ENGINE ASSEMBLY INSTALLATION


  1. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 2 engine mounting bracket LH with the bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  2. INSTALL ENGINE HANGER


    1. A0156PZE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-31110
      No. 2 Engine Hanger 12282-31140
      Bolt 91671-C0830

  3. REMOVE ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

      Note


      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    3. Place the engine onto a work bench.

  4. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. A0156LI

      Install the front engine mounting insulator LH with the 2 bolts and nut.

      Torque:
      for bolt
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      for nut
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut

    3. Install the front engine mounting insulator RH with the 2 bolts and nut.

      Torque:
      for bolt
      79 N*m  { 806 kgf*cm, 58 ft.*lbf }
      for nut
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    4. Remove the 2 engine hangers and 4 bolts.

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. A015BDZE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and their installation holes.

    3. A015E7RE01
      Text in Illustration
      *1 Front Spacer
      *2 Drive Plate and Ring Gear
      *3 Rear Spacer
      A015DIT Automatic Transmission Side

      Install the front spacer, drive plate and rear spacer to the crankshaft.

      Tech Tips

      As the front spacer, the drive plate and ring gear, and the rear spacer are not reversible, be sure to install them in the direction shown in the illustration.

    4. Apply adhesive to 2 or 3 threads at the end of the 8 new bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A0157VCE01

      Uniformly install and 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 1 hour after installing.

  6. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. A015BDZE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and their installation holes.

    3. Temporarily install the flywheel with 8 new bolts.

    4. Install and tighten the 8 bolts uniformly in several steps.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    5. Mark the top of the bolts with paint.

    6. Tighten the 8 bolts 90° in the same sequence.

    7. Check that the paint marks are now at a 90° angle to the top.

  7. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    A0159PSE01

    1. Insert SST into the clutch disc, then insert the clutch disc into the flywheel.

      SST
      09301-00110

      Note

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

  8. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    A015DNWE01

    1. Align the matchmark on the clutch cover with the one on the flywheel.

    2. In the order shown in the illustration, temporarily install the 6 bolts starting from the bolt located near the knock pin on the top.

    3. Check that the disc is in the center by lightly moving SST up and down, and left and right.

      SST
      09301-00110

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

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

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

    A0156EA

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

      Maximum Misalignment
      1.3 mm (0.0512 in.)
    2. A015CBKE01

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

      SST
      09333-00013

  10. CONNECT NO. 1 OIL COOLER HOSE TUBE SUB-ASSEMBLY


    1. Connect the cooler hose tube with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  11. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. Install the rear No. 1 engine mounting insulator to the transmission with the 4 bolts.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

  12. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    Click here

  13. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  14. CONNECT NO. 1 AND NO. 2 FUEL PIPE


    1. Connect the No. 1 and No. 2 fuel pipes Click here.

  15. INSTALL COOLER COMPRESSOR ASSEMBLY

    A015DKAE01

    1. Install the cooler compressor with the 3 bolts.

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

      Tech Tips

      Tighten the bolts in the order shown in the illustration.

    2. Connect the connector.

  16. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A01564IE01

      Remove the attached vinyl tape from the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose.

    4. Connect the suction hose to the cooler compressor with the 2 bolts.

      Torque:
      for bolt A
      9.8 N*m  { 100 kgf*cm, 87 ft.*lbf }
      for bolt B
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

  17. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    A015C1F

    1. Remove the attached vinyl tape from the hose.

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

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the cooler refrigerant discharge hose.

    4. Connect the cooler refrigerant discharge hose to the cooler compressor with the bolt.

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

  18. INSTALL GENERATOR ASSEMBLY


    1. Install the generator bracket to the generator with the bolt.

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

    2. Install the generator with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    3. Connect the generator bracket with the bolt.

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

    4. Connect the wire harness clamp bracket with the bolt.

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

    5. Connect the generator wire to terminal B with the nut.

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

    6. Close the terminal cap.

    7. Connect the generator connector.

  19. CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump with the 2 bolts.

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

    2. Attach the wire harness clamp.

    3. Connect the connector.

  20. CONNECT WATER HOSE SUB-ASSEMBLY


    1. Connect the water hoses.

  21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A0159MME03
      Text in Illustration
      *1 Protrusion
      A015DIT Front

      Install a new gasket to the cylinder head.

      Note

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. A0156P3E02
      Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

      Tighten the 6 nuts in the sequence shown in the illustration.

