ENGINE ASSEMBLY INSTALLATION


  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

    A00OHZI

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 4 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  2. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A00OMAM

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 3 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    2. A00OHT2

      Install the 2 cooler brackets with the 2 bolts and nut.

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

    3. Connect the cooler pipe clamp.

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    A00OJRL

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 2 bolts and 2 nuts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  4. INSTALL FRONT ENGINE MOUNTING INSULATOR

    A00OHRD

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator is necessary.


    1. Install the engine mounting insulator with the 2 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  5. INSTALL ENGINE HANGER


    1. A00OLB6

      Disconnect the air fuel ratio sensor connector and remove the bolt and air fuel ratio sensor bracket.

    2. A00OMWEE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers with 2 bolts as shown in the illustration.

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

      Tech Tips

      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050

    3. Attach an engine sling device and hang the engine with a chain block.

  6. REMOVE ENGINE STAND


    1. Attach a sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  7. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A00OILJE01

      Using SST, hold the crankshaft.

      SST
      09330-00021
      09213-58014   ( 91551-80840 )
    2. A00OJ8VE01

      Install the front spacer, drive plate and rear spacer onto the crankshaft.

    3. A00OKOTE03

      Clean the bolts and bolt holes.

    4. Apply adhesive to 2 or 3 threads at the end of the 8 bolts.

      Text in Illustration
      *1 Adhesive
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    5. A00OIVR

      Install the front spacer, drive plate and rear spacer with the 8 bolts. Uniformly tighten the 8 bolts.

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

  9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. Install the automatic transaxle assembly Click here.

  10. INSTALL FLYWHEEL HOUSING SIDE COVER


    1. Install the flywheel housing side cover to the cylinder block.

  11. INSTALL STARTER ASSEMBLY


    1. Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

    2. Connect the connector.

    3. Connect the starter wire with the nut.

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

    4. Connect the terminal cap.

  12. TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A00OL49

      Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

  13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Place the engine on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. Operate the engine lifter and install the engine to the vehicle.

      CAUTION:

      Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • Make sure that the engine is clear of all wiring and hoses.

      • While raising the engine into the vehicle, do not allow it to contact the vehicle.

    3. A00ON82

      Temporarily install the front suspension crossmember with 2 new bolts.

    4. A00OJJVE02

      Temporarily install the member brace rear RH and LH with 2 new bolts and the 4 bolts.

      Text in Illustration
      A00OJPS New Bolt
      A00OMA6 Bolt
    5. A00OL79

      Install the engine mounting insulator LH with the through bolt and nut.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    6. A00OLN5E01

      Install the engine mounting insulator RH with the bolt and 2 nuts.

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    7. A00ON82

      Tighten the 2 front suspension member bolts.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
    8. A00OJJVE01

      Tighten the 6 member brace rear bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }
    9. A00OLB6

      Remove the 2 bolts and 2 engine hangers.

    10. Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

  14. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A00OJ5H

      Temporarily install the front crossmember with the 4 bolts.

    2. A00OK43

      Temporarily install the front engine mounting insulator to the front engine mounting bracket with the bolt and nut.

    3. Tighten the 4 front crossmember bolts.

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }

    4. Tighten the front engine mounting insulator bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

  15. TIGHTEN FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A00OL49

      Tighten the rear engine mounting insulator bolt.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  16. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A00OI0EE01

      Install the reinforcement with the 4 bolts.

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }

      Note

      Tighten the bolts in the order of C, B, D and A.

  17. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A00OLXIE01

      Install the reinforcement with the 4 bolts.

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }

      Note

      Tighten the bolts in the order of C, B, D and A.

  18. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    A00DUACE08

    1. Apply a few drops of adhesive to 2 or 3 threads of the 6 torque converter setting bolts tips.

      Adhesive
      Toyota Genuine Adhesive 1324,
      Three Bond 1324 or equivalent
    2. A00DSQ6E02

      Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

      Note

      Install the black bolt first, and then the 5 silver bolts.

    3. Install the flywheel housing under cover.

  19. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. Coat the spline of the inboard joint shaft with oil.

      Tech Tips

      Be sure to use the same type of oil that is used for the transaxle.

    2. A00OJ8J

      Align the shaft splines and tap in the drive shaft with a brass bar and hammer.

      Note


      • Make sure that the snap ring opening is facing downwards when installing the drive shaft.

      • Be careful not to damage the oil seal, boot or dust cover.

  20. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH


    1. Coat the spline of the inboard joint shaft with gear oil.

    2. A00OI9Z

      Align the shaft splines and securely insert the drive shaft.

    3. Install the 2 bearing bracket bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note

      Do not damage the oil seal, boot or dust cover.

