ENGINE ASSEMBLY INSTALLATION

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly Click here.


  1. REMOVE ENGINE STAND


    1. Remove the bolts and engine assembly from the engine stand.

  2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021

    2. Clean the 8 bolts and 8 bolt holes.

    3. A01G9KL

      Install the front drive plate spacer.

      Tech Tips

      Align the pin of the front drive plate spacer with the pin hole of the crankshaft.

    4. A01G7HUE03
      Text in Illustration
      *1 Drive Plate
      *2 Rear Spacer
      A01G8AH Transaxle Side

      Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.

    5. A01G9NCE12
      Text in Illustration
      *1 Adhesive

      Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A01G6I0E01

      Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration.

      Torque:
      83 N*m  { 846 kgf*cm, 61 ft.*lbf }

      Note

      Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.

  3. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  4. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. A01G6O7E03
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece

      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 spread
      About 1 g (0.0353 oz.)
    2. A01G9H2E01

      While keeping the engine and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the 10 bolts shown in the illustration.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt C
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note


      • Confirm that the 2 knock pins are installed to the automatic transaxle assembly 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.

      Bolt length
      Bolt A
      55 mm (2.17 in.)
      Bolt B
      50 mm (1.97 in.)
      Bolt C
      33 mm (1.30 in.)

    3. Clean and degrease the bolt and the installation hole in the automatic transaxle assembly.

    4. Apply a few drops of adhesive to 2 or 3 threads at the tip of each bolt.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    5. A01G6UVE01

      Install the bolt.

      Torque:
      Bolt D
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      Bolt length
      Bolt D
      41 mm (1.61 in.)
    6. A01G9PTE01
      Text in Illustration
      *a Paint

      Install the No. 4 water by-pass hose to the water inlet pipe and engage the clamp. (w/ ATF Warmer)

      Note


      • Install the clamp so that the neck of the clamp is aligned with the paint.

      • Ensure that the paint is completely covered by the clamp.

    7. Install the clamp and connect the breather plug. (w/ ATF Warmer)

  6. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly with transaxle.

  7. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary.


    1. Temporarily install the front engine mounting insulator assembly with the 3 nuts.

  8. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.


    1. Temporarily install the engine mounting insulator LH with the 3 nuts.

  9. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator RH is necessary.


    1. Temporarily install the engine mounting insulator RH with the 3 nuts.

  10. INSTALL FRONT FRAME ASSEMBLY


    1. Install the engine mounting insulator RH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    2. Install the engine mounting insulator LH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    3. Install the front engine mounting insulator assembly with the bolt.

      Torque:
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }

    4. Connect the 2 wire clamps and vacuum switching valve connector.

    5. Connect the 2 wire clamps.

    6. Fully tighten the 9 temporarily installed nuts of the front engine mounting insulator assembly, engine mounting insulator LH and engine mounting insulator RH to the specified torque.

      Tech Tips

      Perform this procedure only when replacement of the engine mounting insulator is necessary.

      A01G61UE05
      Text in Illustration
      *1 Front Engine Mounting Insulator Assembly Side *2 Engine Mounting Insulator RH Side
      *3 Engine Mounting Insulator LH Side - -
      Torque:
      A
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
      Torque:
      B
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }

    7. Install the 4 hole plugs.

      Tech Tips

      Perform this procedure only when replacement of the engine mounting insulator is necessary.

      A01G9C6E02
      Text in Illustration
      *1 Engine Mounting Insulator RH Side *2 Engine Mounting Insulator LH Side

  11. INSTALL TRANSMISSION OIL THERMOSTAT (w/ ATF Warmer)


    1. w/ Transmission Oil Thermostat:


      1. Connect the clamp and install the transmission oil thermostat with the bolt.

        Torque:
        20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      2. Connect the inlet oil cooler hose to the transmission oil thermostat and slide the clip to secure it.

      3. Connect the outlet oil cooler hose to the transmission oil thermostat and slide the clip to secure it.

  12. INSTALL TRANSMISSION OIL COOLER (w/ ATF Warmer)


    1. Install the transmission oil cooler and transmission oil cooler stay to the front engine mounting bracket with the 3 bolts.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    2. w/o Transmission Oil Thermostat:


      1. Connect the No. 3 water by-pass hose, No. 4 water by-pass hose, No. 1 oil cooler outlet hose and No. 1 oil cooler inlet hose to the transmission oil cooler and engage the 4 clamps.

    3. w/ Transmission Oil Thermostat:


      1. Connect the No. 3 water by-pass hose, No. 4 water by-pass hose, No. 1 transmission oil cooler hose assembly and No. 1 oil cooler inlet hose to the transmission oil cooler and engage the 4 clamps.

