INSTALL ENGINE MOUNTING INSULATOR RH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 3 bolts.
INSTALL ENGINE MOUNTING INSULATOR LH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 4 bolts.
INSTALL REAR ENGINE MOUNTING INSULATOR
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 2 nuts and 2 bolts.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Install the front suspension crossmember to the engine assembly with the through bolt.
REMOVE ENGINE STAND
| *1 | No. 1 Engine Hanger |
| *2 | No. 2 Engine Hanger |
Install the No. 1 and No. 2 engine hangers with bolts as shown in the illustration.
Tech Tips
| Item | Part No. |
|---|---|
| No. 1 engine hanger | 12281-28010, 12281-0H010 |
| No. 2 engine hanger | 12282-28010, 12282-0H010 |
| Bolt | 91552-81020 |
Attach an engine sling device and hang the engine with a chain block.
Lift the engine and remove it from the engine stand.
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Clean the 8 bolts and 8 bolt holes.
Using SST, hold the crankshaft.
Install the front drive plate spacer.
Tech Tips
Align the pin of the front drive plate spacer with the pin hole of the crankshaft.
| *1 | Drive Plate |
| *2 | Transaxle Side |
| *3 | Rear Drive Plate Spacer |
Install the drive plate and rear drive plate spacer onto the crankshaft.
Apply a few drops of adhesive to 2 or 3 threads of the tip of each mounting bolt.
| Adhesive |
|---|
| Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
Using several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
Install the automatic transaxle Click here.
INSTALL STARTER ASSEMBLY
Install the starter with the 2 bolts.
Connect the starter connector.
Connect the starter wire with the nut and close the terminal cap.
INSTALL COMPRESSOR ASSEMBLY WITH PULLEY
Using a "TORX" socket wrench (E8), install the compressor assembly with pulley with the 2 stud bolts.
Install the 2 bolts and 2 nuts.
Tech Tips
Tighten the bolts and nuts in the order shown in the illustration.
Connect the connector.
Attach the 2 clamps.
INSTALL DRIVE SHAFT BEARING BRACKET
Install the bracket with the 3 bolts.
INSTALL ENGINE WIRE
Install the engine wire to the engine.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Place the engine on an engine lifter.
Tech Tips
Place the engine on wooden blocks or equivalent so that the engine is level.
| *1 | No. 1 Engine Hanger |
| *2 | No. 2 Engine Hanger |
Remove the 2 bolts and No. 1 and No. 2 engine hangers.
Operate the engine lifter and install the engine to the vehicle.
Note
Make sure that the engine is clear of all wiring and hoses.
Temporarily install the front suspension crossmember with 2 new bolts.
Temporarily install the 2 front suspension member brace rears with 2 new bolts and the 4 bolts.
|
New Bolt |
|
Bolt |
Install the engine mounting insulator LH with the through bolt and nut.
Tech Tips
While holding the bolt in place, tighten the nut.
| *1 | Nut A |
| *2 | Nut B |
Install the engine mounting insulator RH with the bolt and 2 nuts.
Install the cooler bracket with the bolt and nut.
Connect the 2 air conditioning tubes.
Install the cooler bracket with the bolt.
Connect the air conditioning tube.
Tighten the front suspension member bolts.
Tighten the 6 front suspension member brace rear bolts.
TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR
Temporarily install the engine mounting insulator with the through bolt and nut.
INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
Install the front crossmember with the 6 bolts.
Tighten the through bolt and nut holding the engine mounting insulator.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT
Install the front suspension member reinforcement LH with the 8 bolts.
Note
Tighten the bolts in the order of C, B, D and A.
Install the front suspension member reinforcement RH with the 8 bolts.
Note
Tighten the bolts in the order of C, B, D and A.
CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
| *1 | Lip |
| *2 | Clip B |
| *3 | Clip A |
| *4 | Lip |
Attach clip B to the body and install the No. 1 steering column hole cover to the body with clip A.
Note
Make sure that the lip of the No. 1 steering column hole cover is not damaged.
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
| *1 | Matchmark |
Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft assembly.
Install the bolt.
INSTALL COLUMN HOLE COVER SILENCER SHEET
Install the column hole cover silencer sheet with the 2 clips.
Install the floor carpet.
INSTALL FRONT DRIVE SHAFT ASSEMBLY
Install the front drive shaft Click here.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
Install the front exhaust pipe Click here.
CONNECT ENGINE WIRE
Connect the 2 clamps and ground cable with the bolt.
Connect the clamp and ground cable with the bolt.
Connect the clamp and ECM connector Click here.
Lower the engine wire and attach the 2 claws.
Install the wire harnesses with the 2 nuts and lock the 2 claws.
Connect the 3 connectors to the engine room relay block.
CONNECT SUCTION HOSE SUB-ASSEMBLY
Remove the attached vinyl tape from the hose and compressor.
Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.
| Compressor oil |
|---|
| ND-OIL 8 or equivalent |
Install the O-ring onto the suction hose sub-assembly.
Install the suction hose sub-assembly onto the compressor assembly with pulley with the bolt.
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
Remove the attached vinyl tape from the hose and compressor.
Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.
| Compressor oil |
|---|
| ND-OIL 8 or equivalent |
Install the O-ring onto the discharge hose sub-assembly.
Install the discharge hose sub-assembly onto the compressor assembly with pulley with the bolt.
INSTALL GENERATOR ASSEMBLY
Install the generator with the 2 bolts.
Connect the wire harness clamp.
Connect the wire harness clamp bracket with the bolt.
Connect the generator wire with the nut.
Close the terminal cap.
Connect the generator connector.
INSTALL FAN & GENERATOR V BELT
Tech Tips
The illustration shows the belt layout.
Using SST, slowly turn the V-ribbed belt tensioner clockwise and install the belt.
Note
Make sure that SST and other tools are set to the tensioner securely.
When compressing the V-ribbed belt tensioner, slowly turn the tensioner.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
Connect the control cable with the bolt.
Connect the control cable to the control cable bracket.
Connect the control cable to the control cable bracket and install the clip.
Connect the control cable to the control shaft lever with the nut.
CONNECT FUEL TUBE
Connect the fuel tube.
Push the fuel tube connector until it makes a "click" sound.
Install the fuel pipe clamp.
Install the fuel tube to the fuel hose clamp.
CONNECT HEATER WATER HOSE
Connect the 2 heater water hoses.
Connect the breather hose.
CONNECT CONNECTOR TUBE HOSE
for RHD:
Connect the connector tube hose.
for LHD:
Connect the connector tube hose.
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
Install the outer cowl top panel with the 9 bolts.
CONNECT OIL COOLER HOSE
Connect the 2 oil cooler hoses.
INSTALL NO. 2 RADIATOR HOSE
Install the No. 2 radiator hose.
Tech Tips
The direction of the hose clamp is indicated in the illustration.
INSTALL NO. 1 RADIATOR HOSE
Install the No. 1 radiator hose.
Connect the No. 1 radiator hose to the No. 2 water by-pass hose.
Connect the No. 1 radiator hose clamp.
Tech Tips
The direction of the hose clamp is indicated in the illustration.
INSTALL AIR CLEANER CASE
Install the air cleaner case with the 3 bolts.
Connect the engine wire.
INSTALL AIR CLEANER CAP AND HOSE
Insert the hinge part of the air cleaner cap and hose into the air cleaner case, and then fasten the 3 hook clamps.
Align the matchmarks of the No. 1 air cleaner hose and throttle body. Then connect the No. 1 air cleaner hose to the throttle body and push apart the tabs of the No. 1 air cleaner hose clamp.
Note
Make sure that the hose clamp is at the correct angle.
Connect the No. 2 fuel vapor feed hose to the air cleaner hose.
Connect the No. 2 ventilation hose to the air cleaner hose.
Connect the purge VSV.
Connect the wire harness and mass air flow meter connector.
CONNECT RADIATOR RESERVOIR
Connect the radiator reservoir with the 2 bolts.
ADD ENGINE COOLANT
Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.
Continue adding TOYOTA SLLC until it is filled to the B line.
| Standard capacity |
|---|
| 5.7 liters (6.0 US qts, 5.0 Imp. qts) |
Note
Do not substitute plain water 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).
Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant. If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
Install the radiator cap.
Start the engine and warm it up until the cooling fan operates. While the cooling fan operates, circulate the coolant for several minutes.
Set the air conditioning as follows while warming up the engine.
| Item | Specified Condition |
|---|---|
| Automatic Air Conditioning System | Temperature: Toward MAX (HOT) Air conditioning switch: off |
Maintain an engine speed of 2000 to 2500 rpm and warm up the engine until the cooling fan operates.
Note
Make sure that the radiator reservoir still has some coolant in it.
Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
If there is not enough coolant, the engine may burn out or overheat.
Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the B line.
Run the engine at 2000 rpm until the coolant level has stabilized.
Press the No. 1 and No. 2 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.
Stop the engine and wait until the coolant cools down to ambient temperature.
Check that the coolant level is between the FULL and LOW lines.
If the coolant level is below the LOW line, repeat all of the procedures above.
If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines.
ADD ENGINE OIL
Add fresh engine oil and install the oil filler cap.
| Standard Oil Grade | ||||||
|---|---|---|---|---|---|---|
|
| Standard Capacity | ||||||||
|---|---|---|---|---|---|---|---|---|
|
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
Install the cover with the 2 nuts.
INSTALL ENGINE UNDER COVER REAR RH
Install the under cover with the 5 clips.
INSTALL CENTER NO. 4 ENGINE UNDER COVER
Install the under cover with the 5 clips.