  21. INSTALL FRONT AXLE ASSEMBLY LH


    1. Install the front axle assembly LH Click here.

  22. INSTALL FRONT AXLE ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  23. CONNECT FRONT STABILIZER LINK ASSEMBLY LH


    1. A003AFXE04

      Connect the front stabilizer link assembly to the front shock absorber with coil spring 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 6 mm hexagon wrench to hold the stud bolt.

  24. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  25. INSTALL FRONT AXLE SHAFT NUT LH


    1. A005TAB

      Using a chisel and a hammer, stake the front axle shaft nut.

  26. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedures described for the LH side.

  27. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A00DU2VE01

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

      Minimum Free Length
      41.5 mm (1.63 in.)

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

    2. A00DUDME11
      Text in Illustration
      *1 Gasket
      *2 Wooden Block

      Using a plastic-faced hammer and wooden block, tap in a new gasket until its surface is flush with the exhaust manifold.

      Note


      • Be sure to install the gasket so that it faces the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • When connecting the exhaust pipe, do not push in the gasket with the exhaust pipe.

    3. A00DRN8

      Install the 2 exhaust pipe supports, and then install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

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

  28. INSTALL FRONT CENTER FLOOR BRACE

    A00DQAY

    1. Install the floor brace with the 4 bolts.

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

  29. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY


    1. A010G9T

      Align the round hole in the No. 1 steering column hole cover with the protrusion of the steering link and install the cover.

  30. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A00ONO5E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft assembly.

    2. A00OMQT

      Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  31. INSTALL COLUMN HOLE COVER SILENCER SHEET


    1. A00OJTQ

      Install the column hole cover silencer sheet with the 2 clips.

    2. Install the floor carpet.

  32. CONNECT WIRE HARNESS AND HOSE


    1. A00OMQX

      Connect the vacuum hose.

    2. A00OLLT

      Connect the connector tube hose.

    3. A00ONVV

      Connect the engine wire with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
    4. A00OIJZ

      Connect the engine wire with the 2 bolts and clamp.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    5. Connect the connector to the battery current sensor.

    6. A00OKYL

      Attach the 2 clamps to install the wire harness, and then install the 2 nuts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Connect the 3 wire harness connectors to the engine room No. 1 junction block.

    8. A00OIYI

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the connector, make sure that dirt, water or other foreign matter does not get caught between the connector and other parts.

      • Make sure that the lever is securely lowered.

    9. Connect the wire harness clamp.

    10. A00OJBJ

      Connect the 2 oil cooler hoses to the oil cooler tube.

  33. CONNECT HEATER WATER HOSE


    1. A00ONW9

      Connect the 2 heater water hoses.

  34. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A00OI9J

      Connect the fuel tube connector and fuel pipe.

      Note

      Align the fuel tube connector with the pipe, and then push the fuel tube connector on until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting the connector, pull the pipe and connector to make sure that they are securely connected. A206121

    2. A00ONLJ

      Attach the claw to install the No. 1 fuel pipe clamp.

  35. CONNECT NO. 1 RADIATOR HOSE


    1. A00OM2QE01

      Connect the radiator hose to the cylinder head.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A00OKT9

      Connect the transmission control cable support together with the cable with the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A00OK5C

      Connect the transmission control cable to the control cable bracket.

    3. A00ON64

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

    4. Connect the transmission control cable to the control shaft lever with the nut.

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

  37. INSTALL BATTERY CARRIER


    1. A00OKIS

      Install the battery carrier with the 4 bolts.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    2. A00OHVH

      Install the radiator pipe with the 2 bolts.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

    3. Connect the 2 wire harness clamps.

  38. INSTALL BATTERY TRAY

  39. INSTALL BATTERY

  40. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. A00OLE3E01

      Install the battery clamp with the bolt and nut.

      Torque:
      for bolt
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    2. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  41. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A00OI1G

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Attach the wire harness clamp to the air cleaner case.

  42. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A00ONJ8

      Connect the air cleaner cap with the band.

    2. Connect the ventilation hose.

    3. A00OMTD

      Connect the 2 clamps.

    4. A00OO0U

      Attach the wire harness to the 2 clamps.

    5. Connect the mass air flow meter connector.

  43. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY


    1. A00OO0Y

      Using an E8 "TORX" socket wrench, connect the compressor with pulley assembly with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A00OJFTE01

      Install the 2 bolts and 2 nuts.

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

      Tech Tips

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

    3. Connect the connector.

  44. CONNECT NO. 2 RADIATOR HOSE


    1. A00OJ7IE01

      Connect the radiator hose to the water inlet.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  45. INSTALL GENERATOR ASSEMBLY


    1. Install the wire harness clamp bracket with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    2. Temporarily install the generator with the bolt.

