003D55E04

      Install 2 new gaskets and the intake pipe No.4 with 4 new nuts and tighten the nuts in the order shown in the illustration. Then, tighten the nuts labeled 1 and 3 to the torque specification again.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    2. Check that the nuts are tightened to the torque specification.

      Note

      Tightening the nuts only once is not enough to tighten them to the torque specification.

  19. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A003H51

      Install the heat insulator with the 4 bolts.

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

    Tech Tips

    w/ Dual VVT-i:

    Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


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

    2. 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.

    3. A003GW2E01
      A003D6DE01

      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
      *A w/ Dual VVT-i
      *B w/o Dual VVT-i
      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.

  21. INSTALL FUEL DELIVERY PIPE SUB-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. Install 4 new injector vibration insulators to the cylinder head sub-assembly.

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

    5. A003F51E01
      Text in Illustration
      *A w/ Dual VVT-i
      *B w/o Dual VVT-i

      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 assemblies when installing the fuel delivery pipe sub-assembly.

      • Make sure that the fuel injector assembly turns smoothly.

    6. Tighten the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    7. Apply a light coat of gasoline or spindle oil to a new O-ring.

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

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    9. Connect the 4 fuel injector connectors.

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

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

  22. INSTALL SPARK PLUG

    Torque:
    18 N*m  { 184 kgf*cm, 13 ft.*lbf }
  23. INSTALL IGNITION COIL ASSEMBLY


    1. Install the ignition coils with the bolts.

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


    1. A003DMO

      Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    2. Connect the ventilation hose No.3.

  25. INSTALL THROTTLE BODY ASSEMBLY

    Tech Tips

    w/ Dual VVT-i:

    Perform "Inspection After Repairs" after replacing the throttle body assembly Click here.


    1. A003BB2E01
      Text in Illustration
      *a Protrusion
      *b Groove

      Install a new gasket onto the intake manifold.

      Tech Tips

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

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*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.

  26. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
  27. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  28. REMOVE ENGINE STAND

  29. INSTALL FRONT SUSPENSION CROSS MEMBER SUB-ASSEMBLY


    1. Install the engine assembly to the cross member.

    2. Connect the engine mounting insulator with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
  30. INSTALL REAR END PLATE


    1. Install the rear end plate with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
  31. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

    Tech Tips

    If any one of the mounting bolts is broken or deformed, replace it.


    1. A003HQNE01

      Apply adhesive to 2 or 3 threads of the mounting bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. Install the flywheel.

    3. A003FK6E01

      Fix the crankshaft with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A003CI3E02

      Install and uniformly tighten the 10 mounting bolts in several steps in the sequence shown in the illustration.(*1)

      Torque:
      27 N*m  { 276 kgf*cm, 20 ft.*lbf }

      If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.

    5. A003FVAE01

      Mark the mounting bolt with paint.(*2)

    6. Retighten the mounting bolt by 90° in the order shown in step (*1).

    7. Check that the painted mark is now at a 90° angle to that in step (*2).

  32. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)


    1. A003BBRE01

      Insert SST into the clutch disc assembly, then insert them into the flywheel sub-assembly.

      SST
      09301-00110

      Note

      Take care not to insert the clutch disc assembly in the wrong direction.

  33. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A003H0AE02

      Align the matchmark on the clutch cover assembly with the one on the flywheel sub-assembly.

    2. Following the procedures shown in the illustration, tighten the 6 bolts starting from the bolt located near the knock pin on the top.

      SST
      09301-00110
      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Evenly tighten the bolts by following the order shown in the illustration.

      • Tighten the bolts after checking that the disc is in the center by lightly moving the SST up and down, left and right.

  34. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A003G6I

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

      Maximum non-alignment
      0.9 mm (0.035 in.)
    2. A003CZWE01

      If alignment is not as specified, adjust the diaphragm spring tip alignment using SST.

      SST
      09333-00013
  35. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. A003HQNE01

      Apply adhesive to 2 or 3 threads of the mounting bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    2. Install the spacer FR, drive plate and spacer RR on the crankshaft.

      Note

      Do not start the engine for at least 1 hour after installing.

    3. A003FK6E01

      Fix the crankshaft with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A003BYKE02

      Install and uniformly tighten the 10 mounting bolts in several steps in the sequence shown in the illustration.

