ENGINE ASSEMBLY INSTALLATION

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

   

   Text in Illustration

   *1	Drive Plate
   *2	Rear Spacer
   	Transaxle Side

5. Apply adhesive to 2 or 3 threads of each bolt.

   

   Text in Illustration

   *1

   Adhesive

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

6. In several steps, uniformly install and tighten the 8 bolts 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.

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

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

   

   Text in Illustration

   *1	Crankshaft
   *2	Torque Converter Centerpiece
   *a	Transaxle serial number 2##########
   *b	Transaxle serial number 3##########

   Clutch spline grease
   Toyota Genuine Clutch Spline Grease or equivalent

   Maximum grease amount
   Approximately 1 g (0.0353 oz.)

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 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 transaxle contact surface of the engine cylinder block before installing the transaxle.

   • Do not forcibly pry on the automatic transaxle assembly.

   • Check that the torque converter rotates.

   Tech Tips

   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.

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

   Adhesive
   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

5. Install the bolt.

   

   Torque:

   Bolt D

   46 N*m  { 469 kgf*cm, 34 ft.*lbf }

   Tech Tips

   Bolt length:

   • Bolt D: 41 mm (1.61 in.)

INSTALL TRANSMISSION OIL COOLER

1. Install the transmission oil cooler with the transmission oil cooler stay to the automatic transaxle assembly with the 2 bolts.

   Torque:

   14 N*m  { 138 kgf*cm, 10 ft.*lbf }

2. Install the No. 1 oil cooler outlet hose and No. 1 oil cooler inlet hose.

3. Install the No. 4 water by-pass hose.

   

   Text in Illustration

   *a

   Paint

   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.

4. Install the clamp and connect the breather plug.

INSTALL COMPRESSOR AND MAGNETIC CLUTCH

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

   

   Torque:

   25 N*m  { 250 kgf*cm, 18 ft.*lbf }

   Note

   Tighten the bolts in the order shown in the illustration to install the cooler compressor.

INSTALL GENERATOR ASSEMBLY

1. Install the generator assembly with the 2 bolts.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

2. Connect the wire harness clamp.

3. Install the generator bracket with the 2 bolts.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

4. Connect the generator connector to the generator assembly.

5. Install the generator wire with the bolt.

   Torque:

   8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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

   Torque:

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

7. Install the terminal cap.

INSTALL V-RIBBED BELT

1. Install the V-ribbed belt.

   

   Text in Illustration

   *1	Water Pump
   *2	Idler
   *3	Generator
   *4	Crankshaft
   *5	Tensioner
   *6	A/C Compressor

2. 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 belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

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.

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.

   

   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.

CONNECT TIE ROD ASSEMBLY LH

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

   Torque:

   49 N*m  { 500 kgf*cm, 36 ft.*lbf }

2. Install a new cotter pin.

   Note

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

INSTALL FRONT SPEED SENSOR LH

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

   Torque:

   19 N*m  { 192 kgf*cm, 14 ft.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

   Tech Tips

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

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

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH

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

   Torque:

   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 a hammer, stake the front axle shaft nut.

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 EXHAUST PIPE ASSEMBLY

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

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

   

   Text in Illustration

   *1	Bolt
   *2	Nut
   *3	Bolt and Nut

   Torque:

   Bolt

   55 N*m  { 561 kgf*cm, 40 ft.*lbf }

   Nut

   55 N*m  { 561 kgf*cm, 40 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.

INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

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

   Torque:

   33 N*m  { 337 kgf*cm, 24 ft.*lbf }

CONNECT SUCTION HOSE SUB-ASSEMBLY

1. Remove the vinyl tape from the 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 suction hose sub-assembly.

4. Connect the suction hose sub-assembly to the compressor and magnetic clutch with the bolt.

   Torque:

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

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the vinyl tape from the hose and compressor and magnetic clutch.

