ENGINE ASSEMBLY INSTALLATION


  1. INSTALL FRONT ENGINE MOUNTING BRACKET LH


    1. A01J6ENE01

      Install the mounting bracket with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  2. INSTALL FRONT ENGINE MOUNTING BRACKET RH


    1. A01J32EE01

      Install the mounting bracket with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  3. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE

    A01J3RJE01

    1. Apply a coat of engine oil to a new O-ring.

    2. Install a new O-ring to the oil control valve.

    3. Install the oil control valve with the bolt.

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

  4. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01J3TTE04

      Apply a light coat of engine oil to the O-ring of the sensor.

    2. Install the sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    3. Install the connector to the connector bracket.

    4. Attach the harness clamp.

    5. Connect the sensor connector.

  5. INSTALL CAMSHAFT POSITION SENSOR

    A01J5CME01

    1. Apply a coat of engine oil to the O-ring.

    2. Install a new O-ring to the sensor.

    3. Install the sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  6. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Using a 19 mm deep socket wrench, install a new gasket and the sensor.

  7. INSTALL KNOCK SENSOR


    1. A01J38TE01

      Install the sensor so that it is horizontal as shown in the illustration. Then install the bolt.

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

      Tech Tips

      It is acceptable for the sensor to be tilted +-10°.

    2. Connect the sensor connector.

  8. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01J4HW

      Install a new gasket and the water by-pass pipe with the 2 nuts.

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

  9. INSTALL ENGINE OIL PRESSURE SWITCH


    1. A01J6EAE02

      Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the oil pressure switch.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after installation of the switch.

    3. Connect the oil pressure switch connector.

    4. Start the engine and check for engine oil leaks.

  10. INSTALL NO. 1 IDLER PULLEY


    1. A01J4B6E01

      Install the spacer, idler pulley and pulley plate with the bolt.

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

  11. INSTALL THERMOSTAT


    1. A01J6VUE02

      Install a new gasket to the thermostat.

      Tech Tips

      When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

    2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

      Tech Tips

      The jiggle valve may be set within 10°of either side of the prescribed position.

  12. INSTALL WATER INLET


    1. Install the inlet with the 2 nuts and bolt.

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

    2. Connect the connector.

  13. INSTALL V-RIBBED BELT TENSIONER


    1. A01J3ARE02

      Temporarily install the belt tensioner with the 3 bolts.

      Tech Tips

      Make sure the flanges of the bolts are contacting the tensioner surface.

    2. Install the tensioner by tightening the 3 bolts in the order shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf, for bolt 1 }
      21 N*m  { 214 kgf*cm, 15 ft.*lbf, for bolt 2 }
      43 N*m  { 438 kgf*cm, 32 ft.*lbf, for bolt 3 }

  14. INSTALL COMPRESSOR MOUNTING BRACKET

    Note

    Install the compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.


    1. A01J5YJ

      Temporarily install the compressor mounting bracket with the 3 bolts.

      Tech Tips

      Temporarily install the compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

    2. Push the compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

      A01J35XE01
      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf, for bolt B }

      Tech Tips

      Make sure there is no clearance between the cylinder block and compressor mounting bracket as shown in the illustration.

    3. A01J3G8E01

      Uniformly tighten the 4 bolts in the order shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf, for bolt A }
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf, for bolt C }

  15. INSTALL IDLE PULLEY ASSEMBLY


    1. Temporarily install the idle pulley assembly with the bolt.

      Note

      Do not use any tools.

    2. Tighten the bolt.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  16. INSTALL EXHAUST MANIFOLD (w/o Secondary Air Injection System)


    1. Install a new gasket.

    2. A01J5UNE01

      Install the exhaust manifold with 6 new nuts, and tighten the nuts in the order shown in the illustration.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  17. INSTALL EXHAUST MANIFOLD (w/ Secondary Air Injection System)


    1. Install a new gasket.

    2. A01J4WJE01

      Install the exhaust manifold with 8 new nuts, and tighten the nuts in the order shown in the illustration.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  18. INSTALL AIR SWITCHING VALVE (w/ Secondary Air Injection System)


    1. Install the air switching valve with 2 new nuts.

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

    2. Connect the air switching valve connector.

  19. INSTALL NO. 4 INTAKE PIPE (w/ Secondary Air Injection System)


    1. A01J6TTE01

      Install 2 new gaskets and the No. 4 intake pipe with 4 new nuts and tighten the nuts in the order shown in the illustration. Then, tighten the nuts labeled 1 and 3 to the torque specification again.

