ENGINE ASSEMBLY INSTALLATION

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

1. Using SST, hold the crankshaft.

   

   SST

   09213-54015

   91551-80650

   09330-00021

2. Clean the bolts and their installation holes.

3. 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. Install the drive plate and rear drive plate spacer onto the crankshaft.

   

   Text in Illustration

   *1	Drive Plate
   *2	Rear Drive Plate Spacer
   	Transaxle Side

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

   

   Text in Illustration

   *1

   Adhesive

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

   

   Torque:

   98 N*m  { 999 kgf*cm, 72 ft.*lbf }

   Note

   Do not start the engine for at least an hour after installing the drive plate.

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

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

   

   Clutch spline grease
   Toyota Genuine Clutch Spline Grease or equivalent

   Maximum grease amount
   Approximately 1 g (0.0353 oz.)

   Text in Illustration

   *1	Torque Converter Centerpiece
   *2	Crankshaft

2. 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 rotates.

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

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. 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. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly LH contact surface of the front axle hub bearing.

   

   Text in Illustration

   Mineral Oil Base Grease

   Tech Tips

   Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

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

   

   Text in Illustration

   *a

   Matchmark

   Note

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

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

   

   Torque:

   32 N*m  { 330 kgf*cm, 24 ft.*lbf }

6. Apply mineral oil base grease to the areas indicated by the arrows in the illustration on the front drive shaft assembly RH contact surface of the front axle hub bearing.

   

   Text in Illustration

   Mineral Oil Base Grease

   Tech Tips

   Apply 0.1 to 0.3 g (0.00353 to 0.0106 oz.) of mineral oil base grease to each area.

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

   

   Text in Illustration

   *a

   Matchmark

   Note

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

INSTALL GENERATOR ASSEMBLY

1. Install the generator 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 generator wire with the nut.

   Torque:

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

4. Install the terminal cap.

5. Connect the generator connector.

INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

1. Using an E8 "TORX" socket, temporarily install the compressor assembly with pulley with the 2 stud bolts.

   

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Tech Tips

   Tighten the stud bolts in the order shown in the illustration.

2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

   

   Torque:

   25 N*m  { 250 kgf*cm, 18 ft.*lbf }

   Tech Tips

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

INSTALL V-RIBBED BELT

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

   

   Text in Illustration

   *1	Crankshaft
   *2	Tensioner
   *3	Generator
   *4	Water Pump
   *5	Cooler Compressor

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 belt is attached to each pulley. In particular, make sure that the belt is securely fitted into the grooves of the crankshaft pulley.

CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

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

   

   Text in Illustration

   *a

   Matchmark

2. Install the bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

INSTALL 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.

   

   Text in Illustration

   *A	Type A Nut
   *B	Type B Nut
   *a	20 mm (0.787 in.)
   *b	22 mm (0.866 in.)
   	Bolt
   	Nut

   Torque:

   Type A Nut and Bolt

   75 N*m  { 765 kgf*cm, 55 ft.*lbf }

   Type B Nut and Bolt

   92 N*m  { 938 kgf*cm, 68 ft.*lbf }

   Note

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

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

INSTALL 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:

   125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

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

INSTALL FRONT AXLE SHAFT NUT LH

1. Clean the threaded parts on the front drive shaft assembly and a new 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. Using a socket wrench (30 mm), install the front axle shaft nut.

   

   Torque:

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

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

INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

   

   Minimum

   40.5 mm (1.60 in.)

   Tech Tips

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

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

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

   

   Text in Illustration

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

   Note

   • Be careful with the installation direction of the gasket.

   • 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 the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

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

INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the attached vinyl tape from the hose.

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

   Compressor oil
   ND-OIL 8 or equivalent

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

4. Install the No. 1 cooler refrigerant discharge hose onto the compressor and pulley with the bolt.

   Torque:

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

INSTALL SUCTION HOSE SUB-ASSEMBLY (for TMMK Made)

1. Remove the attached vinyl tape from the hose.

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

   Compressor oil
   ND-OIL 8 or equivalent

3. Install the O-ring onto the suction hose sub-assembly.

4. Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.

   Torque:

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

5. Connect the 2 connectors.

6. Install the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL NO.1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made)

1. Remove the attached vinyl tape from the hose.

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

5. Connect the 2 connectors.

6. Install the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL STARTER ASSEMBLY

1. Install the starter with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the starter connector.

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

   Torque:

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

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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

2. Install the air cleaner hose with the hose clamp.

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

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

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

6. Connect the vacuum switching valve assembly to the air cleaner hose.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

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

   Note

   Never use water as a substitute for engine coolant.

