ENGINE ASSEMBLY INSTALLATION

INSTALL CLUTCH DISC ASSEMBLY

Text in Illustration

*1	Clutch disc
*2	Flywheel

1. Insert SST into the clutch disc assembly, and then insert them both into the flywheel sub-assembly.

   SST

   09301-00210

   Note

   Insert the clutch disc assembly in the correct direction.

INSTALL CLUTCH COVER ASSEMBLY

Text in Illustration

*1

Matchmark

1. Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.

2. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.

   SST

   09301-00210

   Torque:

   19 N*m  { 195 kgf*cm, 14 ft.*lbf }

   Tech Tips

   
   

   • Following the order in the illustration, tighten the bolts evenly one at a time.

   • Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.

INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

1. Separate the bleeder clutch release tube from the clutch release bleeder.

2. Remove the 2 bolts and the clutch release bleeder.

INSPECT CLUTCH PIPE LINE

1. Using SST, apply pressure of 0.1 MPa to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.

   SST

   09992-00242

   If the pressure drops, replace the bleeder clutch release tube.

INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

Text in Illustration

*1	Bleeder clutch release tube
*2	Clutch release bleeder

1. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.

2. Install the 2 bolts and clutch release bleeder.

   Torque:

   17 N*m  { 170 kgf*cm, 12 ft.*lbf }

3. Using a union nut wrench 10 mm, install the bleeder clutch release tube.

   Torque:

   15 N*m  { 155 kgf*cm, 11 ft.*lbf }

   Note

   Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench Click here.

INSTALL BLEEDER TO ACCUMULATOR TUBE

INSTALL MANUAL TRANSAXLE ASSEMBLY

INSTALL STARTER ASSEMBLY

INSTALL COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

1. Using a "TORX" socket wrench (E8), install the compressor with the 2 stud bolts.

   Torque:

   15 N*m  { 153 kgf*cm, 11 ft.*lbf }

2. 

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

   Torque:

   25 N*m  { 250 kgf*cm, 18 ft.*lbf }

   Tech Tips

   Tighten the bolts and the nuts in the order shown in the illustration.

3. Connect the connector.

CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

1. Remove the attached vinyl tape from the suction 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 onto the suction hose.

4. Connect the suction hose to the cooler compressor with the bolt.

   Torque:

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

CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

1. Remove the attached vinyl tape from the discharge 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 onto the discharge hose.

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

   Torque:

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

INSTALL FRONT FRAME ASSEMBLY

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

INSTALL FRONT AXLE ASSEMBLY LH

1. Push the front axle out of the vehicle to align the splines of the drive shaft with the front axle and insert the front axle.

   Note

   
   

   • Do not push the front axle further out of the vehicle than is necessary.

   • Do not damage the outboard joint boot.

   • Check for any foreign matter on the speed sensor rotor and insertion area.

   • Do not damage the speed sensor rotor.

INSTALL FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH

1. Install the lower arm onto the steering knuckle with a new castle nut.

   Torque:

   98 N*m  { 999 kgf*cm, 72 ft.*lbf }

   Note

   If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

2. Install a new clip.

INSTALL TIE ROD END SUB-ASSEMBLY LH

1. Install the tie rod end onto the steering knuckle with a new castle nut.

   Torque:

   59 N*m  { 600 kgf*cm, 43 ft.*lbf }

   Note

   If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

2. Install a new clip.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH

1. Install the stabilizer link with the nut.

   Torque:

   74 N*m  { 755 kgf*cm, 55 ft.*lbf }

   Tech Tips

   If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold the stud.

INSTALL FRONT SPEED SENSOR

1. Install the speed sensor onto the steering knuckle with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

   Note

   
   

   • Check that the speed sensor tip and installation area are free of foreign matter.

   • Install the speed sensor without turning it from its original installation angle.

2. 

   Install the flexible hose and speed sensor with the bolt.

   Torque:

   Bolt A

   29 N*m  { 296 kgf*cm, 21 ft.*lbf }

   Bolt B

   29 N*m  { 300 kgf*cm, 22 ft.*lbf }

   Note

   Install the flexible hose and speed sensor without twisting them.