      Torque:
      74 N*m  { 750 kgf*cm, 55 ft.*lbf }
  36. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Click here

  37. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  38. INSTALL STARTER ASSEMBLY (for 2.0 kW Type)


    1. Install the starter assembly with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. Connect the starter wire harness with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. Connect the starter connector.

    4. Close the terminal cap.

    5. Connect the ground cable and wiring harness clamp bracket with the 2 bolts.

      Torque:
      25 N*m  { 251 kgf*cm, 18 ft.*lbf }
  39. INSTALL STARTER ASSEMBLY (for 1.7 kW Type)


    1. Install the starter assembly with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. Connect the starter wire and install the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. Connect the starter connector.

    4. Close the terminal cap.

    5. Connect the ground cable and wiring harness clamp bracket with the 2 bolts.

      Torque:
      25 N*m  { 251 kgf*cm, 18 ft.*lbf }
  40. INSTALL STARTER ASSEMBLY (for 1.6 kW Type)


    1. A003BABE01

      Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. Connect the wire harness to terminal 30 and install the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    3. Connect the terminal 50 connector to the starter assembly.

    4. A003F81E01

      Install the ground cable and wire bracket with the 2 bolts.

      Torque:
      25 N*m  { 251 kgf*cm, 18 ft.*lbf }
  41. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION


    1. Using the engine lifter, hold the engine assembly and install the engine assembly w/ transmission.

    2. A003E2LE05

      Install the stabilizer bracket and 16 bolts of the front suspension cross member.

      Torque:
      Bolt A
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
      Bolt B
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      Bolt C
      150 N*m  { 1,530 kgf*cm, 111 ft.*lbf }
    3. Connect the rear engine mount.

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

      Note

      Be sure to tighten the nut side.

    4. Remove the engine lifter slowly.

  42. CONNECT STEERING TORQUE SHAFT ASSEMBLY


    1. A003D4SE01

      Align the matchmarks on the steering torque shaft assembly and the power steering link assembly.

    2. A003FSCE01

      Install bolt (B) and tighten the 2 bolts.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }
  43. CONNECT OIL COOLER HOSE (for Automatic Transmission)


    1. Connect the oil cooler inlet hose and outlet hose with the clamp to the oil cooler tube.

  44. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transmission)


    1. A003GA5E04

      Install the transmission control cable assembly to the control shaft lever and transmission control bracket No.1 with the nut and a new clip.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }
  45. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A003EFYE06

      Coat a new O-ring with ATF and install the oil filler tube.

    2. Install the oil filler tube with 2 bolts.

      Torque:
      12 N*m  { 125 kgf*cm, 10 ft.*lbf }
  46. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)


    1. A003GZ9E01

      Install 2 new clips to the transmission control cable bracket No.1.

    2. Install the transmission control cable assembly to the transmission control cable bracket No.1.

      Note


      • Be sure that A claws of the clips are firmly engaged into the bracket grooves.

      • Be sure the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.

    3. A003H3DE01

      Align the matchmarks on the control cable assembly and the outer lever.

    4. Install the transmission control cable assembly to the outer levers with the 2 nuts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  47. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)


    1. A003DFI

      Install the clutch release cylinder with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
  48. CONNECT SHOCK ABSORBER ASSEMBLY FRONT LH

    Click here

  49. CONNECT SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  50. CONNECT FRONT SUSPENSION SUB-ASSEMBLY UPPER LH


    1. A003DF6E02

      Connect the front suspension upper arm to the steering knuckle with the nut.

      Torque:
      113 N*m  { 1,150 kgf*cm, 83 ft.*lbf }
    2. Install a new cotter pin.

      Note


      • If the holes for the cotter pin are not aligned, tighten the nut up to 60°.

      • Do not damage the ball joint dust cover.

  51. CONNECT FRONT SUSPENSION SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  52. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A003HGAE01

      Install the brake caliper assembly to the steering knuckle with the 2 bolts.

      Torque:
      123 N*m  { 1,250 kgf*cm, 91 ft.*lbf }
  53. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  54. INSTALL SPEED SENSOR FRONT LH (w/ ABS)


    1. A003ICLE01

      Install the speed sensor to the steering knuckle with the 2 bolts.

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

      Note


      • Prevent foreign matter from adhering to the speed sensor.

      • Be careful not to damage the speed sensor.

      • Do not twist the sensor wire when installing the speed sensor.