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

    4. Connect the air fuel ratio sensor connector.

  22. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

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

  23. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A015ASJE02
      Text in Illustration
      *1 Claw
      *2 No. 2 Air Tube

      Install 2 new gaskets.

      Note

      Make sure the gasket's claws are not caught between the No. 2 emission control valve set and No. 2 air tube.

    2. Install the No. 2 air tube with the 2 bolts and 2 nuts.

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

  24. INSTALL NO. 2 MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  25. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A0156IPE03
      Text in Illustration
      *1 Protrusion
      A015DIT Front

      Install a new gasket to the cylinder head.

      Note

      Be careful of the installation direction.

    2. Temporarily install the manifold with 6 new nuts.

    3. A015B0ZE02
      Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

      Tighten the 6 nuts in the sequence shown in the illustration.

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

    4. Connect the air fuel ratio sensor connector.

  26. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the heat insulator with the 3 bolts.

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

  27. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT


    • for Manual Tilt and Manual Telescopic Steering Column: Click here

    • for Power Tilt and Power Telescopic Steering Column: Click here

  28. INSTALL AIR TUBE (w/ Secondary Air Injection System)


    1. A015DETE02
      Text in Illustration
      *1 Claw
      *2 Air Tube

      Install 2 new gaskets.

      Note

      Make sure the gasket's claws are not caught between the No. 1 emission control valve set and air tube.

    2. Install the air tube with the 2 bolts and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 in.*lbf }

  29. INSTALL MANIFOLD STAY


    1. Install the No. 2 manifold stay with the 3 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  30. INSTALL FRONT FENDER APRON TRIM PACKING D


    1. Install the front fender apron trim packing D with the 4 clips.

  31. INSTALL FRONT FENDER APRON TRIM PACKING C


    1. Install the front fender apron trim packing C with the 4 clips.

  32. INSTALL FRONT FENDER APRON TRIM PACKING B


    1. w/ KDSS:

      Install the front fender apron trim packing B with the 3 clips.

    2. w/o KDSS:

      Install the front fender apron trim packing B with the 4 clips.

  33. INSTALL FRONT FENDER APRON TRIM PACKING A


    1. Install the front fender apron trim packing A with the 3 clips.

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe to the exhaust manifold RH with 2 new nuts.

      Torque:
      54 N*m  { 554 kgf*cm, 40 ft.*lbf }

    2. Connect the heated oxygen sensor connector.

  35. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)


    1. A015BIH

      Temporarily install the sensor to the exhaust pipe by hand.

    2. A015ATSE01

      Using SST, tighten the sensor.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

  36. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with 2 new nuts.

      Torque:
      54 N*m  { 554 kgf*cm, 40 ft.*lbf }
    2. A015AJ6E01

      Connect the heated oxygen sensor connector.

      Tech Tips

      Hook the wire harness to the bracket.

  37. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. A01585S

      Check the free length.


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

        Minimum free length
        43 mm (1.693 in.)

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

    2. Connect the center exhaust pipe to the 3 exhaust pipe supports.

    3. Install 2 new gaskets to the front exhaust pipe and front No. 2 exhaust pipe.

    4. Install the center exhaust pipe with the 4 bolts and 2 compression springs.

      Torque:
      for center exhaust pipe and front exhaust pipe
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for center exhaust pipe and front No. 2 exhaust pipe
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  38. INSTALL TAILPIPE ASSEMBLY


    1. Install the tailpipe to the 2 exhaust pipe supports.

    2. Set a new gasket to the center exhaust pipe.

    3. A0158NQE02

      Connect the tailpipe to the center pipe with a new clamp.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips

      Install the clamp within the angle range shown in the illustration.

  39. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)


    1. A015BIH

      Temporarily install the sensor to the exhaust pipe by hand.

    2. A015A5RE01

      Using SST, tighten the sensor.

      SST
      09224-00010
      Torque:
      without SST
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
      with SST
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure SST and the wrench are connected in a straight line.

    3. A01582IE01

      Connect the sensor connector.

  40. CONNECT ENGINE WIRE


    1. A0159CG

      w/ Secondary Air Injection System:

      Attach the clamp and connect the air pump connector.

    2. A0156YV

      Attach the clamp and connect the power steering switch connector.

    3. A015DSI

      w/ Winch:

      Install the winch ground wire with the 2 bolts.

      Torque:
      19 N*m  { 196 kgf*cm, 14 ft.*lbf }
    4. A0158UB

      Attach the 2 clamps and connect the connector.