  13. INSTALL COMPRESSOR AND MAGNETIC CLUTCH


    1. A01G4UME01

      Install the compressor and magnetic clutch and bracket with the 4 bolts.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

    2. Engage the 3 clamps.

    3. Connect the 3 connectors.

  14. 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 to the generator bracket.

    3. Install the generator bracket with the 2 bolts.

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

    4. Install the wire harness clamp with the bolt.

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

    5. Connect the wire harness with the nut.

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

    6. Install the terminal cap.

    7. Connect the connector.

  15. INSTALL V-RIBBED BELT


    1. A01G576E02
      Text in Illustration
      *1 Water Pump
      *2 Idler
      *3 Generator
      *4 Crankshaft
      *5 Tensioner
      *6 A/C Compressor

      Install the V-ribbed belt.

    2. A01G4DV

      Turn the V-ribbed belt tensioner counterclockwise and remove the 5 mm hexagon wrench.

    3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the V-ribbed belt has not slipped out of the grooves on the bottom of the crankshaft pulley by hand.

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on the engine lifter.

      Note


      • Place the height adjustment and plate lift attachments under the engine assembly with transaxle.

      • Servicing an engine assembly with transaxle while it is hanging is dangerous. This can be done only when installing/removing the engine assembly with transaxle to/from an engine stand.

      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.

      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.

    2. Remove the No. 1 engine hanger and No. 2 engine hanger Click here.

    3. Install the engine assembly with transaxle to the vehicle.

      Note


      • Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.

      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

    4. A01G7O4E01

      Install the frame side rail plate RH and frame side rail plate LH with the 4 bolts and 2 nuts.

      Torque:
      A
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      B
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    5. Install the front suspension member rear brace RH and front suspension member rear brace LH with the 4 bolts and 2 nuts.

      Torque:
      C
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      D
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Tech Tips

      Perform "Inspection After Repair" after replacing the engine assembly Click here.

  17. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A01G9NCE09
      Text in Illustration
      *1 Adhesive 1324

      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.

    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 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 bolt, and then the remaining 5 silver colored bolts.

  18. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  19. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. Install the No. 1 exhaust pipe support bracket with the bolt.

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

  20. 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.

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. Coat the spline of the front drive inboard joint assembly with ATF.

    2. Coat the lip of the transaxle case oil seal with MP grease.

    3. A01G6A6

      Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly LH.

      Note


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

      • Do not damage the transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • Make sure to center the front drive shaft assembly LH during installation to prevent damage to the front drive shaft hole snap ring LH.

      Tech Tips

      Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

    4. A01G8NGE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly LH to the front axle hub sub-assembly.

      Note

      Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH


    1. Coat the spline of the front drive inboard joint assembly with ATF.

    2. Coat the lip of the front transaxle case oil seal with MP grease.

    3. Install a new bearing bracket hole snap ring to the front drive shaft assembly RH.

    4. Install the front drive shaft assembly RH.

      Note


      • Do not damage the front transaxle case oil seal.

      • Do not damage the front axle inboard joint boot.

      • When inserting the front drive shaft assembly RH, keep it level.

    5. A01G6DR

      Install the bearing bracket hole snap ring and a new bolt.

      Torque:
      32 N*m  { 330 kgf*cm, 24 ft.*lbf }
    6. A01G7BGE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly RH to the front axle hub sub-assembly.

      Note

      Be careful not to damage the front axle outboard joint boot or speed sensor rotor.

  23. 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 }

  24. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  25. CONNECT TIE ROD ASSEMBLY LH


    1. A01G8GAE01
      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.

  26. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  27. 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.

  28. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. 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.

  30. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. INSTALL FRONT AXLE SHAFT NUT LH


    1. Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using a non-residue solvent.

      Note


      • Be sure to perform this work even when using a new drive shaft.

      • Keep the threaded parts free of oil and foreign matter.

    2. A01G5RB

      Using a socket wrench (30 mm), install the front axle shaft nut.

      Torque:
      294 N*m  { 2998 kgf*cm, 217 ft.*lbf }

      Tech Tips

      Keep depressing the brake pedal to prevent the front drive shaft from rotating.

    3. Using a chisel and a hammer, stake the front axle shaft nut.

  32. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  33. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01G7BZE02
      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 }

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY


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

    2. A01G6WQE01
      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, 41 ft.*lbf }
      Nut
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }
      Bolt and Nut
      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.

  35. 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 }

  36. 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 }

  37. 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 }

  38. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01G6R0

      Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.

      Note


      • Check that there is no damage or foreign matter on the fuel tube connector.

      • After connecting, check that the fuel tube connector and the fuel tube sub-assembly are securely connected by pulling on them.

    2. A01G5E7

      Install the fuel pipe clamp.

      Tech Tips

      The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube sub-assembly is not securely connected.

  39. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


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

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

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

      Note

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

    3. Connect the wire harness clamp.

  40. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket to the battery carrier with the bolt.