  55. INSTALL SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  56. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)


    1. A003BT1E01

      Remove the SST from the extension housing.

    2. Install the propeller with center bearing shaft assembly in the extension housing.

    3. A003C3U

      Install the center support bearing assembly No.1, and temporarily tighten the 2 bolts.

    4. A003AD9E01

      Align the matchmarks on the propeller shaft flange and differential flange.

    5. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

      Torque:
      74 N*m  { 755 kgf*cm, 54 ft.*lbf }
    6. A003CNLE01

      Check that the center line of the bracket is at right angles to the shaft axial direction.

    7. A003IAIE01

      Adjust the center support bearing assembly No.1.

      Tech Tips


      • With the vehicle unladen, adjust the center support bearing No.1 to maintain the angles, as shown.

      • In the same conditions, check the center line in the axial direction. Adjust the bearing if necessary.

      • The center bearing center line and center bearing housing center line must be adjusted to within -1.0 to 1.0 mm (-0.0394 to 0.0394 in.) of each other in the vehicle's longitudinal direction with the vehicle unladen.

    8. Tighten the 2 bolts.

      Torque:
      36 N*m  { 369 kgf*cm, 27 ft.*lbf }
  57. INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    1. A003BT1E01

      Remove the SST from the extension housing.

    2. Install the propeller shaft assembly in the extension housing.

    3. Align the matchmarks on the propeller shaft flange and differential flange.

    4. A003AD9E01

      Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

      Torque:
      74 N*m  { 755 kgf*cm, 54 ft.*lbf }
  58. INSTALL EXHAUST PIPE ASSEMBLY CENTER (for Super Long Wheelbase)


    1. Install a new gasket to the exhaust pipe assembly center.

    2. Connect the exhaust pipe assembly center to the exhaust pipe supports.

    3. Install the exhaust pipe assembly center and exhaust pipe assembly tail with the 2 bolts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }
  59. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for Super Long Wheelbase)


    1. w/ Secondary air infection system:


      1. Install the air fuel ratio sensor. Click here

        Torque:
        44 N*m  { 449 kgf*cm, 32 ft.*lbf }
    2. For Unleaded gasoline engine:


      1. Install the oxygen sensor. Click here

        Torque:
        44 N*m  { 449 kgf*cm, 32 ft.*lbf }
    3. Inspect the compression spring.


      1. A003DPX

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5 mm (1.594 in.)

        Tech Tips

        If the free length is less than the minimum, replace the compression spring.

    4. A003FTXE03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the exhaust manifold.

      3. Install a new gasket to the exhaust pipe assembly front.

      4. Connect the exhaust pipe assembly front to the exhaust pipe support.

      5. Install the exhaust pipe assembly front with the 4 bolts, 2 nuts, and 2 compression springs.

        Torque:
        Exhaust manifold side
        43 N*m  { 438 kgf*cm, 32 ft.*lbf }
        Exhaust pipe assembly center side
        48 N*m  { 489 kgf*cm, 35 ft.*lbf }

        Note

        After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front.

    5. For Unleaded gasoline engine:


      1. Connect the sensor connector(s).

  60. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for Long Wheelbase)


    1. w/ Secondary air injection system:


      1. Install the fuel ratio sensor. Click here

        Torque:
        44 N*m  { 449 kgf*cm, 32 ft.*lbf }
    2. For unleaded gasoline engine:


      1. Install the oxygen sensor. Click here

        Torque:
        44 N*m  { 449 kgf*cm, 32 ft.*lbf }
    3. Inspect the compression spring.


      1. A003DPX

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5mm(1.594 in.)

        Tech Tips

        If the free length is less than the minimum, replace the compression spring.

    4. A003FTXE03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the exhaust manifold.

    5. Install a new gasket to the exhaust pipe assembly front.

    6. Connect the exhaust pipe assembly front to the exhaust pipe support.

    7. Install the exhaust pipe assembly front with the 4 bolts, 2 nuts, and 2 compression springs.

      Torque:
      Exhaust manifold side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Torque:
      Exhaust pipe assembly tail side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost the same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front.

    8. For unleaded gasoline engine:


      1. Connect the sensor connector(s).

  61. CONNECT ENGINE WIRE


    1. Connect the +B terminal and connector of the starter.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A003HGCE04

      Install the connectors and nut as shown in the illustration.

