ENGINE ASSEMBLY INSTALLATION

INSTALL ENGINE HANGERS

1. 

   Text in Illustration

   *1	No. 1 Engine Hanger
   *2	No. 2 Engine Hanger
   *a	Stopper
   *b	Rib

   Install the No. 1 engine hanger with the bolt as shown in the illustration.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

   Note

   Make sure to install the No. 1 engine hanger with the stopper contacting the rib of the cylinder head sub-assembly as shown in the illustration.

   Tech Tips

   Item	Part No.
   No. 1 Engine Hanger	12281-0V010
   No. 2 Engine Hanger	12282-0V010
   Bolt	90105-C0170

2. Install the No. 2 engine hanger with the bolt as shown in the illustration.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

   Note

   Make sure to install the No. 2 engine hanger with the stopper positioned between the ribs of the cylinder head sub-assembly as shown in the illustration.

3. Using an engine sling device and engine lift, secure the engine assembly with transaxle.

   Note

   
   

   • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

   • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

1. 

   Text in Illustration

   *1	Crankshaft
   *a	Torque Converter Assembly Centerpiece
   	Clutch Spline Grease

   Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

   Clutch Spline Grease
   Toyota Genuine Clutch Spline Grease or equivalent

   Maximum Grease Amount
   Approximately 1 g (0.0353 oz)

2. 

   Text in Illustration

   *1

   Knock Pin

   Confirm that the knock pins are installed to the engine assembly and are not damaged.

3. While keeping the engine assembly 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.

   Bolt	Bolt Length	Torque
   (A)	55 mm (2.17 in.)	64 N*m (653 kgf*cm, 47 ft.*lbf)
   (B)	50 mm (1.97 in.)	46 N*m (469 kgf*cm, 34 ft.*lbf)
   (C)	32 mm (1.26 in.)	44 N*m (449 kgf*cm, 32 ft.*lbf)
   	33 mm (1.30 in.)	43 N*m (438 kgf*cm, 32 ft.*lbf)

   Note

   
   

   • When tightening the bolts, make sure that the contact surfaces of the engine assembly and automatic transaxle assembly are in close contact with one another.

   • Do not use excessive force when installing the automatic transaxle assembly.

   • Check that the torque converter assembly rotates.

   • Make sure that the wire harness and other similar items are not pinched between the contact surfaces.

   • In order to protect the automatic transaxle oil pan sub-assembly, place attachments on the transmission jack.

   • Make sure that the attachments and automatic transaxle oil pan sub-assembly are centered on the transmission jack.

   • To prevent the automatic transaxle oil pan sub-assembly from being deformed, do not place any attachments under the automatic transaxle oil pan sub-assembly.

   • Secure the automatic transaxle assembly to the transmission jack using a belt, etc. to prevent it from falling.

INSTALL FRONT ENGINE MOUNTING BRACKET

1. Install the front engine mounting bracket to the transaxle housing with the 3 bolts.

   Torque:

   64 N*m  { 653 kgf*cm, 47 ft.*lbf }

INSTALL WIRE HARNESS CLAMP BRACKET

1. Install the wire harness clamp bracket to the transaxle housing with the bolt.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

2. Engage the 4 clamps to connect the wire harness to the wire harness clamp bracket.

3. Connect the oxygen sensor connector.

4. Install the clamp to the wire harness clamp bracket.

5. Connect the transmission breather hose sub-assembly to the clamp.

INSTALL GENERATOR ASSEMBLY

1. Install the generator assembly with the 2 bolts.

   Torque:

   52 N*m  { 530 kgf*cm, 38 ft.*lbf }

2. Install the wire harness clamp bracket to the generator assembly with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

   Torque:

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

4. Close the terminal cap.

5. Connect the generator assembly connector.

INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

INSTALL V-RIBBED BELT

1. 

   Text in Illustration

   *1	Crankshaft Pulley
   *2	V-ribbed Belt Tensioner Assembly
   *3	Generator Assembly
   *4	Engine Water Pump Assembly
   *5	Compressor Assembly with Pulley

   Set the V-ribbed belt onto each part as shown in the illustration except the engine water pump pulley.

2. Loosen the V-ribbed belt by turning the belt tensioner clockwise.

3. Set the V-ribbed belt onto the engine water pump pulley.

   Note

   Make sure that the V-ribbed belt is securely fitted into the grooves of each pulley.

INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

1. 

   Text in Illustration

   *a

   Adhesive

   Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   Note

   In order to ensure proper sealing of the 6 drive plate and torque converter assembly setting bolts, apply adhesive to the 6 drive plate and torque converter assembly setting bolts and install them within 10 minutes of adhesive application.

2. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

   Torque:

   41 N*m  { 418 kgf*cm, 30 ft.*lbf }

   Note

   First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.

CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

1. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks and install the steering intermediate shaft to the steering link assembly.

2. Install the bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

1. Remove the vinyl tape from the No. 1 cooler refrigerant suction hose and compressor assembly with pulley.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

   Compressor Oil
   ND-OIL 8 or equivalent

3. Install the O-ring to the No. 1 cooler refrigerant suction hose.

4. Connect the No. 1 cooler refrigerant suction hose to the compressor assembly with pulley with the bolt.

   Torque:

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

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor assembly with pulley.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

   Compressor Oil
   ND-OIL 8 or equivalent

3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

4. Connect the No. 1 cooler refrigerant discharge hose to the compressor assembly with pulley with the bolt.

   Torque:

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

5. Engage the clamp.

6. Connect each connector.

7. Connect the wire harness with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

CONNECT UNION TO CHECK VALVE HOSE

1. Connect the union to check valve hose to the vacuum pump assembly, and slide the clip to secure it.

CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

1. Move the shift lever to N.

2. Connect the transmission control cable assembly to the transmission control shaft lever with the nut.

   Torque:

   13 N*m  { 133 kgf*cm, 10 ft.*lbf }

3. Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

INSTALL STARTER ASSEMBLY

1. Install the starter assembly with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the starter assembly connector.

3. Connect terminal 30 with the nut.

   Torque:

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

4. Close the terminal cap.

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

1. Connect the air cleaner cap with air cleaner hose to the throttle body with motor assembly.

2. Install the air cleaner cap with air cleaner hose with the 2 guides and 2 air cleaner cap clamps.

3. Tighten the hose clamp.

4. Connect the union to connector tube hose to the air cleaner hose sub-assembly.

5. Engage the wire harness clamp.

6. Connect the mass air flow meter sub-assembly connector.

7. Engage the ventilation hose clamp.

8. Connect the ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

ADD ENGINE OIL

1. Add clean engine oil and install the oil filler cap sub-assembly.

   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

   Standard Capacity
   Item Specified Condition Drain and refill with oil filter change 4.4 liters (4.6 US qts, 3.9 Imp. qts) Drain and refill without oil filter change 4.0 liters (4.2 US qts, 3.5 Imp. qts) Dry fill 5.3 liters (5.6 US qts, 4.7 Imp. qts)

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Slowly fill the radiator assembly with engine coolant.

   Specified Capacity
   7.3 liters (7.7 US qts, 6.4 Imp. qts)

   Note

   Do not substitute plain water for engine coolant.

   Tech Tips

   TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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).

3. Remove the reserve tank cap.

4. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

5. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

   If the engine coolant level is low, add engine coolant.

6. Install the radiator cap sub-assembly and reserve tank cap.

7. Bleed air from the cooling system.

   Note

   
   

   • Before starting the engine, turn the A/C switch off.

   • Adjust the heater control to the maximum hot setting.

   • Adjust the blower speed to the low setting.

   
   

   1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine 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 No. 2 radiator hose.

   2. Maintain the engine speed at 2500 to 3000 rpm.

   3. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air from the cooling system.

      CAUTION:

      When squeezing the No. 1 radiator hose and No. 2 radiator hose:

      
      

      • Wear protective gloves.

      • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

      • Keep your hands away from the fan and No. 2 fan.

      Note

      
      

      • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

      • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

      • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

      • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.

8. Stop the engine, and wait until the engine coolant cools down.

9. Add engine coolant to the full line on the radiator reserve tank assembly.

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

WARM UP ENGINE

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note

   To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

INSPECT FOR ENGINE OIL LEAK

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

INSPECT FOR COOLANT LEAK

1. Remove the radiator cap sub-assembly.

2. 

   Text in Illustration

   *a	Radiator Cap Tester

   Fill the radiator assembly with engine coolant, and then install a radiator cap tester.

3. Warm up the engine.

4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17 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 leaks.

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

5. Remove the radiator cap tester.

6. Install the radiator cap sub-assembly.

INSPECT FOR EXHAUST GAS LEAK

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

1. Perform Inspection After Repair after repairing an exhaust gas leak Click here.

INSPECT FOR REFRIGERANT LEAK

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

2. Carry out the test under the following conditions:

   
   

   • Turn the engine switch off.

   • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

     Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm², 57 to 85 psi)

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

   • Repeat the inspection 2 or 3 times.

3. Remove the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

4. Remove the front bumper assembly Click here.

5. Remove the radiator side deflector RH Click here.

6. 