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

    2. Check that the nuts are tightened to the torque specification.

  20. INSTALL EXHAUST MANIFOLD HEAT INSULATOR (w/ Secondary Air Injection System)


    1. Install the exhaust manifold heat insulator with the 5 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  21. INSTALL EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)


    1. Install the heat insulator with the 5 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  22. INSTALL INTAKE MANIFOLD


    1. A01J5MAE01

      Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Connect the crankshaft position sensor to the clamp.

  23. INSTALL INJECTOR


    1. A01J59BE01

      Install a new insulator to the injector.

    2. Apply a light coat of grease or gasoline to a new O-ring and install it to the injector.

    3. Apply a light coat of grease or gasoline on the place where the delivery pipe touches the O-ring.

    4. A01J42GE01

      To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it right and left.

      Note


      • Be careful not to twist the O-ring.

      • After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.

    5. Position the injector connector so that it faces downward.

  24. INSTALL FUEL DELIVERY PIPE


    1. A01J6O0

      Install the 4 spacers to the cylinder head.

    2. A01J6IU

      Install the delivery pipe together with the 4 injectors and 2 spacers with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    3. Connect the 4 injector connectors.

    4. A01J6CW

      Connect the 4 clamps and wire harness to the delivery pipe.

    5. Connect the vacuum hose.

  25. INSTALL THROTTLE BODY


    1. A01J5FA

      Install a new gasket on the intake manifold.

      Tech Tips

      Align the protrusion of the gasket with the groove of the intake manifold.

    2. A01J53W

      Install the throttle body with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    3. Connect the water by-pass hose to the throttle body.

    4. Connector the throttle position sensor and control motor connector.

  26. INSTALL ENGINE WIRE


    1. A01J704E02

      Connect the wire harness (engine ground wire) to the engine rear side with the 2 bolts so that it is within the specified range shown in the illustration.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

    2. Connect the oil pressure sensor connector.

    3. Connect the noise filter connector.

    4. Connect the camshaft position sensor connector.

    5. Connect the 4 injector connectors.

    6. Connect the crankshaft position sensor connector.

    7. Connect the oil control valve connector.

    8. Connect the purge VSV connector.

    9. Connect the throttle body connector.

    10. Connect the engine coolant temperature sensor connector.

    11. Connect the knock sensor connector.

    12. Connect the wire harness to the clamps.

  27. INSTALL GENERATOR


    1. A01J5WDE03

      Install the generator with the 2 bolts.

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

    2. Install the generator wire with the bolt and nut.

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

    3. Attach the terminal cap.

    4. Connect the connector.

  28. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

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

  29. INSTALL SPARK PLUG

  30. INSTALL IGNITION COIL


    1. Install the ignition coil with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 4 ignition coil connectors.

  31. REMOVE ENGINE FROM ENGINE STAND

  32. INSTALL ENGINE ASSEMBLY


    1. A01J6KXE02

      Attach the engine sling device and chain block to the engine hangers.

    2. Slowly lower the engine assembly into the engine compartment.

    3. A01J5NEE01

      Install the engine mounting brackets with the 4 bolts and 4 nuts.

      Torque:
      38 N*m  { 388 kgf*cm, 28 ft.*lbf }

  33. INSTALL REAR END PLATE


    1. Install the end plate with the 2 bolts.

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

  34. INSTALL FLYWHEEL (for Manual Transmission)

    Tech Tips


    • A01J4Y8E02

      The mounting bolts are tightened in 2 progressive steps.

    • If any of the mounting bolts is broken or deformed, replace it.