    3. Connect the clamps of the engine wire and earth cable.

    4. Connect the connectors of the ECM.

    5. Install the wire harness support of the engine ECM.

  62. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. A003DDVE01

      Temporarily install the bolt A to install the compressor.

    2. Install the compressor completely by tightening the 4 bolts in the order shown in the illustration.

      Torque:
      25 N*m  { 255 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 suction tube clamp with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
    4. Connect the compressor connector.

  63. INSTALL OIL LEVEL GAUGE GUIDE


    1. A003EFGE01

      Install the gauge guide with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
  64. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

  65. INSTALL VANE PUMP ASSEMBLY


    1. A003HW8E01

      Install the vane pump with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. Connect the PS fluid pressure switch connector.

  66. CONNECT FUEL HOSE NO.2


    1. Connect the fuel hose No.2 to the delivery pipe.

  67. CONNECT FUEL HOSE


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

  68. CONNECT AIR HOSE NO.5 (w/ Secondary Air Injection System)


    1. Connect the air hose No.5 to the air switching valve.

  69. 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. A003COPE01

      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. Tighten the 2 hose clamps.

      Torque:
      for clamp A
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  70. INSTALL AIR PRESSURE SENSOR (w/ Manifold Absolute Pressure Sensor)


    1. Install the air pressure sensor with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. Install the air pressure sensor together with the bracket with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. Attach the wire harness clamp.

    4. Connect the vacuum hose and clamp.

    5. Connect the connector.

  71. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the intake manifold.

  72. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. A003F6O

      Connect the fuel vapor feed hose to the VSV.

  73. CONNECT HEATER WATER HOSE OUTLET B


    1. Connect the heater water outlet hose B to the heater unit.

  74. CONNECT HEATER WATER HOSE INLET A


    1. Connect the heater water inlet hose A to the heater unit.

  75. CONNECT RADIATOR HOSE OUTLET


    1. Connect the radiator outlet hose to the clamp.

  76. CONNECT RADIATOR HOSE INLET


    1. Connect the radiator inlet hose to the clamp.

  77. INSTALL FAN & GENERATOR V BELT

    A003FDNE02

    1. Install the drive belt to the pulleys except the drive belt tensioner pulley.

    2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.

      Note


      • The backside of the drive belt should face the tensioner pulley.

      • Check that the drive belt is properly set to each pulley.

    3. A003C31E02

      After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.

  78. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  79. INSTALL FRONT DOOR SCUFF PLATE

  80. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  81. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  82. INSTALL FRONT WHEELS

    Torque:
    100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }
  83. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  84. CONNECT BATTERY NEGATIVE CABLE

  85. ADD ENGINE OIL

  86. 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
      Item Specified Condition
      w/o Rear Heater 11.2 liters (11.8 US qts, 9.9 Imp. qts)
      w/ Rear Heater 13.2 liters (13.9 US qts, 11.6 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 bled 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 step *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 lines.

  87. INSPECT FUEL LEAKS


    1. When using the intelligent tester


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to the on position and intelligent tester main switch ON.

        Note

        Do not start the engine.

      3. Select the Active Test mode on the intelligent tester.

        Tech Tips

        Please refer to the intelligent tester operator's manual for further details.

    2. When not using the intelligent tester.


      1. A003CJUE01

        Disconnect the fuel pump connector.

      2. Using a service wire, connect terminals FP and +B of the relay block.

        Note

        Pay attention to the terminal connecting position to avoid a malfunction.

      3. Turn the ignition switch to the ON position, and check that the fuel pump operates.

        Note

        Do not start the engine.

    3. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.

    4. Check that the pulsation damper screw rises up when the fuel pump operates.

      If operation is not as specified, check the following parts:


      • Fusible link

      • Fuel pump

      • Wiring connections

      • ECM

      • Fuses

    5. Turn the ignition switch off.

    6. Disconnect the intelligent tester from the DLC3.

  88. INSPECT ENGINE OIL LEAKS

  89. INSPECT MANUAL TRANSMISSION OIL (for Manual Transmission)


    1. A003AJCE01

      Park the vehicle in a level place.

    2. Remove the transmission filler plug and gasket.

    3. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

      Oil grade
      TOYOTA Genuine Manual Transmission Gear oil API GL-3 (GL-4) or equivalent
      Viscosity
      Above -10°C (14°F): SAE 75W-90, 80W or 80W-90
      Below -10°C (14°F): SAE 75W-90
      Capacity
      2.6 liters (2.7 US qts, 2.3 Imp. qts)

      Note


      • Problems may occur when the oil level is too high or too low.

