ENGINE ASSEMBLY INSTALLATION

INSTALL INNER OIL SEAL (for Manual Transaxle)

INSTALL RING GEAR SUB-ASSEMBLY (for Manual Transaxle)

INSTALL ONE-WAY CLUTCH ASSEMBLY (for Manual Transaxle)

INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

1. Using SST, hold the crankshaft.

   SST

   09960-10010   ( 09962-01000, 09963-01000 )

2. Clean the 8 bolts and their holes.

3. 

   Text in Illustration

   *1

   Adhesive

   Apply adhesive to 2 or 3 end threads of each bolt tip.

   Adhesive
   Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent

4. 

   Text in Illustration

   *1	Front Flywheel Plate Spacer
   *2	Flywheel
   *3	Rear Flywheel Plate Spacer
   	Engine
   	Transaxle

   Temporarily install the front flywheel plate spacer, the flywheel and the rear flywheel plate spacer with the 8 bolts.

   Tech Tips

   
   

   • The front spacer is reversible.

   • As the rear flywheel plate spacer and the flywheel are not reversible, be sure to install them in the direction shown in the illustration.

5. Fully tighten the 8 bolts in the order shown in the illustration.

   Torque:

   78 N*m  { 795 kgf*cm, 57 ft.*lbf }

   Note

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

INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

1. 

   Text in Illustration

   *1	Clutch disc
   *2	Flywheel

   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 (for Manual Transaxle)

1. 

   Text in Illustration

   *a	Temporarily
   *b	Matchmark

   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 (for Manual Transaxle)

INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

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 (for Manual Transaxle)

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 (for Manual Transaxle)

1. 

   Text in Illustration

   *1	Bleeder clutch release tube
   *2	Clutch release bleeder

   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 (for Manual Transaxle)

1. Install the bleeder clutch release tube with the bolt.

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

2. 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 MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

1. 

   Text in Illustration

   *1	Knock Pin
   *2	Crankshaft

   Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.

2. Apply clutch spline grease to the round of the crankshaft contact surface (*3) with the torque converter centerpiece.

   Clutch spline grease
   Toyota Genuine Clutch Spline Grease or equivalent

   Maximum spread
   Approximately 1 g (0.353 oz)

3. 

   Torque:

   *1

   64 N*m  { 653 kgf*cm, 47 ft.*lbf }

   *2

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

   *3

   39 N*m  { 398 kgf*cm, 29 ft.*lbf }

   Maintain the engine and CVT in a horizontal position, align the knock pins and holes (*4), and tighten the 9 bolts shown the illustration.

   Torque:

   *1

   64 N*m  { 653 kgf*cm, 47 ft.*lbf }

   *2

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

   *3

   39 N*m  { 398 kgf*cm, 29 ft.*lbf }

   Note

   
   

   • Confirm that there are 2 knock pins on the fitting surface of the engine block before installing the CVT.

   • Do not twist or apply excessive force to the CVT.

   • Check that the torque converter rotates smoothly after installation of the CVT.

   Tech Tips

   
   

   Bolt length

   • *1: 45 mm (1.77 in.)

   • *2: 45 mm (1.77 in.)

   • *3: 35 mm (1.38 in.)

INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)

INSTALL STARTER ASSEMBLY

1. Install the starter assembly with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the connector.

3. Connect terminal 30 with the nut.

   Torque:

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

4. Close the terminal cap.

INSTALL FLYWHEEL HOUSING SIDE COVER

1. Insert the protruding portion into the end of the cylinder block and while pushing it along the cylinder block, fit the claw into the cylinder block.

   Note

   
   

   • Make sure that the claw makes a click sound, indicating that it fits tightly.

   
   

   • Replace the claw with a new one if it does not fit tightly or is deformed.

INSTALL DRIVE SHAFT HEAT INSULATOR BRACKET

1. Install the drive shaft heat insulator bracket onto the engine with the 2 bolts.

   Torque:

   16 N*m  { 166 kgf*cm, 12 ft.*lbf }

INSTALL ENGINE MOVING CONTROL ROD

1. Install the engine moving control rod with the bolt.

   Torque:

   100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

INSTALL ENGINE MOVING CONTROL ROD COVER (for Cold Area)

1. Install the engine moving control rod cover with the 2 clips.

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.

INSTALL 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 }

INSTALL FRONT FRAME ASSEMBLY

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

INSTALL DRIVE SHAFT HEAT INSULATOR

1. Install the drive shaft heat insulator with the 2 bolts and the 2 nuts.

   Torque:

   16 N*m  { 166 kgf*cm, 12 ft.*lbf }

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 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 LH

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 SHAFT LH NUT

INSTALL FUEL TUBE SUB-ASSEMBLY

INSTALL EFI FUEL PIPE CLAMP

1. Install the EFI fuel pipe clamp.

CONNECT NO. 2 RADIATOR HOSE

1. 