    1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

      Adhesive
      Toyota Genuine Adhesive, Three Bond 1324, or equivalent

    2. Install the flywheel.

    3. A01J4YIE02

      Fix the crankshaft in place with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A01J3D7E02

      Install and uniformly tighten the 10 mounting bolts in several passes in the order shown in the illustration.

      Torque:
      26.5 N*m  { 270 kgf*cm, 20 ft.*lbf }

      If any of the mounting bolts does not meet the torque specification, replace the mounting bolts.

    5. A01J46PE01

      Mark the mounting bolts with paint.

    6. Retighten the mounting bolts by 90° in the numerical order shown in the illustration.

    7. A01J3D7E02

      Check that the painted marks are now at a 90° angle to the position.

  35. INSTALL DRIVE PLATE (for Automatic Transmission)

    A01J4Y8E02

    Tech Tips


    • The mounting bolts are tightened in 2 progressive steps.

    • If any of the mounting bolts is broken or deformed, replace it.


    1. Apply adhesive to 2 or 3 threads of the mounting bolt end.

      Adhesive
      Toyota Genuine Adhesive, Three Bond 1324, or equivalent

    2. Install the drive plate.

    3. A01J4YIE02

      Fix the crankshaft in place with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    4. A01J4GVE04

      Install and uniformly tighten the 10 mounting bolts in several passes in the order shown in the illustration.

      Torque:
      74 N*m  { 755 kgf*cm, 55 ft.*lbf }

      If any of the mounting bolts does not meet the torque specification, replace the mounting bolts.

  36. INSTALL CLUTCH DISC (for Manual Transmission)

    A01J67XE03

    1. Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel.

      SST
      09301-00110

      Note

      Make sure not to insert the clutch disc facing the wrong direction.

  37. INSTALL CLUTCH COVER (for Manual Transmission)


    1. A01J6DFE03

      Align the matchmarks on the clutch cover and flywheel.

    2. Tighten the 6 bolts as described below.


      1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.

      2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.

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

    3. Lightly move SST up and down, and right and left.

      SST
      09301-00110

    4. Check that the disc is in the center, and then tighten the bolts.

  38. INSTALL MANUAL TRANSMISSION UNIT


    1. Install the manual transmission unit from the vehicle.

      If necessary, refer to the corresponding manual transmission section, and perform the work by following the installation procedures for the manual transmission assembly.

  39. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


    1. Install the automatic transmission assembly from the vehicle.

      If necessary, refer to the corresponding automatic transmission section, and perform the work by following the installation procedures for the automatic transmission assembly.

  40. INSTALL STARTER


    1. Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    2. Connect the starter wire to terminal 30 with the nut.

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

    3. Install the terminal cap.

    4. Connect the starter connector.

  41. INSTALL REAR PROPELLER SHAFT (for 4WD)


    1. A01J7E1E01

      Align the matchmarks on the propeller shaft flange and differential flange.

    2. Connect the propeller shaft with the 4 bolts, 4 washers and 4 nuts.

      Torque:
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }
    3. A01J4VEE01

      Align the matchmarks on the propeller shaft flange and transfer flange.

    4. Connect the propeller shaft with the 4 washers and 4 nuts.

      Torque:
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }

  42. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 2WD)


    1. A01J65JE05

      Remove SST from the extension housing.

    2. Install the propeller shaft into the extension housing.

    3. A01J7J6E01

      Temporarily install the center support bearing with the 2 plates and 2 bolts. Tighten the bolts as much as possible by hand.

    4. A01J503E02

      Align the matchmarks on the propeller shaft flange and differential flange.

    5. Connect the propeller shaft with the 4 bolts, 4 washers and 4 nuts.

      Torque:
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }
    6. A01J4P9E02

      Unload the vehicle. The center line of the center bearing and center bearing housing (see illustration) must be adjusted to within 0 +/-1 mm (0 +/-0.0394 in.) of each other. Measure the difference along the vehicle front/rear axis.

    7. Tighten the 2 bolts of the center support bearing.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  43. INSTALL FRONT PROPELLER SHAFT (for 4WD)


    1. A01J6C5E01

      Align the matchmarks on the yoke and transfer flange.