    5. A015704

      Install the ground wire with the bolt and attach the wire harness clamp.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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

    7. Connect the wire to the positive (+) battery cable with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    8. Connect the wire and 2 clips to the engine room junction block with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    9. Connect the 2 clips and 2 connectors to the engine room junction block.

    10. w/ Secondary Air Injection System:

      Attach the clamp and connect the 2 air injection control driver connectors.

    11. Connect the ground wire to the bracket with the bolt.

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

    12. Install the engine room relay block cover.

    13. A015BSF

      Connect the 4 connectors to the junction block.

    14. Attach the wire harness clamp.

    15. Connect the ECM connector Click here.

    16. Install the junction block cover.

  41. INSTALL INTAKE AIR SURGE TANK


    1. Install a new gasket to the intake air surge tank.

    2. A0155LOE01

      Install the intake air surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Text in Illustration
      A015DIT Bolt
      A015CC1 Nut

    3. Install the throttle body bracket with the 2 bolts.

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

    4. Install the No. 1 surge tank stay with the 2 bolts.

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

    5. Attach the wire harness clamp.

    6. Install the bracket with the bolt and attach the 2 wire harness clamps.

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

    7. Install the No. 2 surge tank stay with the 2 bolts.

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

    8. for Manual Transmission:

      Connect the clutch flexible hose bracket with the nut.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    9. A0157KME01
      Text in Illustration
      *a Front
      *b RH

      Connect the No. 1 PCV hose.

      Tech Tips

      Connect the No. 1 PCV hose so that the direction of the hose clamp is as indicated in the illustration.

    10. Connect the No. 1 vacuum switching valve connector.

    11. Connect the purge line hose.

    12. Connect the throttle body connector.

    13. Connect the No. 4 water by-pass hose.

    14. Connect the No. 5 water by-pass hose.

  42. INSTALL AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)


    1. A0156MEE01
      Text in Illustration
      *1 Paint Mark
      *a Top
      *b RH Side

      for Bank 1 Side:

      Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    2. A0159P0E01
      Text in Illustration
      *1 Paint Mark
      *a Top
      *b LH Side

      for Bank 2 Side:

      Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

      Tech Tips

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Install the 3 bolts.

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

    4. Connect the No. 3 air hose.

  43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case with the 3 bolts.

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

    2. Install the air cleaner filter element.

  44. INSTALL AIR CLEANER CAP AND HOSE


    1. Install the air cleaner cap and hose.


      1. Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.

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

      2. Tighten the clamp.

        Torque:
        2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

      3. Attach the clamp and connect the ventilation hose, vacuum hose and mass air flow meter connector.

  45. INSTALL RADIATOR ASSEMBLY


    1. A015884

      Set the radiator bracket hooks into the radiator support holes.

    2. Install the radiator with the 4 bolts.

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

  46. CONNECT OUTLET OIL COOLER HOSE (for Automatic Transmission)


    1. Connect the cooler hose.

  47. CONNECT INLET OIL COOLER HOSE (for Automatic Transmission)


    1. Connect the cooler hose.

  48. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Place the shroud together with the coupling fan between the radiator and engine.

      Note

      Be careful not to damage the radiator core.

    3. Temporarily install the fluid coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

      Note

      Match the paint marks on the heads of the water pump studs with the paint marks on the flange of the fluid coupling and install the fluid coupling.

    4. A01557N

      Attach the claws of the shroud to the radiator as shown in the illustration.

    5. Install the shroud with the 2 bolts.

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

    6. Connect the reservoir hose to the upper side of the radiator tank.

    7. Install the fan and generator V-belt Click here.

    8. Tighten the 4 nuts of the fluid coupling fan.

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

  49. CONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)


    1. Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

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

  50. INSTALL NO. 2 RADIATOR HOSE


    1. Install the No. 2 radiator hose and attach the clamp.

  51. INSTALL NO. 1 RADIATOR HOSE

  52. INSTALL RADIATOR SIDE DEFLECTOR LH


    1. Install the deflector with the 4 clips.

  53. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)


    1. Install the deflector with the 4 clips.

  54. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)


    1. Install the oil cooler air duct with the 4 bolts.

      Torque:
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

  55. INSTALL V-BANK COVER


    1. A015D9LE01
      Text in Illustration
      *1 Pin
      *2 Hook

      Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

  56. INSTALL FRONT BUMPER COVER


  57. INSTALL RADIATOR GRILLE


    1. w/ Wide View Front Monitor System:


      1. Connect the connector.

    2. Attach the 2 clips and 8 claws to install the radiator grille assembly.

    3. Install the 3 screws.

  58. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the radiator support seal with the 7 clips.