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

    4. Check for oil leakage if the oil level is low.

    5. Install the transmission filler plug and a new gasket.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  90. INSPECT AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

    Tech Tips

    Drive the vehicle so that the engine and transmission are at normal operating temperature.

    Fluid temperature
    70 to 80 °C (158 to 176 °F)

    1. A003EB4E01

      Park the vehicle on a level surface and set the parking brake.

    2. With the engine idling and the brake pedal depressed, move shift the lever into all positions from P to L and return to the P position.

    3. Take out the dipstick and wipe it clean.

    4. Put it back all the way.

    5. Take it out again and check that the fluid level is within the HOT range.

      If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add the proper amount of new fluid and recheck the fluid level.

  91. INSPECT ENGINE COOLANT LEAKS

    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.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  92. INSPECT SHIFT LEVER POSITION (for Automatic Transmission)


    1. When shifting from P position only with ignition switch ON and depress the break pedal.

    2. Make sure that the shifting lever moves smoothly and can be moderately operated.

    3. When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves reward when shifting R position.

  93. ADJUST SHIFT LEVER POSITION (for Automatic Transmission)


    1. A003CCGE02

      Remove a clip, nut, and disconnect between the control shaft lever to transmission control cable assembly from the control shaft lever and transmission control cable bracket No.1.

    2. A003HNXE05

      Turn the control shaft lever until stop to a clockwise direction, return the control shaft lever 2 notches to N position.

    3. A003HJP

      Set the shift lever to N position while holding the shift lever lightly toward the R position side and install it.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }

      Note

      Tighten the nut with it closing up cranky.

    4. Inspect the operation condition and work.

  94. INSPECT EXHAUST GAS LEAKS

  95. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  96. INSTALL ENGINE SIDE UNDER COVER RH (w/ Engine Side Under Cover RH)

    Torque:
    13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  97. INSTALL ENGINE SIDE UNDER COVER LH (w/ Engine Side Under Cover LH)

    Torque:
    13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  98. INSTALL ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)

    Torque:
    13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  99. INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

    Torque:
    13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  100. INSPECT 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 rpm 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 items:

        Powertrain / Engine and ECT / Data list / IGN Advance

        Ignition timing
        5 to 15° BTDC at idle

        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 the first signal.

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

      2. Turn the ignition switch to the ON position.

      3. A003F4KE01

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

        SST
        09843-18040

        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 the neutral.

        Tech Tips


        • After connecting terminals (TC and CG), engine rpm changes to approximately 1,000 to 1,500 rpm for 5 seconds, 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 rpm is returned to idle speed.

      4. Inspect the ignition timing

        Ignition timing
        3 to 7° BTDC at idle
      5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

      6. Inspect the ignition timing

        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.

  101. INSPECT IDLE SPEED


    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 rpm should be stabilized.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Tech Tips

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

      2. Start the engine and idle it.

      3. Turn the intelligent tester main switch on.

      4. Enter the following items:

        Powertrain / Engine and ECT / Data list / Engine SPD

        Idle speed
        600 to 700 rpm

        Note


        • When checking the idle speed, the transmission should be in the neutral position.

        • Switch off all accessories and air conditioning before connecting the intelligent tester.

      5. Turn the ignition switch off.

      6. Disconnect the intelligent tester from the DLC3.

    3. A003AU4E01

      When not using the intelligent tester:


      1. Install SST to terminal 9 (TAC) of DLC3, then connect a tachometer.

        SST
        09843-18030

        Note

        Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      2. Turn the ignition switch to the ON position.

      3. Inspect the engine idling speed.

        Idle speed
        600 to 700 rpm
      4. Turn the ignition switch off.

      5. Disconnect the tachometer.

      6. Remove the SST from terminal 9 (TAC).

        SST
        09843-18030
  102. INSPECT CO (for Leaded Gasoline Specification Vehicle)

    Tech Tips

    This check is used only to determine whether or not the idle CO complies with regulations.