    2. Connect the propeller shaft with the 4 washers and 4 nuts.

      Torque:
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }
    3. A01J3MDE01

      Align the matchmarks on the yoke and differential flange.

    4. Install the propeller shaft with the 4 bolts, 4 washers and 4 nuts.

      Torque:
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }

  44. INSTALL FRONT EXHAUST PIPE


    1. A01J7NV

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

      Minimum length
      40 mm (1.57 in.)

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

    2. Install the front exhaust pipe to the exhaust pipe support.

    3. A01J65VE03

      Install a new gasket to the exhaust manifold.

      Tech Tips

      Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and exhaust pipe are properly fit.

      Note


      • Be careful with the installation direction of the gasket.

      • Do not reuse the gasket.

      • To ensure a proper seal, do not use the front exhaust pipe to force the gasket onto the exhaust manifold.

    4. Install the front exhaust pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

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

  45. INSTALL HOOD


    1. Install the hood with the 4 bolts.

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

    2. Connect the washer nozzle hose.

    3. Adjust the hood Click here.

  46. INSTALL COOLER COMPRESSOR


    1. A01J4BDE01

      Loosely install the bolt labeled A to install the compressor.

    2. Install the compressor completely by tightening the 4 bolts in the order shown in the illustration.

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

      Note

      In order to prevent misalignment, which causes belt rattle, tightening of the bolts must be performed in the order shown.

    3. Connect the suction hose with the 2 bolts.

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

    4. Connect the compressor connector.

  47. INSTALL OIL DIPSTICK GUIDE


    1. Install a new O-ring and the oil dipstick guide with the bolt.

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

  48. INSTALL OIL DIPSTICK


    1. Install the oil dipstick.

  49. INSTALL VANE PUMP


    1. Install the vane pump with the 2 bolts.

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

    2. Connect the PS oil pressure switch connector.

  50. CONNECT ENGINE WIRE


    1. Connect the wire clamp to the engine mounting bracket front LH with the bolt.

      Torque:
      13 N*m  { 128 kgf*cm, 9 ft.*lbf }

    2. Connect the 2 engine room junction block connectors and connect the wire clamp.

    3. Connect the cable to the engine room junction block with the nut.

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

    4. Install the engine room relay block cover (side).

    5. Install the engine room relay block cover (upper).

    6. Connect the ground wire with the nut.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    7. A01J3LNE01

      Connect the ground wire to the left side of the frame with the bolt so that it is within the range shown in the illustration.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

    8. Connect the sensor bracket to the right side of the frame with the bolt.

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

    9. w/ Secondary Air Injection System:

      Connect the air fuel ratio sensor connector.

    10. w/o Secondary Air Injection System:

      Connect the heated oxygen sensor connector.

    11. A01J6A7E01

      Push the engine wire through the dash panel into the cabin.

      Tech Tips

      The The wire should be within the range shown in the illustration.

    12. Connect the ground wire with the bolt.

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

    13. Attach the wire harness clamp.

    14. w/ Secondary Air Injection System:

      Connect the air injection driver connector.

    15. Connect the ECM connectors.


      1. Connect the 4 ECM connectors.

      2. Install the glove compartment door.

  51. CONNECT FUEL HOSE


    1. A01J4QHE04

      Connect the No. 2 fuel hose to the pressure regulator.

    2. Connect the No. 1 fuel hose to the pulsation damper.


      1. A01J6RTE09

        Check that there is no damage or contamination in the connected part of the pipe.

      2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.

      3. A01J6RTE10

        After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.

      4. A01J6A2E05

        Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.

  52. CONNECT HOSE


    1. Connect the vacuum hose (for brake master cylinder).

    2. Connect the purge line hose to the purge VSV.

  53. INSTALL RADIATOR


    1. A01J6XQE02

      Install the radiator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01J56D

      Attach the 4 clamps to the radiator side as shown in the illustration.

    3. Connect the 2 front airbag sensor connectors.

  54. INSTALL FAN PULLEY

  55. INSTALL FAN SHROUD

    A01J738E03

    1. Install the fan pulley to the water pump.

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

      Note

      Be careful not to damage the radiator core.