INSTALL FRONT AXLE HUB NUT LH

INSTALL FAN AND GENERATOR V BELT

1. Install the V-ribbed belt.

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

INSTALL NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)

1. Temporarily install the No. 1 V belt onto each pulley.

   Note

   
   

   • Before installing the V belt, check each pulley for any liquid or chips.

   
   

   • Check that the ribs of the V belt are correctly fitted into the grooves of the pulleys.

ADJUST NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)

1. Check the belt for wear, cracks or other signs of damage.

   If any of the following defects is found, replace the V belt.

   Tech Tips

   
   

   • The belt is cracked.

   • The belt is worn out to the extent that the cords are exposed.

   • The belt has chunks missing from the ribs.

2. 

   Check that the belt fits properly in the ribbed grooves.

   Tech Tips

   Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom to the pulley. If it has slipped out, replace the V belt. Install a new V belt correctly.

3. 

   Text in Illustration

   *1	Crankshaft
   *2	A/C Compressor
   *3	Tensioner

   Inspect the No. 1 V belt deflection.

   Deflection
   Pressing Force N ( kg, lb) New Belt mm (in.) Used Belt mm (in.) 10 (10, 22) 8.0 to 10.0 (0.315 to 0.394) 10.0 to 12.0 (0.394 to 0.472)

   Tech Tips

   No. 1 V belt tension

   New Belt N (kg, lb)	Used Belt N (kg, lb)
   397 to 593 (40 to 60, 89 to 133)	300 to 398 (31 to 41, 67 to 89)

   Note

   
   

   • Check the No. 1 V belt deflection at the specified point.

   • When installing a new belt, set its deflection value as specified.

   • When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.

   • When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.

INSPECT NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)

1. Check the belt for wear, cracks or other signs of damage.

   If any of the following defects is found, replace the V belt.

   Tech Tips

   
   

   • The belt is cracked.

   • The belt is worn out to the extent that the cords are exposed.

   • The belt has chunks missing from the ribs.

2. 

   Check that the belt fits properly in the ribbed grooves.

   Tech Tips

   Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom to the pulley. If it has slipped out, replace the V belt. Install a new V belt correctly.

3. 

   Text in Illustration

   *1	Crankshaft
   *2	A/C Compressor
   *3	Tensioner

   Inspect the No. 1 V belt deflection.

   Deflection
   Pressing Force N ( kg, lb) New Belt mm (in.) Used Belt mm (in.) 10 (10, 22) 8.0 to 10.0 (0.315 to 0.394) 10.0 to 12.0 (0.394 to 0.472)

   Tech Tips

   No. 1 V belt tension

   New Belt N (kg, lb)	Used Belt N (kg, lb)
   397 to 593 (40 to 60, 89 to 133)	300 to 398 (31 to 41, 67 to 89)

   Note

   
   

   • Check the No. 1 V belt deflection at the specified point.

   • When installing a new belt, set its deflection value as specified.

   • When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.

   • When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.

INSTALL NO. 4 ENGINE COVER (w/ No. 4 Engine Cover)

1. Temporarily install the No. 4 engine cover with the 2 bolts and nut.

2. Fully tighten the 2 bolts and nut in the order shown in the illustration.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL NO. 1 COOLER COVER (w/ No. 1 Cooler Cover)

1. Temporarily install the No. 1 cooler cover with the 2 nuts.

2. Fully tighten the 2 nuts in the order shown in the illustration.

   Torque:

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

INSTALL FUEL FILTER ASSEMBLY

INSTALL ENGINE COVER ASSEMBLY

CONNECT NO. 3 AIR HOSE

CONNECT NO. 2 AIR HOSE

ADD MANUAL TRANSAXLE OIL

1. Install a new gasket and the manual transmission drain plug.

   Torque:

   45 N*m  { 459 kgf*cm, 33 ft.*lbf }

2. 

   Text in Illustration

   *1	0 to 5 mm (0 to 0.20 in.)

   Add manual transaxle oil.

FILL BRAKE FLUID RESERVOIR WITH BRAKE FLUID

1. 

   Text in Illustration

   *1	MAX Line
   *2	MIN Line

   Fill the reservoir with brake fluid.

   Brake Fluid
   SAE J1703 or FMVSS No. 116 DOT 3

   Note

   Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

BLEED CLUTCH LINE

Text in Illustration

*1	Bleeder plug cap
*2	Bleeder plug

Tech Tips

In case of clutch fluid replacement, make sure that the old fluid is replaced in the clutch line between the reservoir and the bleeder before bleeding.