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

    2. Connect the 2 wire clamps.

  41. CONNECT ENGINE WIRE


    1. A01G878

      Connect the 2 wire clamps.

    2. Connect the connector to the ECM with the lock lever.

    3. Connect the engine wire to the engine room relay block.

    4. Connect the 4 connectors.

    5. A01G6U2

      Connect the engine wire to the engine room relay block.

    6. Connect the 2 wire clamps and install the 2 nuts.

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

    7. Install the No. 1 relay block cover.

  42. 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 }

  43. CONNECT OUTLET HEATER WATER HOSE (w/o ATF Warmer)


    1. Connect the outlet heater water hose to the water outlet and slide the clip to secure it.

  44. CONNECT INLET HEATER WATER HOSE (w/o ATF Warmer)


    1. Connect the inlet heater water hose to the water outlet and slide the clip to secure it.

  45. CONNECT WATER HOSE SUB-ASSEMBLY (w/ ATF Warmer)


    1. Connect the water hose sub-assembly to the water outlet and slide the clip to secure it.

  46. CONNECT INLET HEATER WATER HOSE (w/ ATF Warmer)


    1. Connect the inlet heater water hose to the water outlet and slide the clip to secure it.

  47. CONNECT NO. 3 WATER BY-PASS HOSE (w/ ATF Warmer)


    1. Connect the No. 3 water by-pass hose to the transmission oil cooler and slide the clip to secure it.

  48. CONNECT INLET NO. 1 OIL COOLER HOSE (w/o ATF Warmer)


    1. Connect the inlet No. 1 oil cooler hose to the automatic transaxle assembly and slide the clip to secure it.

  49. CONNECT OUTLET NO. 1 OIL COOLER HOSE (w/o ATF Warmer)


    1. Connect the outlet No. 1 oil cooler hose to the automatic transaxle assembly and slide the clip to secure it.

  50. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ ATF Warmer)


    1. w/ Transmission Oil Thermostat:


      1. Connect the 2 oil cooler tube sub-assemblies to the transmission oil thermostat and slide the 2 clips to secure them.

  51. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

  52. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

    2. Install the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.

  53. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the brake booster and slide the clip to secure it.

  54. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve and slide the clip to secure it.

  55. CONNECT EARTH WIRE


    1. Install the earth wire with the 2 bolts.

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

  56. INSTALL NO. 3 ENGINE MOUNTING STAY RH

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.


    1. A01G5BPE01
      Text in Illustration
      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket

      Temporarily install the No. 3 engine mounting stay RH and engine moving control rod to the engine moving control rod bracket with the 2 bolts.

    2. Tighten the bolt A.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  57. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY


    1. A01G6Y5E01

      When replacing the engine moving control rod or No. 3 engine mounting stay RH.


      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

        Note

        Temporarily tighten bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).

      2. Tighten the bolt (E).

        Torque:
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    2. A01G4MUE01

      When not replacing the engine moving control rod or No. 3 engine mounting stay RH.


      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

        Note

        Temporarily tighten bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).

  58. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the bolt.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    2. Tighten the 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  59. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. Install the intake air resonator sub-assembly with the 2 bolts.

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

    2. Connect the 2 vacuum hoses and engage the claw.

  60. INSTALL INLET NO. 1 AIR CLEANER


    1. A01G4V3

      Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.

    2. Engage the pin to the radiator support.

  61. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. Install the battery clamp with the bolt and nut.

      Torque:
      Bolt
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Connect the positive (+) cable to the positive (+) battery terminal.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A01G68JE01
      Text in Illustration
      *1 Air Cleaner Case Sub-assembly
      *2 Inlet No. 1 Air Cleaner
      *a Projection
      *b Hole

      Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner.

    2. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.

    3. Tighten the 2 bolts.

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

    4. Connect the 3 wire harness clamps, connector, vacuum hose and No. 1 fuel vapor feed hose.

  63. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

      Note

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  64. 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 sub-assembly to the air cleaner case with the 2 clamps.

    3. Connect the 3 hoses.

    4. Connect the ventilation hose.

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

  65. INSTALL INLET NO. 2 AIR CLEANER


    1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.

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

    2. Connect the 2 wire harness clamps and vacuum hose clamp.

  66. INSPECT VACUUM HOSES


    1. Inspect the vacuum hoses.

      A01G4HD

  67. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the negative (-) cable to the negative (-) battery terminal.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

      Note

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

  68. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

  69. ADD ENGINE OIL


    1. A01G8XW

      Add clean engine oil and install the oil filler cap.

      Note

      Do not allow engine oil adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

      If engine oil is on the location indicated by the arrow, replace the belt tensioner.

      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 Standard Condition
      Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 Imp. qts)
      Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 Imp. qts)
      Dry fill 6.8 liters (7.2 US qts, 6.0 Imp. qts)

  70. ADD ENGINE COOLANT

    Click here

  71. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  72. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump or appropriate equipment.