      A015BVKE02

  59. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  60. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 10 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  61. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Push in the clip to install the front fender splash shield sub-assembly LH.

    2. Install the 3 bolts and screw.

  62. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Push in the clip to install the front fender splash shield sub-assembly RH.

    2. Install the 3 bolts and 2 screws.

  63. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  64. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  65. ADD ENGINE OIL


    1. Add fresh oil.

      Note

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

      A0156PU

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

      Standard Engine Oil
      Oil Grade Oil Viscosity (SAE)
      API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil

      5W-30

      10W-30
      API grade SL, SM or SN multigrade engine oil

      15W-40

      20W-50
      Standard Engine Oil (for China)
      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 Oil Capacity
      Item Specified Condition
      Drain and refill without oil filter change 5.6 liters (5.9 US qts, 4.9 Imp. qts)
      Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 Imp. qts)
      Dry fill 7.1 liters (7.5 US qts, 6.2 Imp. qts)

  66. ADD ENGINE COOLANT


    1. Add engine coolant.

      Standard Capacity (for Manual transmission)
      Item Specified Condition
      w/ Rear Heater 14.6 liters (15.4 US qts, 12.8 Imp. qts)
      w/o Rear Heater 11.7 liters (12.4 US qts, 10.3 Imp. qts)
      Standard capacity (for Automatic transmission)
      11.2 liters (11.8 US qts, 9.9 Imp. qts)
      Standard Capacity (for China)
      14.4 liters (15.2 US qts, 12.7 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 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 consists of a combination of low phosphates and organic acids).

    2. Slowly pour coolant into the radiator reservoir until it reaches the F line.

    3. Install the reservoir cap.

    4. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

    5. Install the radiator cap.

    6. Set the air conditioning as follows while warming up the engine.

      Item Condition
      Fan speed Any setting except off
      Temperature Toward WARM
      Air conditioning switch Off

    7. Start the engine and warm it up until the thermostat opens.

      Tech Tips

      The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    8. Maintain the engine speed at 2000 to 2500 rpm.

      Note


      • Make sure that the radiator reservoir still has some coolant in it.

      • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Run the engine at 2000 rpm until the coolant level has stabilized.

    9. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:


      • Wear protective gloves. Hot areas on the parts may injure your hands.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

    10. Stop the engine, and wait until the engine coolant cools down to ambient temperature.

      CAUTION:

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

    11. Check that the coolant level is between the F and L lines.

      If the coolant level is below the L line, repeat all of the procedures above.

      If the coolant level is above the F line, drain coolant so that the coolant level is between the F and L lines.

  67. INSPECT FOR FUEL LEAK


    1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch to ON and turn the GTS on.

        Note

        Do not start the engine.

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

      4. Check that there are no leaks from the fuel system.

        If there are fuel leaks, repair or replace parts as necessary.

      5. Turn the ignition switch off.

      6. Disconnect the GTS from the DLC3.

  68. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 psi), and then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and engine water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

  69. INSPECT FOR OIL LEAK


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

  70. INSPECT FOR EXHAUST GAS LEAK


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

  71. CHECK ENGINE OIL LEVEL


    1. Warm up the engine, and then stop the engine and wait for 5 minutes.

    2. Check that the engine oil level is between the low level and full level marks on the dipstick.

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

      Note

      Do not fill engine oil above the full level mark.

      Tech Tips

      A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.


      • When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.

      • If low quality oil or oil of an inappropriate viscosity is used.

      • When driving at high engine speed or with a heavy load, (when towing, or), when driving while accelerating or decelerating frequently.

      • When leaving the idling for a long time, or when driving frequently through heavy traffic.

      When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.

  72. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard:
      Condenser Core Thickness Air Conditioning Type Cool Box Refrigerant Charging Amount
      22 mm (0.866 in.) w/o Rear Cooler w/ Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/o Cool Box 870 +/-30 g (30.7 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 1010 +/-30 g (35.6 +/-1.1 oz.)
      w/o Cool Box 960 +/-30 g (33.9 +/-1.1 oz.)
      16 mm (0.630 in.) w/o Rear Cooler w/ Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/o Cool Box 770 +/-30 g (27.2 +/-1.1 oz.)
      w/ Rear Cooler w/ Cool Box 970 +/-30 g (34.2 +/-1.1 oz.)
      w/o Cool Box 920 +/-30 g (32.5 +/-1.1 oz.)
      A015D7VE19

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  73. WARM UP ENGINE


    1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  74. CHECK FOR REFRIGERANT GAS LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation under these conditions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A015C1XE21

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

    5. Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

  75. PERFORM RESET MEMORY (for Automatic Transmission)


    1. Perform the Reset Memory procedures Click here.

  76. INSPECT IGNITION TIMING

    Note


    • Turn all electrical systems off.


