ENGINE ASSEMBLY INSTALLATION

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

INSTALL COMPRESSOR AND MAGNETIC CLUTCH

INSTALL GENERATOR ASSEMBLY

1. Install the generator assembly with the 2 bolts.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

2. Connect the wire harness clamp.

3. Install the generator bracket with the 2 bolts.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

4. Connect the generator connector to the generator assembly.

5. Install the generator wire with the bolt.

   Torque:

   8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

6. Install the nut and connect the wire harness to terminal B.

   Torque:

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

7. Install the terminal cap.

INSTALL V-RIBBED BELT

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

1. Install a new front drive shaft hole snap ring LH.

   Note

   Face the end gap of the front drive shaft hole snap ring downward.

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

1. 

   Text in Illustration

   *A	for TMC, TMMR Made
   *B	for TMMK Made
   *a	20 mm (0.787 in.)
   *b	22 mm (0.866 in.)
   	Bolt
   	Nut

   Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

   Torque:

   for TMC, TMMR Made

   75 N*m  { 765 kgf*cm, 55 ft.*lbf }

   for TMMK Made

   92 N*m  { 938 kgf*cm, 68 ft.*lbf }

   Note

   
   

   • The tightening torque for the bolt differs depending on the type of nut.

   • Make sure to tighten the bolt to the same torque as the nuts.

CONNECT TIE ROD ASSEMBLY LH

1. 

   Text in Illustration

   *a

   Matchmark

   Install the lock nut and tie rod assembly LH to the steering rack end sub-assembly until the matchmarks are aligned.

   Tech Tips

   After adjusting the front wheel alignment, tighten the lock nut.

INSTALL FRONT SPEED SENSOR LH

1. Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt and clamp.

   Torque:

   19 N*m  { 192 kgf*cm, 14 ft.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

   Tech Tips

   Install the speed sensor harness bracket first and then the front flexible hose.

2. Install the front speed sensor to the steering knuckle with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH

INSTALL FRONT AXLE SHAFT NUT LH

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

1. Install 3 new gaskets to the front exhaust pipe assembly.

2. 

   Text in Illustration

   *1	Bolt
   *2	Nut
   *3	Bolt and Nut

   Install the front exhaust pipe assembly with the 4 bolts and 4 nuts.

   Torque:

   Bolt

   55 N*m  { 561 kgf*cm, 40 ft.*lbf }

   Nut

   55 N*m  { 561 kgf*cm, 40 ft.*lbf }

   Bolt and Nut (for TMC Made)

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

   Bolt and Nut (for TMMR Made)

   49 N*m  { 500 kgf*cm, 36 ft.*lbf }

3. Install the No. 1 exhaust pipe support bracket with the 2 bolts (for Rear Side).

   Torque:

   33 N*m  { 337 kgf*cm, 24 ft.*lbf }

4. Connect the 2 heated oxygen sensor connectors.

5. Install the 2 wire harnesses to the clamp.

INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

1. Install the No. 1 exhaust pipe support bracket with the 2 nuts (for Front Side).

   Torque:

   33 N*m  { 337 kgf*cm, 24 ft.*lbf }

CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

1. Remove the vinyl tape from the No. 1 cooler refrigerant suction hose and compressor and magnetic clutch.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

   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 and magnetic clutch 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 and magnetic clutch.

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

   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 and magnetic clutch with the bolt.

   Torque:

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

5. Engage the 2 clamps and connect the 3 connectors.

CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

1. Connect the transmission control cable assembly to the transmission control cable bracket with a new clip.

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

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

   Note

   Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in neutral.

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 connector.

3. Install the terminal nut and cover the nut with the cap.

   Torque:

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

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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

2. Install the air cleaner cap with hose to the air cleaner case with the 2 clamps.

3. Connect the wire harness clamp and mass air flow meter connector.

4. Connect the 3 hoses.

5. Connect the ventilation hose.

6. Connect the mass air flow meter connector and wire harness clamp.

ADD ENGINE OIL

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 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 ENGINE OIL LEVEL

1. Warm up the engine, stop it and wait 5 minutes. The oil level should be between the engine oil level dipstick low level mark and full level mark.