1. Remove the bleeder plug cap.

2. Connect a vinyl tube to the bleeder plug.

3. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.

4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

5. Repeat both of the previous 2 steps 6 times.

6. Tighten the bleeder plug.

   Torque:

   8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

7. Depress the clutch pedal 10 times or more and confirm its operation.

   Note

   This must be performed before the engine is started.

8. Install the bleeder plug cap.

9. Check that all the air has been bled from the clutch line.

CHECK BRAKE FLUID LEVEL

ADD ENGINE OIL

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

   Engine Oil
   Engine Oil Grade Oil Viscosity (SAE) w/o DPF ACEA C2, B1, API CF-4 or CF (You may also use API CE or CD) 0W-30 5W-30 10W-30 15W-40 20W-50 w/ DPF ACEA C2 0W-30 5W-30

   Capacity
   Item Capacity Drain and refill with oil filter change 4.0 liters (4.2 US qts, 3.5 Imp. qts) Drain and refill with out oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) Dry fill 4.8 liters (5.1 US qts, 4.2 Imp. qts)

ADD ENGINE COOLANT (w/o Combustion Type Power Heater)

1. Tighten the radiator drain cock plug.

2. 

   Text in Illustration

   *1	Air Bleed Valve 1
   *2	Air Bleed Valve 2

   Loosen the air bleed valve 1 and the air bleed valve 2.

3. Add TOYOTA Super Long Life Coolant (SLLC).

   Standard Capacity
   Item Capacity w/o Combustion Type Power Heater 4.5 liters (4.8 US qts, 4.0 Imp. qts)

   Note

   Never use water as a substitute for engine coolant.

   Tech Tips

   TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

4. 

   Text in Illustration

   *1

   B Line

   Add coolant to the B line of the radiator reserve tank.

5. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

   If the coolant level is low, add coolant.

6. 

   Text in Illustration

   *1	Air Bleed Valve 1
   *2	Air Bleed Valve 2

   Tighten the air bleed valve 1 and the air bleed valve 2.

7. Install the reserve tank cap sub-assembly.

8. Start the engine and warm it up.

9. Bleed air from the cooling system.

   Note

   
   

   • Before starting the engine, turn the A/C switch off.

   • Adjust the air conditioning temperature setting to MAX (HOT).

   • Adjust the air conditioning blower setting to LO.

   
   

   1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      Tech Tips

      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:

      When squeezing the radiator hoses:
      

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fan.

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

11. 

    Text in Illustration

    *1	FULL Line
    *2	LOW Line

    After the engine has cooled down, check that the coolant level is between the FULL and LOW lines.

    If the coolant level is low, add coolant to the reservoir tank FULL line.

ADD ENGINE COOLANT (w/ Combustion Type Power Heater)

1. Tighten the radiator drain cock plug.

2. 

   Text in Illustration

   *1	Air Bleed Valve 1
   *2	Air Bleed Valve 2

   Loosen the air bleed valve 1 and the air bleed valve 2.

3. Add TOYOTA Super Long Life Coolant (SLLC).

   Standard Capacity
   Item Capacity w/ Combustion Type Power Heater 4.9 liters (5.2 US qts, 4.3 Imp. qts)

   Note

   Never use water as a substitute for engine coolant.

   Tech Tips

   TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

4. 

   Text in Illustration

   *1

   B Line

   Add coolant to B line of the radiator reserve tank.

5. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

   If the coolant level is low, add coolant.

6. 

   Text in Illustration

   *1	Air Bleed Valve 1
   *2	Air Bleed Valve 2

   Tighten the air bleed valve 1 and the air bleed valve 2.

7. Start the engine, maintain the speed at 3000 rpm for 10 seconds, and idle the engine for 10 seconds. Repeat the same procedure above 4 more times.

8. Install the reserve tank cap sub-assembly.

9. Loosen the air bleed valve 1 and the air bleed valve 2.

10. Add 350 cc (21.3 cu in.) coolant.

11. Tighten the air bleed valve 1 and the air bleed valve 2.

12. Start the engine and warm it up.

13. Bleed air from the cooling system.

    Note

    
    

    • Before starting the engine, turn the A/C switch off.