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

    4. Attach the shroud's claws to the radiator as shown in A in the illustration.

    5. Install the shroud with the 2 bolts.

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

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

    7. Install the drive belt Click here.

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

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  56. INSTALL AIR PUMP INLET (w/ Secondary Air Injection System)


    1. Install the air pump inlet to the upper radiator tank with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  57. INSTALL DRIVE BELT


    1. A01J3KGE04

      Install the drive belt to the pulleys except the drive belt tensioner pulley.

    2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.

      Note


      • The backside of the drive belt should face the tensioner pulley.

      • Check that the drive belt is properly set to each pulley.

    3. A01J5HFE01

      After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.

  58. CONNECT RADIATOR OUTLET HOSE

  59. CONNECT RADIATOR INLET HOSE

  60. INSTALL RADIATOR GRILLE


    1. Attach the 6 claws to install the radiator grille.

    2. Install the 2 screws and 2 clips.

  61. INSTALL INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY


    1. A01J33PE01

      Install the air cleaner and intake air connector assembly with the 4 bolts, and tighten the hose clamp.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf, for air cleaner }
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf, for intake air connector }
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf, for hose clamp }

    2. Connect the MAF meter connector and harness clamps.

    3. Connect the No. 2 ventilation hose.

    4. Connect the vacuum hose.

  62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  63. ADD ENGINE OIL


    1. Clean and install the oil drain plug with a new gasket.

      Torque:
      37.5 N*m  { 382 kgf*cm, 28 ft.*lbf }

    2. Add fresh engine oil.

      Standard capacity
      Item Specified Condition
      Drain and refill with oil filter change 5.6 liters (5.9 US qts, 4.9 Imp. qts)
      Drain and refill without oil filter change 5.3 liters (5.6 US qts, 4.6 Imp. qts)
      Dry fill 6.3 liters (6.7 US qts, 5.5 Imp. qts)

    3. Install the oil filler cap.

  64. ADD ENGINE COOLANT


    1. Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf, for cylinder block drain cock plug }
      Standard capacity
      Item Specified Condition
      A/T 8.1 liters (8.6 US qts, 7.1 Imp. qts)
      M/T 7.8 liters (8.2 US qts, 6.9 Imp. qts)

    2. Fill the radiator with TOYOTA SLLC to the F line.

      Tech Tips


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

      • Please contact your TOYOTA dealer for further details.

        Note

        Never use water as a substitute for engine coolant.

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

      If the coolant level drops below the F line, add TOYOTA SLLC to the F line.

    4. Install the radiator cap.

    5. Bleed air from the cooling system.


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

      2. Maintain the engine speed at 2,000 to 2,500 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

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

      CAUTION:

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

    7. A01J31CE01

      Check the coolant level in the radiator reservoir.

      If the coolant level is below the L line, add SLLC to the reservoir F line.

  65. CHECK FOR FUEL LEAKS


    1. Connect the intelligent tester to the DLC3.


      1. Turn the ignition switch ON.

        Note

        Do not start the engine.

      2. Push the intelligent tester main switch ON.

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

    2. Check for fuel leaks.


      1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.

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

  66. CHECK FOR OIL LEAKS


    1. Start the engine, and check that there are no oil leaks after performing maintenance.

  67. CHECK FOR COOLANT LEAKS


    1. Check for engine coolant leaks Click here.

  68. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 under cover with the 4 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    2. Install the side cover RH with the 2 clips and 2 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    3. Install the side cover LH with the 2 clips and 2 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  69. INSPECT IGNITION TIMING


    1. Warm up the engine and stop the engine.

      Note

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

    2. A01J4GEE03

      When using the intelligent tester:

      Check the ignition timing.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine at idle.

      3. Turn the intelligent tester main switch ON.

      4. Enter the following item: Powertrain / Engine and ECT / Data List / IGN Advance.

        Standard ignition timing
        0 to 20° BTDC @ idle

        Tech Tips

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

    3. A01J4G5E01

      When not using the intelligent tester:

      Check the ignition timing.