   If the engine oil level is low, check for leakage and add oil up to the full level mark.

   Note

   Do not add engine oil to above the full level mark.

INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

1. Check that the engine coolant level is between the low and full lines when the engine is cold.

   If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the full line.

   Note

   Do not substitute plain water for engine coolant.

INSPECT FOR FUEL LEAK

1. Check fuel pump operation.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the engine switch on (IG) and turn the intelligent tester on.

      Note

      Do not start the engine.

   3. Enter the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump / Speed.

   4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, fuel pump control ECU, ECM and wiring connectors.

2. Inspect for fuel leaks.

   
   

   1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

3. Turn the engine switch off.

4. Disconnect the intelligent tester from the DLC3.

INSPECT FOR COOLANT LEAK

INSPECT IGNITION TIMING

1. Warm up and stop the engine.

   Tech Tips

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

2. When using the intelligent tester:

   Check the ignition timing.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Start the engine and run it at idle.

   3. Turn the intelligent tester main switch on.

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

      Standard ignition timing
      9.5 to 24.5° BTDC at idle

      Note

      
      

      • Check the ignition timing with the cooling fans off.

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

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

      Tech Tips

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

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

   6. Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1.

   7. Monitor IGN Advance.

   8. Perform the Active Test.

      Standard ignition timing
      8 to 12° BTDC at idle

      Note

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

      Tech Tips

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

3. When not using the intelligent tester:

   
   
   1. 

      Text in Illustration

      *1

      DLC3

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

      SST

      09843-18040

      Note

      
      

      • Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components.

      • Check the ignition timing with the cooling fans off.

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

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

   2. Remove the V-bank cover sub-assembly Click here.

   3. Connect the timing light tester probe to the ignition coil wire for No. 1 cylinder.

      Note

      Use a timing light that detects primary signals.

   4. Check the ignition timing at idle.

      Standard ignition timing
      8 to 12° BTDC at idle

      Note

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

      Tech Tips

      Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed.

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

   6. Check the ignition timing at idle.

      Standard ignition timing
      9.5 to 24.5° BTDC at idle

   7. Confirm that the ignition timing advances immediately when the engine rpm is increased.

   8. Remove the timing light from the engine.

   9. Install the V-bank cover sub-assembly Click here.

INSPECT ENGINE IDLE SPEED

1. Warm up and stop the engine.

   Tech Tips

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

2. When using the intelligent tester:

   Check the idle speed.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Start the engine and run it at idle.

   3. Turn the intelligent tester main switch 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 idle speed with the cooling fans off.

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

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

      Tech Tips

      
      

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

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

3. When not using the intelligent tester:

   
   
   1. 

      Text in Illustration

      *1

      DLC3

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

      SST

      09843-18030

   2. Check the idle speed.

      Standard idle speed
      600 to 700 rpm

      Note

      
      

      • Check the idle speed with the cooling fans off.

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

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

      Tech Tips

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

INSPECT CO/HC

1. Start the engine.

2. Keep the engine speed at 2500 rpm for approximately 180 seconds.

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

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

   Tech Tips

   When performing the 2 mode (with the engine idling/running at 2500 rpm) test, follow the measurement order 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 the DTCs Click here.

   2. See the table below for possible causes, then inspect and correct the applicable causes if necessary.

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

INSPECT SHIFT LEVER POSITION

1. When the shift lever is moved from P to R with the engine switch on (IG) and brake pedal depressed, make sure that the shift lever moves smoothly and correctly the position.

2. Start the engine and make sure that the vehicle moves forward when the shift lever is moved from N to D and moves rearward when the shift lever is moved to R.

ADJUST SHIFT LEVER POSITION