    3. A00OK6FE02

      Temporarily install the adjusting bar with the 2 bolts.

      Text in Illustration
      A00OJPS Bolt A
      A00OMA6 Bolt B

      Tech Tips

      Item Bolt Length
      Bolt A 35 mm (1.38 in.)
      Bolt B 30 mm (1.18 in.)

    4. Tighten bolt A.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
    5. A00OLM4

      Install the wire harness to terminal B with the nut and install the terminal cap.

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

    6. Connect the connector and attach the wire harness clamp.

  46. INSTALL V-RIBBED BELT


    1. Temporarily install the V-ribbed belt.

  47. ADJUST V-RIBBED BELT


    1. A00OILIE01

      Turn bolt C to adjust the tension of the V-ribbed belt.

    2. Tighten bolts A and B.

      Torque:
      for bolt A
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }
      for bolt B
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note

      Do not loosen bolt D.

  48. CONNECT RADIATOR RESERVOIR ASSEMBLY


    1. A00OII3

      Install the grommet to the radiator reservoir.

    2. Connect the radiator reservoir with the 2 bolts.

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

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  50. ADD AUTOMATIC TRANSAXLE FLUID

    Fluid type
    Toyota Genuine ATF WS

  51. INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL


    1. Inspect automatic transaxle fluid level Click here.

  52. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug.

    2. A00OLAS

      Add TOYOTA Super Long Life Coolant (SLLC) through the radiator reservoir filler opening until the coolant reaches the B line.

      Standard capacity
      6.2 liters (6.6 US qts, 5.4 Imp. qts)

      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).

      Note

      Never use water as a substitute for engine coolant.

    3. 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.

    4. Install the cap and warm up the engine sufficiently.

    5. 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

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. After the engine has warmed up, repeat the following procedure for at least 7 minutes: run the engine at 3000 rpm for 5 seconds, and then at idle speed for 45 seconds (repeat this procedure at least 8 times).

      3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:

        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. A00OLAS

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

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

  53. ADD ENGINE OIL


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

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

    2. Add new engine oil.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)
      API grade SL or SM multigrade engine oil

      • 15W-40

      • 20W-50
      API grade SL "Energy-Conserving", SM "Energy-Conserving" or ILSAC multigrade engine oil

      • 0W-20

      • 5W-20

      • 5W-30

      • 10W-30
      Standard Capacity
      Item Specified Condition
      Drain and refill without oil filter change 3.9 liters (4.1 US qts, 3.4 Imp. qts)
      Drain and refill with oil filter change 4.2 liters (4.4 US qts, 3.7 Imp. qts)
      Dry fill 4.7 liters (5.0 US qts, 4.1 Imp. qts)

    3. Install the oil filler cap.

  54. INSPECT FOR FUEL LEAK


    1. Make sure that there are no fuel leaks after performing maintenance on the fuel system.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON, and push the intelligent tester main switch on.

        Note

        Do not start the engine.

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

      4. Check that there are no leaks from the fuel system.

      5. Turn the ignition switch off.

      6. Disconnect the intelligent tester from the DLC3.

  55. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the reserve tank cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    1. A005TAG

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

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator 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 or traces of external engine coolant leakage, check the heater core, cylinder block and head.

  56. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  57. INSPECT FOR EXHAUST GAS LEAK

    If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  58. INSPECT V-RIBBED BELT


    1. A005UX6

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

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


      • 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. A005S3QE02

      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.

    3. A005SS9E01

      Check the V-ribbed belt deflection and tension.

      Standard Deflection
      Item Specified Condition
      New belt 7.0 to 8.2 mm (0.276 to 0.323 in.)
      Used belt 7.6 to 10.0 mm (0.299 to 0.394 in.)
      Standard Tension
      Item Specified Condition
      New belt 700 to 800 N (70 to 80 kgf, 157.4 to 179.8 lbf)
      Used belt 550 to 750 N (55 to 75 kgf, 123.6 to 168.6 lbf)

      Tech Tips


      • When inspecting the V-ribbed belt deflection, apply 98 N (10 kgf, 22.0 lbf) of tensile force to it.

      • Check the V-ribbed belt deflection at the specified point.

      • V-ribbed belt tension and deflection should be checked after 2 revolutions of engine cranking.

      • Measure the belt tension when the engine is cold.

      • When adjusting the belt, be sure to adjust it so that the tension is as close as possible to the median of the specified range.

      • When replacing the belt with a new one, be sure to perform the following after adjusting the belt: idle the engine for 5 minutes, and then adjust the belt to the specified value for a new belt after the engine has cooled.

      • When inspecting a belt which has been used for over 5 minutes, apply the used belt specifications.