    1. Initial condition:


      1. Engine at normal operating temperature

      2. Air cleaner installed

      3. All pipes and hoses of the air induction system connected

      4. All accessories switched off

      5. All vacuum lines properly connected

      6. EFI system wiring connectors fully seated

      7. Ignition timing set correctly

      8. Transmission in the neutral position

      9. Tachometer and CO meter calibration at idle

        Note

        If a CO meter is not available, do not attempt to adjust the idle mixture. Always use a CO meter when adjusting the idle mixture. It is unnecessary to use the idle mixture screw for adjustments if the vehicle is in good condition.

    2. Warm up the engine by driving at constant speed (approximately 50 km/h (31 mph)). Close the throttle valve for 5 minutes after the engine coolant temperature becomes stable (80 to 90°C (176 to 194°F)) and idle the engine for 5 minutes.

    3. A003I5WE01

      Insert a tester probe at least 40 cm (1.3 ft) into the tail pipe.

    4. Wait at least 1 minute before measurement to allow the concentration to stabilize. Complete the measurement within 3 minutes.

      Idle CO concentration
      1.0 to 2.0%
    5. A003CR7E01

      If the CO concentration does not conform to regulations, adjust it by turning the idle mixture adjusting screw in the variable resistor with SST.

      SST
      09243-00020
    6. A003HUDE01

      The idle mixture adjusting screw can be adjusted within an 180° angle range.

      Tech Tips


      • If the CO concentration is within the specification, this adjustment is complete.

      • If the CO concentration cannot be corrected by idle mixture adjustment, see the table below for other possible causes.

    7. Remove the SST.

      CO Problems Causes
      High Rough idle (black smoke from exhaust)
      1. Clogged air filter

      2. Plugged ventilation valve

      3. Faulty SFI system:


        • Faulty fuel pressure regulator

        • Clogged fuel return line

        • Defective engine coolant temperature (ECT) sensor

        • Faulty ECM

        • Faulty injectors

        • Faulty throttle position sensor

        • Faulty MAF meter

  103. INSPECT CO,HC (for Unleaded Gasoline Specification Vehicle)

    Tech Tips

    The ECM properly controls the CO/HC concentration in the emission gas.


    1. Start the engine.

    2. Run the engine at 2,500 rpm for approximately 180 seconds.

    3. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tail pipe while idling.

    4. Check the CO/HC concentration with the engine idling and/or running at 2,500 rpm.

      Tech Tips


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

      • Check the heated oxygen sensor operation Click here.

      • Check the heated air fuel ratio sensor operation Click here.

      • See the table below for possible causes, then inspect the applicable causes and repair them if necessary.

      CO HC Problems Causes
      Normal High Rough idle
      1. Faulty ignitions:


        • Incorrect timing

        • Fouled, shorted or improperly gapped plugs

      2. Incorrect valve clearance

      3. Leaks in intake and exhaust valves

      4. Leaks in cylinders

      Low High Rough idle (Fluctuating HC reading)
      1. Vacuum leaks:


        • PCV hoses

        • Intake manifold

        • Throttle body

        • Brake booster line

      2. Lean mixture causing misfire

      High High Rough idle (Black smoke from exhaust)
      1. Restricted air filter

      2. Plugged PCV valve

      3. Faulty SFI systems:


        • Faulty pressure regulator

        • Defective engine coolant temperature sensor

        • Defective mass air flow meter

        • Faulty ECM

        • Faulty injectors

        • Faulty throttle body

  104. INSPECT FUNCTION OF THROTTLE BODY


    1. Check the throttle control motor operating sounds.


      1. Turn the ignition switch to the ON position.

      2. A003FZY

        When pressing the accelerator pedal, listen to the running sounds of the motor. Make sure no friction noise comes from the motor.

        If friction noise exists, replace the throttle body.

    2. A003DF8E02

      Check the throttle position sensor.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to the ON position.

      3. Turn the intelligent tester main switch on.

      4. Enter the following menus: Power train / Engine / Data List / Throttle Sensor Position and Throttle Position Sensor Position #2.

      5. Depress the accelerator pedal. When the throttle valve is fully opened, check that the value of the "Throttle Sensor Position" is within the specification.

        Standard throttle valve opening percentage
        60% or more

        Note

        When checking the standard throttle valve opening percentage, the shift lever should be in the N position.

        Tech Tips

        If the percentage is less than 60%, replace the throttle body.

  105. INSPECT ABS SENSOR SIGNAL (w/ ABS)

    Click here

  106. PERFORM INITIALIZATION

    Click here