   Text in Illustration

   *1	White Paint Mark
   *a	View A
   *b	Upper Side
   *c	Projection On Radiator

   Connect the radiator hose to the radiator assembly with the hose clamp.

   Note

   Perform the installation with the hose clip and mark at the correct angle.

INSTALL AIR CLEANER AND HOSE

1. 

   Text in Illustration

   *1	Clamp
   *2	Guide

   Align the 2 hinges with the guides on the case and engage them in the grooves.

2. Install the air cleaner and hose with the 2 clamps.

3. 

   Text in Illustration

   *1	Recession
   *2	Protrusion
   *a	View A
   *b	Upper Side

   Connect the air cleaner hose with the hose clamp as shown in the illustration.

   Torque:

   3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

   Note

   
   

   • The clamp should contact the air cleaner hose stopper.

   
   

   • Perform the installation with the hose clip at the correct angle.

4. Connect the ventilation hose.

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

INSTALL FAN AND GENERATOR V-RIBBED BELT

Text in Illustration

*1	V-ribbed belt
*a	Paint Mark

1. Install the V-ribbed belt.

   Note

   
   

   • There are 2 types of V-ribbed belt. The type to use depends on the type of generator, so be sure to confirm the belt type before installing.

     Generator	Paint Mark
     80 A	Blue
     100 A	Red

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

   
   

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

2. Turn the V-ribbed belt tensioner clockwise and remove the 4 mm bi-hexagon wrench.

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

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

   Note

   
   

   • Before installing the No. 1 V-ribbed belt, check each pulley for any liquid or chips.

   
   

   • Check that the ribs of the No. 1 V-ribbed belt are correctly fitted into the grooves of the pulleys.

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

1. Turn the adjust bolt B to adjust the tension of No. 1 V-ribbed belt.

   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)

2. Tighten bolt A.

   Torque:

   44 N*m  { 449 kgf*cm, 32 ft.*lbf }

INSPECT FAN AND GENERATOR V-RIBBED BELT

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

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

   Text in Illustration

   *a	Correct
   *b	Incorrect

   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 of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

INSPECT NO. 1 V-RIBBED (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 No. 1 V-ribbed 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. 

   Text in Illustration

   *a	Correct
   *b	Incorrect

   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 No. 1 V-ribbed belt. Install a new No. 1 V-ribbed belt correctly.

3. 

   Text in Illustration

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

   Inspect the No. 1 V-ribbed 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-ribbed 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-ribbed 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. 1 ENGINE COVER (w/ No. 1 Engine Cover)

1. Temporarily install the No. 1 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 FRONT EXHAUST PIPE ASSEMBLY

INSTALL FRONT BUMPER ENERGY ABSORBER SUB-ASSEMBLY

1. Install the front bumper energy absorber with the 14 screws.

INSTALL FRONT BUMPER COVER

1. Engage the 6 claws and install the front bumper cover.

2. 

   Tighten the 4 screws.

3. 

   Install the 5 clips.

4. 

   Install the pin hold clip.

   Note

   Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertically.

   Tech Tips

   Use the same procedure for the RH and LH sides.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug.

2. 

   Text in Illustration

   *1	Air Bleed Valve

   Loosen the air bleed valve.

3. Remove the water filler cap sub-assembly.

4. 

   Text in Illustration

   *a	Filler Tube End
   *b	Coolant Level

   Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC) from the water filler (Coolant level should be within 20 mm (0.787 in.) from the filler tube end).

   Standard Capacity
   Item Capacity M/T 4.7 liters (5.0 US qts, 4.1 Imp. qts) CVT 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).

5. Remove the reserve tank cap.

   If the coolant level is low, add coolant.

6. 

   Text in Illustration

   *a

   FULL Line

   Fill the radiator reserve tank with coolant to the FULL line.

7. 

   Text in Illustration

   *1	Air Bleed Valve

   Tighten the air bleed valve.

8. Install the water filler cap sub-assembly and reserve tank cap.

9. Start the engine and warm it up.

10. Bleed air from the cooling system.

    Tech Tips

    
    

    • 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. Run the engine intermittently for 7 minutes or more (5 seconds running at 3000 rpm and 45 seconds idling, repeat several times).

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

12. 

    Text in Illustration

    *a	FULL Line
    *b	LOW Line

    After the engine is 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 OIL

1. Add new engine oil.

   Standard Oil Grade
   Oil Grade Oil Viscosity (SAE) API grade SL "Energy-Conserving". SM "Energy-Conserving" or ILSAC multigrade engine oil 0W-20 5W-20 5W-30 10W-30 API grade SL or SM multigrade engine oil 15W-40 20W-50

   Standard Capacity
   Item Specified Condition Drain and refill with oil filter change 3.5 liters (3.7 US qts, 3.1 Imp. qts) Drain and refill without oil filter change 3.3 liters (3.5 US qts, 2.9 Imp. qts) Dry fill 3.9 liters (4.1 US qts, 3.4 Imp. qts)

2. Install the oil filler cap.

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.

ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

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.

ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

Tech Tips

Refer to the following diagram when adding fluid.

1. When adding fluid (large fill volume) *1

   
   

   1. 

      Be sure that the vehicle remains level and lift the vehicle.

   2. Use a socket hexagon wrench (6 mm) to remove the drain plug and gasket.

   3. 

      Text in Illustration

      *1	No. 1 Transmission Oil Filler Tube

      Use a socket hexagon wrench (6 mm) to check that the No. 1 transmission oil filler tube is tightened to the specified torque.

      Torque:

      0.8 N*m  { 8.2 kgf*cm, 7 in.*lbf }

      Note

      If the No. 1 transmission oil filler tube is not tightened to the specified torque, then the fluid level cannot be adjusted correctly.

   4. 

      Remove the refill plug and gasket.

   5. 

      Add fluid into the refill hole until it flows out from the overflow hole.

      Note

      This transmission requires Toyota Genuine CVT Fluid TC.

   6. Wait until the steady flow slows to a trickle, install a gasket, and temporarily tighten the drain plug with a socket hexagon wrench (6 mm).

      Tech Tips

      Because the drain plug will be removed again, the gasket can be reused at this time.

      

   7. Fill the specified volume of transmission fluid into the refill hole.

      Note

      The fill amount varies depending on the procedures being completed.

      Reference Capacity

      Related Procedure Fill Volume Transaxle replacement (with a new torque converter) 1.4 liters (1.48 US qts, 1.23 Imp. qts) Transaxle replacement (when reusing the torque converter) 0.4 liters (0.42 US qts, 0.35 Imp. qts) Torque converter replacement 1.6 liters (1.69 US qts, 1.41 Imp. qts) Torque converter removal/installation 0.4 liters (0.42 US qts, 0.35 Imp. qts) Oil pan removal/installation (when oil drained) 0.4 liters (0.42 US qts, 0.35 Imp. qts) Drive shaft removal/installation 0.4 liters (0.42 US qts, 0.35 Imp. qts)

   8. Install the gasket and temporarily tighten the refill plug.

      Tech Tips

      Because the refill plug will be removed again, the gasket can be reused at this time.

   9. Lower the vehicle.

2. When refilling (small fill volume) *2

   
   

   1. 

      Be sure that the vehicle remains level and lift the vehicle.

   2. Remove the refill plug and gasket.

   3. 

      Fill the specified volume of transmission fluid into the refill hole.

      Reference Capacity
      Related Procedure Fill Volume Oil cooler removal/installation or replacement 0.4 liters (0.42 US qts, 0.35 Imp. qts) Repair of oil seeping or oozing 0.4 liters (0.42 US qts, 0.35 Imp. qts)

   4. Install the gasket and temporarily tighten the refill plug.

      Tech Tips

      Because the refill plug will be removed again, the gasket can be reused at this time.

   5. Lower the vehicle.

FILL BRAKE FLUID RESERVOIR (for Manual Transaxle)

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 (for Manual Transaxle)

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 IN RESERVOIR (for Manual Transaxle)

FLUID TEMPERATURE CHECK (for CVT)

FLUID LEVEL CHECK (for CVT)

INSPECT FOR ENGINE 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 RESERVOIR ENGINE COOLANT LEVEL

Text in Illustration

*1	Full Line
*2	Low Line

1. The engine coolant should be between the LOW and FULL lines when the engine is cold.

   Tech Tips

   If it is below the LOW line, check for leaks and add Toyota Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line.

INSPECT FOR MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

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. Install the manual transmission filler plug and a new gasket.

   Torque:

   39 N*m  { 400 kgf*cm, 29 ft.*lbf }

INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK (for CVT)

1. Clean the area and check for fluid leaks.

INSPECT FOR 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 IGNITION TIMING

INSPECT ENGINE IDLING SPEED

1. Warm up and stop the engine.

2. Connect the intelligent tester to the DLC3.

3. Start the engine and run it at idle.

4. Turn the tester on.

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

   Tech Tips

   Refer to the intelligent tester operator's manual for further details.

6. Inspect the engine idle speed.

   Standard Idle Speed
   Transaxle Idling Speed Manual Transaxle 550 to 650 rpm CVT 600 to 700 rpm

7. Turn the ignition switch off.

8. Disconnect the intelligent tester from the DLC3.

INSPECT CO/HC

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 (1.3 ft.) into the tailpipe while idling.

4. Check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

   Tech Tips

   When doing the 2 mode (with the engine idling/ running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.

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

   
   

   1. Check the A/F sensor and heated oxygen sensor operation.

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

      CO	HC	Problem	Possible Cause
      Normal	High	Rough idle	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leakage from intake and exhaust valves Leakage from cylinders
      Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
      High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element Plugged PCV valve Faulty EFI system: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Throttle body