   Specified capacity
   7.3 liters (7.7 US qts, 6.4 lmp. qts)

   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).

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

4. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

   If the coolant level is low, add coolant.

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

6. 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 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 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 radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the cooling fans.

      Note

      • Make sure that the radiator reserve tank assembly still has some 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 coolant, the engine may overheat or be seriously damaged.

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

7. Stop the engine and wait until the engine coolant cools down.

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

CHARGE 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)

   

   Text in Illustration

   *a	Sub-cool System	*b	High Pressure
   *c	Refrigerant Amount	*d	Standard charge amount
   *e	Charge additional 100g (3.5oz.)	*f	Point where bubbles disappear
   *g	Mean value in proper range	*h	Overcharged

   Standard charge amount
   480 to 580g (16.9 to 20.4oz.)

   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. This vehicle is not equipped with a sight glass.

   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.

INSPECT FOR FUEL LEAK

1. Check fuel pump operation.

   1. Connect the Techstream to the DLC3.

   2. Turn the ignition switch to ON and turn the Techstream 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 for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, 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 ignition switch off.

4. Disconnect the Techstream from the DLC3.

INSPECT FOR COOLANT LEAK

1. Fill the radiator with 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/cm², 17 psi), and check that the pressure does not drop.

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

INSPECT REFRIGERANT LEAK

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

2. Carry out the test under the following conditions:

   • Ignition switch off.

   • Secure 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.

   • 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)

3. Using a halogen leak detector, inspect for refrigerant leaks from the air conditioning system.

   

   Text in Illustration

   *1	Halogen Leak Detector
   *a	Inspect for Leak

4. Bring the halogen leak detector close to the drain hose with the detector power off, and then turn the detector on.

   

   Text in Illustration

   *1	Halogen Leak Detector
   *2	Drain Hose

   Tech Tips

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

   • Bring the halogen leak detector sensor under the drain hose.

   • When bringing the halogen leak detector close to the drain 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.

5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

6. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

   Tech Tips

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

INSPECT IGNITION TIMING

1. Warm up and stop the engine.

2. When using the Techstream:

   1. Connect the Techstream to the DLC3.

      Note

      When checking the ignition timing, the transmission should be in neutral.

   2. Start the engine and idle it.

   3. Turn the Techstream main switch on.

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

      Standard ignition timing
      BTDC 5 to 15 deg. at idle

      Tech Tips

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

      If the ignition timing is not as specified, check the valve timing.

   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 of the Data List.

      Standard ignition timing
      BTDC 8 to 12 deg. at idle

      Tech Tips

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

      If the ignition timing is not as specified, check the valve timing.

   8. Enter the following menus: Connect the TC and TE1 / OFF.

   9. Turn the ignition switch off.

   10. Disconnect the Techstream from the DLC3.

3. When not using the Techstream:

   1. Remove the No. 1 engine cover sub-assembly.

   2. Pull out the wire harness as shown in the illustration.

      

   3. Connect the clip of a timing light to the wire harness.

      Note

      Use a timing light that detects primary signals.

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

      

      Text in Illustration

      *1

      DLC3

      SST

      09843-18040

      Note

      • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      • When checking the ignition timing, the transmission should be in neutral.

   5. Using a timing light, check the ignition timing.

      Standard ignition timing
      8 to 12° BTDC at idle

   6. Remove SST from the DLC3.

   7. Check the ignition timing.

      Standard ignition timing
      5 to 15° BTDC at idle

      If the ignition timing is not as specified, check the valve timing.

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

   9. Disconnect the timing light from the engine.

   10. Install the No. 1 engine cover sub-assembly.

INSPECT ENGINE IDLE SPEED

1. Warm up and stop the engine.

2. When using the Techstream:

   1. Connect the Techstream to the DLC3.

      Note

      • Switch off all accessories and the A/C before connecting the Techstream.

      • When checking the idle speed, the transmission should be in neutral.

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

   3. Turn the Techstream main switch on.

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

      Standard idle speed
      610 to 710 rpm

      Tech Tips

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

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

   5. Disconnect the Techstream from the DLC3.

3. When not using the Techstream:

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

      

      Text in Illustration

      *1

      DLC3

      SST

      09843-18030

      Note

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

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

      • Inspect the idle speed with the cooling fans off.

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

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

   3. Check the idle speed.

      Standard idle speed
      610 to 710 rpm

      If the 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. Immediately check CO/HC concentration at idle and 2500 rpm.

   Tech Tips

   • When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.

   • If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

   1. Check the DTCs Click here.

   2. See the table below for possible causes, and then inspect and correct the applicable causes 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 7 clips.