   Text in Illustration

   *a	Check for leaks
   *b	Halogen Leak Detector Sensor
   *c	Distance between Sensor and Joint to be Checked: 10 mm or less
   *d	Halogen Leak Detector Sensor Moving Speed: 25 to 50 mm/sec.

   How to check for refrigerant leaks in pipe joints:

   Note

   Gas leaking from a joint can be dissipated by even the slightest breeze. Move the halogen leak detector sensor 360° around each joint instead of keeping it in one spot when checking.

7. Using a halogen leak detector, check for refrigerant leaks at the pipe joints shown in the illustration.

   

   Text in Illustration

   *a	Area to be Checked	*b	Service Valve (High)
   *c	Service Valve (Low)	*d	Pipe Joint
   *e	Air Conditioner Pressure Sensor Joint	*f	Cooler Expansion Valve Joint
   *g	Condenser Joint (Inlet)	*h	Condenser Joint (Outlet)
   *i	Compressor Joint (Inlet)	*j	Compressor Joint (Outlet)

   Tech Tips

   
   

   • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

   • Disconnect the pressure sensor connector and leave it for approximately 20 minutes.

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

   Standard
   There are no refrigerant leaks from the joints.

   If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

8. 

   Text in Illustration

   *1	Drain Cooler Hose
   *a	Halogen Leak Detector

   Bring the halogen leak detector sensor close to the drain cooler hose with the detector turned off, and then turn the detector on.

   Note

   Keep water away from the halogen leak detector to prevent malfunction.

   Tech Tips

   
   

   • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

   • When bringing the halogen leak detector sensor close to the drain cooler 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 checking for leaks.

   Standard
   Refrigerant is not leaking from the drain cooler hose.

   If refrigerant is leaking, check for refrigerant leaks from the No. 1 cooler evaporator sub-assembly.

9. Remove the blower motor with fan sub-assembly Click here.

10. 

    Text in Illustration

    *1	No. 1 Cooler Evaporator Sub-assembly
    *a	Halogen Leak Detector

    Insert the halogen leak detector sensor into the air conditioning unit assembly, bring the sensor close to the No. 1 cooler evaporator sub-assembly and check for refrigerant leaks.

    Tech Tips

    After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

    Standard
    Refrigerant is not leaking from the No. 1 cooler evaporator sub-assembly.

    If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

11. Install the blower motor with fan sub-assembly Click here.

12. Install the radiator side deflector RH Click here.

13. Install the front bumper assembly Click here.

14. Install the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

INSPECT IGNITION TIMING

INSPECT ENGINE IDLE SPEED

1. Warm up and stop the engine.

2. When using the GTS:

   
   

   1. Connect the GTS to the DLC3.

   2. Start the engine and run it at idle.

   3. Turn the GTS on.

   4. Enter the following menus: Powertrain / Engine / Data List / Engine Speed.

   5. Read the value displayed on the tester.

      Standard Idle Speed
      600 to 700 rpm

      Note

      
      

      • Check the engine idle speed with the cooling fans off.

      • Turn off all electrical systems and the A/C.

      • When checking the engine idle speed, the transaxle should be in neutral or park.

3. When not using the GTS:

   
   
   1. 

      Text in Illustration

      *a

      DLC3

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

      SST

      09843-18030

      Note

      Be sure to connect the tachometer probe to the correct terminal. Connecting the wrong terminals can cause damage to electrical components.

   2. Start the engine and run it at idle.

   3. Inspect the engine idle speed.

      Standard Idle Speed
      600 to 700 rpm

      Note

      
      

      • Check the engine idle speed with the cooling fans off.

      • Turn off all electrical systems and the A/C.

      • When checking the engine idle speed, the transaxle should be in neutral or park.

   4. Turn the engine switch off.

   5. Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.

INSPECT CO/HC

1. Start the engine.

2. Run the engine at 2500 rpm for approximately 180 seconds.

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

4. Immediately check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

   Tech Tips

   When performing a 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations. If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order given below.

   
   

   1. Check for DTCs Click here.

   2. See the following table for possible causes, then inspect the applicable parts and repair them if necessary.

      CO	HC	Problem	Cause
      Normal	High	Rough idle	Faulty ignition: Incorrect valve timing Fouled, shorted or improperly gapped spark plugs Incorrect valve clearance (valve lash adjuster assembly) Leaks in intake or exhaust valves Leaks in cylinders Faulty EGR
      Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle with motor body assembly Brake booster line Lean mixture causing misfire Faulty EGR
      High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty SFI system: Fuel pressure regulator assembly Engine coolant temperature sensor Mass air flow meter sub-assembly ECM Fuel injector assemblies Throttle position sensor (built into throttle with motor body assembly) Faulty EGR