INSTALL NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)
Install the under cover with the 3 bolts.
INSTALL NO. 1 ENGINE UNDER COVER
Install the under cover with the 5 clips.
INSTALL FRONT LOWER BUMPER ABSORBER
Install the front lower bumper absorber with the 8 bolts and 3 screws.
Install the 4 screws and 2 bolts.
INSTALL FRONT WHEELS
INSTALL BATTERY CARRIER
Install the battery carrier with the 4 bolts.
Connect the 2 wire harness protector clamps.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY CLAMP SUB-ASSEMBLY
Attach the hook of the battery clamp to the battery carrier.
Partially tighten the nut and temporarily install the bolt so that the clamp position can be adjusted.
Adjust the battery clamp position.
Tighten the nut and bolt.
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
Connect the cable and tighten the nut.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Connect the cable and tighten the nut.
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
CHARGE REFRIGERANT
Perform vacuum purging using a vacuum pump.
Charge refrigerant HFC-134a (R134a).
| Standard |
|---|
| 440 +/-30 g (15.5 +/-1.1 oz) |
Note
Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
Approximately 200 g (7.05 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
WARM UP ENGINE
Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.
Note
Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.
CHECK FOR REFRIGERANT GAS LEAK
After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
Perform the operation observing the following instructions:
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.
Tech Tips
When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).
| *1 | Check for Leakage |
| *2 | Halogen Leak Detector |
Using a halogen leak detector, check the refrigerant line for leakage.
If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.
Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.
INSPECT FOR FUEL LEAK
Make sure that there are no fuel leaks after performing maintenance on the fuel system.
Connect the intelligent tester to the DLC3.
Turn the engine switch on (IG) and push the intelligent tester main switch on.
Note
Do not start the engine.
Select the Active Test mode on the intelligent tester.
Tech Tips
Refer to the intelligent tester operator's manual for further details.
Check that there are no leaks from the fuel system.
Turn the engine switch off.
Disconnect the intelligent tester from the DLC3.
INSPECT FOR OIL LEAK
Start the engine. Make sure that there are no oil leaks from the area that was worked on.
INSPECT FOR COOLANT LEAK
Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator reservoir.
Fill the radiator reservoir with coolant, and then attach a radiator cap tester.
Warm up the engine.
Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage.
If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
Reinstall the radiator cap.
INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL
Inspect the transaxle fluid level Click here.
INSPECT SHIFT LEVER POSITION
When moving the shift lever from P to R with the ignition switch ON and the brake pedal depressed, make sure that the shift lever moves smoothly and correctly into position.
Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D and moves in reverse after moving the shift lever to R. If the operation cannot be performed as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition.
ADJUST SHIFT LEVER POSITION
Remove the console box assembly Click here.
Apply the parking brake and move the shift lever to N.
Disconnect the end of the transmission control cable assembly from the shift lever assembly.
| *1 | Stopper |
| *2 | Nut |
Pull out the stopper of the transmission control cable.
Note
Do not remove the stopper. If the stopper is removed, reinstall it to its original position.
Rotate the nut counterclockwise approximately 180° and, while holding the nut in that position, disconnect the transmission control cable from the shift lever retainer.
Note
Do not over-rotate the nut as it will come off the internal spring and the transmission control cable will not be reusable.
Push the 2 claws together at the top of the transmission control cable lock piece. While holding the 2 claws together, push the 2 lugs on the bottom of the lock piece toward each other and upward to pull out the lock piece.
Turn the nut of the transmission control cable 180° counterclockwise. While holding the nut in place, push in the stopper until the stopper clicks twice.
| *1 | Stopper | *2 | Nut |
Install the outer part of the transmission control cable to the shift lever retainer. Check that the spring is positioned at "A" and push in the stopper.
| *1 | Stopper | *3 | Shift Lever Retainer |
| *2 | Nut | *4 | Spring |
Tech Tips
If the stopper cannot be pushed in, slightly turn the nut clockwise and then push in the stopper again.
| *1 | Lock Piece |
Connect the end of the cable to the shift lever assembly.
Note
Make sure that the lock piece is pulled up.
Push on the end of the cable all the way to the base of the pin.
| *1 | Lock Piece |
| *2 | Adjuster Case |
Push the lock piece into the adjuster case.
Note
Securely push in the lock piece until it locks.
After adjusting the shift lever position, check the operation and function of the shift lever. If there is a problem, adjust the position again.
Install the console box Click here.
INSTALL RADIATOR SUPPORT OPENING COVER
Install the radiator support opening cover with the 8 clips.
INSTALL ENGINE ROOM SIDE COVER
Install the engine room side cover with the clip.
INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY
Install the front wiper motor and link Click here.
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Inspect and adjust the front wheel alignment Click here.
RESET MEMORY
When replacing the engine assembly, perform the Reset Memory procedure (A/T initialization) Click here.