ENGINE ASSEMBLY INSTALLATION

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

1. 

   Text in Illustration

   *1	Torque Converter Assembly Centerpiece
   *2	Crankshaft

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

   Clutch spline grease
   Toyota Genuine Clutch Spline Grease or equivalent

   Maximum spread
   About 1 g (0.0353 oz.)

2. 

   Text in Illustration

   *1

   Knock Pin

   While keeping the engine and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the 9 bolts shown in the illustration.

   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

   
   

   • Confirm that the 2 knock pins are installed to the transaxle contact surface of the engine cylinder block before installing the automatic transaxle assembly.

   • Do not forcibly pry on the automatic transaxle assembly.

   • Check that the torque converter assembly rotates.

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 with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

3. Connect the wire harness and install the nut.

   Torque:

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

4. Install the terminal cap.

5. Connect the 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	Cooler Compressor

   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 water pump pulley.

   Note

   Make sure that the V-ribbed belt is attached to each pulley. In particular, 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

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 a new bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

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

   Torque:

   92 N*m  { 938 kgf*cm, 68 ft.*lbf }

CONNECT TIE ROD ASSEMBLY LH

1. Connect the tie rod assembly LH to the steering knuckle with the nut.

   Torque:

   49 N*m  { 500 kgf*cm, 36 ft.*lbf }

2. Install a new cotter pin.

   Note

   Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

INSTALL FRONT SPEED SENSOR LH

1. Install the front speed sensor and front flexible hose to the front shock absorber 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

1. Install the front stabilizer link assembly to the front shock absorber assembly with the nut.

   Torque:

   74 N*m  { 755 kgf*cm, 55 ft.*lbf }

   If the ball joint turns together with the nut, use a hexagon wrench to hold the stud bolt.

INSTALL FRONT AXLE SHAFT NUT LH

INSTALL FRONT EXHAUST PIPE ASSEMBLY

1. 

   Text in Illustration

   *1	Exhaust Manifold Converter Sub-assembly
   *2	Gasket
   *3	Wooden Block

   Using a vernier caliper, measure the free length of the compression spring.

   Minimum

   40.5 mm (1.59 in.)

   Tech Tips

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

2. Fully insert a new gasket to the exhaust manifold converter sub-assembly.

3. 

   Text in Illustration

   *1	Exhaust Manifold Converter Sub-assembly
   *2	Front Exhaust Pipe Assembly
   *3	Gasket
   *a	Space between flanges: 8.5 mm (0.335 in.)

   Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

   Note

   
   

   • Be sure to install the gasket in the correct direction.

   • Do not reuse the gasket.

   • Do not damage the gasket.

   • Do not push in the gasket by using the exhaust pipe when connecting it.

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

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

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

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

   Tech Tips

   After the installation, check that the gaps between the flanges of the exhaust manifold converter sub-assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

   

7. Connect the heated oxygen sensor connector.

CONNECT FUEL TUBE SUB-ASSEMBLY

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.

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

   Compressor oil
   ND-OIL 8 or equivalent

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

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

   Torque:

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

CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

1. Remove the attached vinyl tape from the No. 1 cooler refrigerant suction hose.

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

   Compressor oil
   ND-OIL 8 or equivalent

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

4. Install the No. 1 cooler refrigerant suction hose onto the compressor assembly with pulley with the bolt.

   Torque:

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

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 connector.

3. Connect the wire harness and install the nut, close the cap.

   Torque:

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

INSTALL RADIATOR RESERVE TANK ASSEMBLY

1. Install the radiator reserve tank with the 2 bolts.

   Torque:

   7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

2. Connect the radiator reserve tank hose.

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

1. 

   Text in Illustration

   *a	Hinge
   *b	Clamp

   Connect the 2 hinges of the air cleaner cap sub-assembly.

2. Install the air cleaner cap sub-assembly with the 2 clamps.

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

4. Connect the ventilation hose to the cylinder head cover.

5. Install the fuel vapor feed hose to the air cleaner hose.

6. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly.

7. Connect the vacuum switching valve assembly to the air cleaner cap sub-assembly.

ADD ENGINE OIL

1. Add new 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 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)

2. Install the oil filler cap.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. 

   Text in Illustration

   *a

   Code Mark

   Check the code mark on the fan shroud.

3. Slowly fill the radiator assembly with TOYOTA Super Long Life Coolant (SLLC).

   Specified capacity:

   Code Mark F and X	7.3 liters (7.7 US qts, 6.4 Imp. qts)
   Code Mark R	7.9 liters (8.3 US qts, 7.0 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. Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

5. Squeeze the No. 1 and No. 2 radiator hoses 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 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:

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

      
      

      • Wear protective gloves.

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

      • Keep your hands away from the cooling fans.

      Note

      
      

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

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

      • If there is not enough 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

INSPECT FOR FUEL LEAK

1. Check fuel pump operation.

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the engine switch on (IG) and turn the GTS 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 tube sub-assembly from the fuel pipe. 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, 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 GTS from the DLC3.

INSPECT FOR COOLANT LEAK

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. Race the engine at 2500 rpm for approximately 90 seconds.

   3. Turn the GTS on.

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

      Tech Tips

      Refer to the GTS operator's manual for further details.

   5. Inspect the engine idle speed.

      Standard idle speed
      610 to 710 rpm

      Note

      
      

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

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

      • When checking the engine idle speed, the shift lever should be in N.

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

   6. Disconnect the GTS from the DLC3.

3. When not using the GTS:

   
   
   1. 

      Text in Illustration

      *1

      DLC3

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

      SST

      09843-18030

      Note

      Confirm the terminal before connecting the tachometer probe. Connecting the wrong terminals may result in damage to electrical components.

   2. Race the engine at 2500 rpm for approximately 90 seconds.

   3. Check the idle speed.

      Standard idle speed
      610 to 710 rpm

      Note

      
      

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

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

      • When checking the engine idle speed, the shift lever should be in N.

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

   4. Disconnect the tachometer probe from the DLC3.

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 idling.

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

   Tech Tips

   
   

   • When doing 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, troubleshoot in the order given below.

   
   

   1. Check the DTCs Click here.

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

      CO	HC	Symptom	Causes
      Normal	High	Rough idle	1. Faulty ignition Incorrect timing Plugs are contaminated or shorted, or gaps are defective 2. Leaky intake and exhaust valves 3. Leaky cylinder
      Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks PCV hose 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. Faulty SFI system Faulty pressure Defective ECT sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty MAF sensor

INSTALL COOL AIR INTAKE DUCT SEAL

1. Install the cool air intake duct seal with the 9 clips.