      • When using a belt tension gauge, confirm its accuracy by using a master gauge first.

  59. INSPECT IGNITION TIMING


    1. Warm up and stop the engine.

    2. When using an intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine and idle it.

      3. Turn the intelligent tester main switch on.

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

        Standard ignition timing
        8 to 12° BTDC @ idle

        Tech Tips

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

        Note


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

        • Check the ignition timing with the cooling fan off.

        • When checking the ignition timing, the shift lever should be in N or P.

    3. When not using the intelligent tester:


      1. Remove the No. 2 cylinder head cover.

      2. A00ONYL

        Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.

        Note

        Use a timing light that detects primary signals.

      3. Start the engine and idle it.

      4. A00OIT9E01
        Text in Illustration
        *1 Front view of DLC3

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

        SST
        09843-18040

        Note


        • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

        • When checking the ignition timing, the shift lever should be in N or P.

      5. A00ON5R

        Using the timing light, check the ignition timing.

        Standard ignition timing
        8 to 12° BTDC @ idle

        Note


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

        • Check the ignition timing with the cooling fan off.

        • When checking the ignition timing, the shift lever should be in N or P.

      6. Remove SST from the DLC3.

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

      8. Turn the ignition switch off.

      9. Remove the timing light.

      10. Install the No. 2 cylinder head cover.

  60. INSPECT ENGINE IDLE SPEED


    1. Warm up and stop the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

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

        Standard Idle Speed
        625 to 725 rpm

        Tech Tips

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

        Note


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

        • Check the ignition timing with the cooling fan off.

        • When checking the idling speed, the shift lever should be in N or P.

    3. Turn the ignition switch off.

    4. Disconnect the intelligent tester from the DLC3.

    5. A00OIT9E02
      Text in Illustration
      *1 Front view of DLC3

      When not using the intelligent tester:


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

        SST
        09843-18030

        Note


        • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

        • When checking the idling speed, the shift lever should be in N or P.

      2. Check the idle speed.

        Standard Idle Speed
        625 to 725 rpm

      3. Disconnect the tachometer probe from the DLC3.

  61. 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 (1.31 ft.) into the tailpipe while idling.

    4. Check the CO/HC concentration during idling 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 measuring procedures are determined by applicable local regulations.

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


      1. Check the air fuel ratio sensor Click here and heated oxygen sensor operation Click here.

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

        CO HC Problems Possible Causes
        Normal High Rough idling

        1. Faulty ignition:


          • Incorrect timing

          • Plugs are contaminated or shorted, or gaps are defective

        2. Incorrect valve clearance

        3. Leakage from intake or exhaust valves

        4. Leakage from cylinders
        Low High

        Rough idling

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • PCV hoses

          • Intake manifold

          • Throttle body

          • Brake booster line

        2. Lean mixture causing misfire
        High High

        Rough idling

        (Black smoke from exhaust)

        1. Restricted air cleaner filter element

        2. Plugged PCV valve

        3. Faulty SFI system:


          • Faulty pressure regulator

          • Faulty engine coolant temperature sensor

          • Faulty mass air flow meter

          • Faulty ECM

          • Faulty injectors

          • Faulty throttle body

  62. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  63. ADJUST FRONT WHEEL ALIGNMENT


    1. Adjust the front wheel alignment Click here.

  64. INSTALL NO. 2 ENGINE UNDER COVER


    1. A00OLHN

      Install the under cover with the 4 clips.

  65. INSTALL CENTER NO. 4 ENGINE UNDER COVER


    1. A00ONX6

      Install the under cover with the 2 clips.

  66. INSTALL REAR ENGINE UNDER COVER RH


    1. A00OMDF

      Install the under cover RH with the 5 clips.

  67. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the under cover LH with the 5 clips.

  68. INSTALL NO. 1 ENGINE UNDER COVER (for Rough Road Area Specification Vehicles)


    1. A00OL2M

      Install the under cover with the 3 clips.

  69. INSTALL NO. 1 ENGINE UNDER COVER


    1. A00ON3U

      Install the under cover with the 10 clips.

  70. INSTALL FRONT LOWER BUMPER ABSORBER


    1. A00OI9A

      Install the front lower bumper absorber with the 3 screws and 8 bolts.

    2. A00OL3A

      Install the 4 screws and 2 bolts.

  71. INSTALL RADIATOR SUPPORT OPENING COVER


    1. A00OKW2

      Install the radiator support opening cover with the 7 clips.

  72. INSTALL NO. 2 CYLINDER HEAD COVER


    1. A00OMDB

      Attach the 4 clips to install the cover.

      Note


      • Be sure to attach the clips securely.

      • Do not apply excessive force or hit the cover to attach the clips. This may cause the cover to break.