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

   Compressor oil
   ND-OIL 8 or equivalent

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

4. Connect the No. 1 cooler refrigerant discharge hose to the compressor and magnetic clutch with the bolt.

   Torque:

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

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

CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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

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

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

   Note

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

INSTALL STARTER ASSEMBLY

1. Install the starter with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the starter connector.

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

   Torque:

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

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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

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

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

4. Connect the 3 hoses.

5. Connect the ventilation hose.

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

ADD ENGINE OIL

1. Add clean engine oil and install the oil filler cap.

   Standard Oil Grade
   Oil Grade Oil Viscosity (SAE) ILSAC multigrade engine oil 0W-20

   Standard Oil Grade (Destination package for Mexico)
   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 lmp. qts) Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts) Dry fill 6.8 liters (7.2 US qts, 6.0 lmp. qts)

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)

   

   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.

WARM UP ENGINE

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note

   To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

INSPECT FOR REFRIGERANT LEAK

1. After recharging the air conditioning system with refrigerant, 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 ENGINE OIL LEVEL

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

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

   Note

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

   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 speeds or with a heavy load (when towing, etc.), or when accelerating or decelerating frequently while driving.

   • 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.

INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

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

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

   Note

   Do not substitute plain water for engine coolant.

INSPECT FOR FUEL LEAK

1. Check fuel pump operation.

   1. Connect the Techstream to the DLC3.

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

      Note

      Do not start the engine.

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

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

2. Inspect for fuel leaks.

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

3. Turn the engine switch off.

4. Disconnect the 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*cm, 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 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 Techstream:

   Check the ignition timing.

   1. Connect the Techstream to the DLC3.

   2. Start the engine and run it at idle.

   3. Turn the Techstream main switch on.

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

      Standard ignition timing
      9.5 to 24.5° BTDC at idle

      Note

      • Check the ignition timing with the cooling fans off.

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

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

      Tech Tips

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

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

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

   7. Monitor IGN Advance.

   8. Perform the Active Test.

      Standard ignition timing
      8 to 12° BTDC at idle

      Note

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

      Tech Tips

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

3. When not using the Techstream:

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

      

      Text in Illustration

      *1

      DLC3

      SST

      09843-18040

      Note

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

      • Check the ignition timing with the cooling fans off.

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

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

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

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

      Note

      Use a timing light that detects primary signals.

   4. Check the ignition timing at idle.

      Standard ignition timing
      8 to 12° BTDC at idle

      Note

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

      Tech Tips

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

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

   6. Check the ignition timing at idle.

      Standard ignition timing
      9.5 to 24.5° BTDC at idle

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

   8. Remove the timing light from the engine.

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

INSPECT ENGINE IDLE SPEED

1. Warm up and stop the engine.

   Tech Tips

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

2. When using the Techstream:

   Check the idle speed.

   1. Connect the Techstream to the DLC3.

   2. Start the engine and run it at idle.

   3. Turn the Techstream main switch on.

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

   5. Read the value displayed on the tester.

      Standard idle speed
      600 to 700 rpm

      Note

      • Check the idle speed with the cooling fans off.

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

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

      Tech Tips

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

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

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

   2. Check the idle speed.

      Standard idle speed
      600 to 700 rpm

      Note

      • Check the idle speed with the cooling fans off.

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

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

      Tech Tips

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

INSPECT CO/HC

1. Start the engine.

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

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

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

   Tech Tips

   When performing the 2 mode (with the engine idling/running at 2500 rpm) test, follow the measurement order determined by applicable local regulations.

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

   1. Check the DTCs Click here.

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

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

INSPECT SHIFT LEVER POSITION

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

ADJUST SHIFT LEVER POSITION

1. Move the shift lever to N.

2. Remove the console box Click here.

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

   

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

   

   Text in Illustration

   *1	Slider
   *2	Lock Piece
   *a	Slide
   *b	Pull

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

   

   Text in Illustration

   *1	Lock Piece

   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 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.

INSTALL COOL AIR INTAKE DUCT SEAL

1. Install the cool air intake duct seal with the 7 clips.