    2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)
      A01G8AXE02
      Text in Illustration
      *a Standard charge amount *b Mean value in proper range
      *c Overcharged *d High pressure
      *e Sub-cool system *f Refrigerant amount
      Standard charge amount
      470 to 530 g (16.6 to 18.6 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • The refrigerant amount should be checked by quantity (weight).

      • The graph above is shown for reference only.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an air conditioning system.

  73. 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).

  74. 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. A01G4W3E01
      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.

      A01G8VCE01
      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. A01G7D2E01
      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. A01G9IQE01
      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).

  75. INSPECT ENGINE OIL LEVEL


    1. Warm up the engine, stop it and wait 5 minutes. The engine 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 engine oil up to the full level mark.

      Note

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

  76. 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.

  77. 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.

  78. INSPECT FOR COOLANT LEAK

    CAUTION:

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

    Note

    Before performing each inspection, turn the A/C switch OFF.


    1. A01G6OC

      Fill the radiator with engine coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.

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

  79. INSPECT FOR OIL LEAK

  80. INSPECT FOR EXHAUST GAS LEAK

  81. 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 GTS:

      Check the ignition timing.


      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 / 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 GTS 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 / ON.

      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 GTS operator's manual for further details.

    3. When not using the GTS:


      1. A01G5DSE37
        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.

  82. 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 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 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 GTS operator's manual for further details.

    3. When not using the GTS:


      1. A01G5DSE38
        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.

  83. INSPECT CO/HC

    Tech Tips

    This check determines whether or not the idle CO/HC complies with regulations.


    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

        1. Faulty ignition:


          • Incorrect valve timing

          • Fouled, shorted or improperly gapped spark plugs

        2. Incorrect valve clearance (valve lash adjuster assembly)

        3. Leaks in intake or exhaust valves

        4. Leaks in cylinders
        Low High

        Rough idle

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • PCV hoses

          • Intake manifold

          • Throttle with motor body assembly

          • Brake booster line

        2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air cleaner filter element sub-assembly

        2. Plugged PCV valve

        3. Faulty SFI system:


          • Faulty fuel pressure regulator assembly

          • Defective engine coolant temperature sensor

          • Defective mass air flow meter sub-assembly

          • Faulty ECM

          • Faulty fuel injector assemblies

          • Faulty throttle position sensor (built in throttle with motor body assembly)

  84. CHECK FOR SPEED SENSOR SIGNAL

    Click here

  85. 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 into 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.

  86. ADJUST SHIFT LEVER POSITION


    1. Move the shift lever to N.

    2. Remove the console box Click here.

    3. A01G8RR

      Disconnect the end of the transmission control cable assembly from the lower shift lever assembly.

    4. A01G54UE03
      Text in Illustration
      *1 Slider
      *2 Lock Piece
      *a Slide
      *b Pull

      Slide the slider of the transmission control cable assembly in the direction indicated by the arrow and pull the lock piece outward.

    5. A01G85ZE01
      Text in Illustration
      *1 Lock Piece

      Install the end of the transmission control cable assembly to the lower shift lever assembly.

      Note


      • Check that the lock piece is pulled up.

      • Install the cable end all the way to the base of the pin.

    6. Push the lock piece into the adjuster case.

      Note


      • Check that the park/neutral position switch assembly and the shift lever are in neutral.

      • Securely push in the lock piece until the slider lock is engaged.

    7. After adjusting the shift lever position, check the operation and function of the shift lever. If there is a problem, adjust the position again.

    8. Install the console box Click here.

  87. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  88. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. Fit the 3 retainers and install the V-bank cover sub-assembly.

  89. INSTALL COOL AIR INTAKE DUCT SEAL


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

  90. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal LH with the 2 bolts and clip.

  91. INSTALL ENGINE UNDER COVER LH (w/ Front Lower Bumper Absorber)


    1. Install the engine under cover LH with the 2 clips.

  92. INSTALL ENGINE UNDER COVER LH (w/o Front Lower Bumper Absorber)


    1. Install the engine under cover LH with the 2 clips and 2 screws.

  93. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH with the 3 screws.

  94. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal RH with the 2 bolts and clip.

  95. INSTALL ENGINE UNDER COVER RH (w/ Front Lower Bumper Absorber)


    1. Install the engine under cover RH with the 3 clips.

  96. INSTALL ENGINE UNDER COVER RH (w/o Front Lower Bumper Absorber)


    1. Install the engine under cover RH with the 3 clips and 2 screws.

  97. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


    1. Install the front wheel opening extension pad RH with the 3 screws.

  98. INSTALL FRONT LOWER BUMPER ABSORBER (w/ Front Lower Bumper Absorber)


    1. Install the front lower bumper absorber with the 6 screws and 6 bolts.