    • Adjust the air conditioning temperature setting to MAX (HOT).

    • Adjust the air conditioning blower setting to LO.

    
    

    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

       Tech Tips

       Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

       CAUTION:

       When squeezing the radiator hoses:
       

       • Wear protective gloves.

       • Be careful as the radiator hoses are hot.

       • Keep your hands away from the radiator fan.

14. Stop the engine, and wait until the engine coolant cools down.

15. 

    Text in Illustration

    *1	FULL Line
    *2	LOW Line

    After the engine has cooled down, check that the coolant level is between the FULL and LOW lines.

    If the coolant level is low, add coolant to the reservoir tank FULL line.

CHARGE REFRIGERANT (w/ Air Conditioning System)

Tech Tips

Charge refrigerant in accordance with the equipment manual.

1. Perform vacuum purging using a vacuum pump.

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

   SST

   09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

   Standard
   330 to 390 g (11.6 to 13.8 oz.)

   Note

   
   

   • Do not start the engine before charging it with refrigerant as the cooler compressor does not work properly without sufficient refrigerant. This could cause the compressor to overheat.

   • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear.

     The volume of refrigerant should be measured, not checked with the sight glass.

   Tech Tips

   
   

   • The relationship between the refrigerant charge amount and the pressure is as follows.

     

   • High Charge Range:

     If the refrigerant is overcharged, the pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.

   • Low Charge Range:

     A shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens the compressor life. Operation with insufficient coolant raises the refrigerant temperature and causes heat deterioration of the rubber seals and hoses. Cracking and subsequent refrigerant leakage may occur.

   
   

   1. Install the caps onto the service valves on the refrigerant line.

WARM UP ENGINE (w/ Air Conditioning System)

INSPECT REFRIGERANT LEAK (w/ Air Conditioning System)

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

2. Perform the operation as follows:

   
   

   • 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 the compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)

   Tech Tips

   It is impossible for the above pressure to be maintained if there is leakage.

3. Using the halogen leak detector, check the refrigerant line, especially at the connection points, for leakage.

4. 

   Text in illustration

   *1	Drain hose
   *2	Halogen leak detector

   Bring the halogen leak detector close to the drain hose before performing the test.

   Tech Tips

   
   

   • After the blower motor has stopped, leave the cooling unit for at least 15 minutes.

   • Place 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 other volatile gases.

   If such a reaction is unavoidable, the vehicle must be lifted up.

5. If no gas leakage is detected from the drain hose, remove the blower motor from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

INSPECT MANUAL TRANSAXLE OIL LEVEL

1. 

   Text in Illustration

   *1	0 to 5 mm (0 to 0.20 in.)

   Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the manual transmission filler plug opening.

   Note

   Excessively large or small amounts of oil may cause problems.

2. Check for oil leakage when the oil level is low.

3. 

   Text in Illustration

   *1	Filler plug

   Install the manual transmission filler plug and a new gasket.

   Torque:

   39 N*m  { 400 kgf*cm, 29 ft.*lbf }

INSPECT FOR COOLANT LEAK

1. 

   Text in Illustration

   *1	Radiator Cap Tester

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

2. Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.

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

INSPECT FOR FUEL LEAK

1. Connect an intelligent tester to the DLC3.

2. Turn the ignition switch to ON.

3. Turn the tester on.

4. Enter the following menus: Powertrain / Engine / Active Test.

5. Perform the Active Test.

   Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
   Test the Fuel Leak	Pressurize common rail internal fuel pressure, and check for fuel leaks	Stop/Start	Perform inspection of the high pressure fuel system. Test is possible when the following conditions are met: Warmed up engine. Vehicle is stopped. Battery voltage is 12 V or more. PM regeneration is not operating. Engine speed is less than 4000 rpm. Results of real-vehicle check: Engine Speed: 2702 rpm Fuel Pressure: 108570 kPa Target Common Rail Pressure: 105500 kPa Target Pump SCV Current: 1.2 A MAP: 127 kPa MAF: 28 g/sec.

INSPECT FOR OIL LEAK

1. Start the engine. Check for engine oil leaks from the connected parts of the oil filter cap and oil filter drain plug.