      1. Using SST, connect tachometer probe to terminal TAC of the DLC3.

        SST
        09843-18030

        Note


        • Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.

        • Turn off all electrical systems before connecting the terminals.

      2. A01J79VE01

        Clamp the tester probe of a timing light to the 4 lead wires or green-red lead wire of the ignition coil connector for No. 1 cylinder.

      3. Start the engine.

      4. A01J6S2E01

        Using SST, connect terminals TC and CG of the DLC3.

        SST
        09843-18040

        Note

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

        Tech Tips

        A01J7H2E01

        • After connecting terminals (TC and CG), engine rpm changes to approximately 1,000 to 1,500 rpm for 5 seconds, then returns to idle speed. Because the ECM checks that the ISC (idle speed control system) operates properly.

        • Perform the inspection of the ignition timing after engine rpm is returned to idle speed.

      5. A01J5FFE01

        Using a timing light, measure the ignition timing.

        Standard ignition timing
        3 to 7° BTDC @ idle

      6. Remove the SST from terminals 13 (TC) and 4 (CG) of the DLC3.

      7. Check the ignition timing.

        Standard ignition timing
        0 to 20° BTDC @ idle

      8. Confirm that ignition timing moves to the advanced angle side when the engine speed is increased.

      9. Remove the timing light.

  70. CHECK ENGINE IDLE SPEED


    1. Warm up and stop the engine.

      Note

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

    2. When using the intelligent tester:

      Check the idle speed.


      1. A01J4GEE03

        Connect the intelligent tester to the DLC3.

        Tech Tips

        Please refer to the intelligent tester II operator's manual for further details.

      2. Start the engine at idle.

      3. Turn the intelligent tester main switch ON.

      4. Enter the following item: Powertrain / Engine and ECT / Data List / Engine SPD.

        Standard idle speed
        600 to 700 rpm

        Note


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

        • Switch off all accessories and air conditioning before connecting the intelligent tester.

    3. A01J4G5E01

      When not using the intelligent tester:

      Check the idle speed.


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

        SST
        09843-18030

      2. Start the engine at idle.

      3. Check the idle speed.

        Standard idle speed
        600 to 700 rpm

  71. CHECK CO/HC


    1. Start and warm up the engine.

    2. Run the engine at 2,500 rpm for approximately 180 seconds and idle the engine.

    3. A01J60NE01

      Insert CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe.

    4. Check CO/HC concentration at idle.

      Idle CO concentration
      0 to 0.5%
      Idle HC concentration
      Applicable local regulation

    5. If the CO/HC concentration is not as specified, perform troubleshooting in the order given below.


      1. w/ Secondary Air Injection System:

        Check the air fuel ratio sensor operation Click here.

      2. w/o Secondary Air Injection System:

        Check the heated oxygen sensor operation Click here.

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

        CO HC Problems Causes
        Normal High Rough idle

        1. Faulty ignitions:


          • Incorrect timing

          • Plugs are contaminated, shorted or gaps are defective

        2. Incorrect valve clearance

        3. Leaks in intake and exhaust valves

        4. Leaks in cylinders
        Low High

        Rough idle

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • Ventilation hoses

          • 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. Plugged ventilation valve

        3. Faulty SFI system:


          • Faulty pressure regulator

          • Defective ECT sensor

          • Defective Mass Air Flow (MAF) meter

          • Faulty ECM

          • Faulty injectors

          • Faulty throttle position sensor

  72. CHECK FUNCTION OF THROTTLE BODY


    1. A01J6NO

      Check the throttle control motor operating sound.


      1. Turn the ignition switch ON.

      2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor.

        If friction noise is heard, replace the throttle body.

    2. A01J639E01

      Check the throttle position sensor.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch ON.

      3. Under Current Data, check that the throttle valve opening percentage (Throttle Pos) is within the standard.

        Standard throttle valve opening percentage
        60% or more

        Note

        When checking the standard throttle valve opening percentage, the shift lever should be in the N position.

        If the percentage is less than 60%, replace the throttle body.

  73. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.