    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / IGN Advance.

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

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

    3. A0159JBE05
      Text in Illustration
      *a Front view of DLC3

      When not using the GTS:


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

        SST
        09843-18040

        Note

        Be sure not to improperly connect the terminals. This may damage the engine.

      2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

        Note


        • Use a timing light that detects primary signals.


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

      3. Inspect the ignition timing during idling.

        Standard ignition timing
        8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

      4. Remove SST from the DLC3.

      5. Inspect the ignition timing during idling.

        Standard ignition timing
        7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

      6. Disconnect the timing light from the engine.

  77. INSPECT ENGINE IDLE SPEED

    Note


    • Turn all the electrical systems off.


    • Perform the inspection when the cooling fan motor is turned off.


    1. Warm up the engine.

    2. When using the GTS:


      1. Connect the GTS to the DLC3.

      2. Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Engine Speed.

      3. Inspect the engine idle speed.

        Standard idle speed
        690 to 790 rpm (transmission in neutral and A/C switch off)
    3. A0159JBE06
      Text in Illustration
      *a Front view of DLC3

      When not using the GTS:


      1. Connect SST to terminal 9 (TAC) of the DLC3.

        SST
        09843-18030

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

      3. Inspect the engine idle speed.

        Standard idle speed
        690 to 790 rpm (transmission in neutral and A/C switch off)

  78. INSPECT CO/HC

    Tech Tips

    This check is to determine whether or not the idle CO/HC concentration complies with regulations.


    1. Start the engine.

    2. Run the engine 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. Immediately check the CO/HC concentration during idling and/or at 2500 rpm.

      Tech Tips

      When carrying out the 2 tests (idling and 2500 rpm), the measurement orders are prescribed by the applicable local regulations.

    5. If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below.


      1. Check the air fuel ratio sensor operation Click here and heated oxygen sensor operation Click here.

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

        CO HC Symptom Causes
        Normal High Rough idling

        1. Faulty ignition:


          • Incorrect timing

          • Plugs are contaminated or shorted, or plug gaps are incorrect

        2. Incorrect valve clearance

        3. Leaky intake and exhaust valves

        4. Leaky cylinders
        Low High

        Rough idling

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • Ventilation hoses

          • Intake manifold

          • Throttle body

        2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air filter

        2. Plugged PCV valve

        3. Faulty SFI system:


          • Faulty pressure regulator

          • Defective engine coolant temperature sensor

          • Faulty mass air flow meter

          • Faulty ECM

          • Faulty injectors

          • Faulty throttle position sensor

  79. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood with the 4 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

  80. INSPECT HOOD SUB-ASSEMBLY


    1. Check that the clearance measurements of areas A to C are within the standard range.

      A0156XSE01
      Standard Measurement
      Area Specified Condition
      A (Reference) 2.3 to 5.3 mm (0.0906 to 0.209 in.)
      B 2.0 to 5.0 mm (0.0787 to 0.197 in.)
      C -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)

  81. ADJUST HOOD SUB-ASSEMBLY


    1. A0156IY

      Adjust the hood position.


      1. Loosen the 4 hinge bolts of the hood.

      2. Move the hood and adjust the clearance between the hood and front fender.

      3. Tighten the 4 hinge bolts of the hood after the adjustment.

        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      4. A01562N

        Adjust the cushion rubber so that the height of the hood and fender are aligned.

        Tech Tips

        Raise or lower the hood front end by turning the cushion rubber.

    2. Adjust the hood lock.


      1. A0159F8

        Using a screwdriver, remove the hood lock nut cap as shown in the illustration.

        Tech Tips

        Tape the screwdriver tip before use.

      2. A015774

        Loosen the 2 bolts and hood lock nut.

      3. Adjust the hood lock position so that the striker can enter it smoothly.

      4. Tighten the bolts and nut after the adjustment.

        Torque:
        5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      5. Install a new cap.

  82. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL


    1. The engine coolant should be between the L and F lines when the engine is cold.

      If the engine coolant is below the L line, check for leakage and add TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology to the F line.

      Note

      Do not substitute plain water for engine coolant.