INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY
Install a new gasket to the intake manifold.
Align the protrusion of the gasket with the groove on the intake manifold.
Temporarily install the throttle with motor body assembly and fuel tube bracket with the 4 bolts.
Connect the 2 water by-pass hoses.
Connect the purge line hose.
Install the fuel tube bracket and the throttle with motor body assembly with the 4 bolts.
Connect the throttle with motor body assembly connector to the throttle with motor body assembly.
Connect the wire harness clamp to the fuel tube bracket.
Install the fuel tube to the fuel tube bracket.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
Install the air cleaner filter element to the air cleaner case sub-assembly.
|*1||Air Cleaner Hose Clamp|
Connect the air cleaner cap sub-assembly to the throttle with motor body assembly and release the lock of the air cleaner hose clamp.
Align the groove of the air cleaner cap sub-assembly with the tab of the throttle with motor body assembly and install the hose.
Make sure that the tab of the air cleaner hose clamp stays within the range shown by *a.
Connect the ventilation hose to the cylinder head cover.
Install the air cleaner cap sub-assembly and tighten the 2 bolts.
Connect the wire harness clamp.
Connect the mass air flow meter connector.
Connect the purge line hose to the 2 clamps.
Connect the 2 vacuum switching valve vacuum hoses.
Connect the vacuum switching valve connector.
ADD ENGINE COOLANT
Tighten the radiator drain cock plug by hand.
Slowly fill the radiator assembly with the engine coolant.
|6.6 liters (7.0 US qts, 5.8 Imp. qts)|
Never use water as a substitute for engine coolant.
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).
Remove the reserve tank cap.
Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.
Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the engine coolant level is low, add engine coolant.
Install the radiator cap sub-assembly and reserve tank cap.
Bleed air from the cooling system.
Before starting the engine, turn the A/C switch off.
Adjust the heater control to the maximum hot setting.
Adjust the blower speed to the low setting.
Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.
The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.
Maintain the engine speed at 2000 to 2500 rpm.
Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
When squeezing the No. 1 radiator hose and No. 2 radiator hose:
Wear protective gloves.
Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.
Keep your hands away from the fan and No. 2 fan.
If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.
Make sure that the radiator reserve tank assembly still has some engine coolant in it.
If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.
If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.
Stop the engine and wait until the engine coolant cools down.
Add engine coolant to the full line on the radiator reserve tank assembly.
INSPECT FOR COOLANT LEAK
Before performing each inspection, turn the A/C switch off.
Fill the radiator assembly with engine coolant and attach a radiator cap tester.
Warm up the engine.
Using a radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm2, 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY
Install the front outer cowl top panel sub-assembly with the 10 bolts.
Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
Install the No. 1 engine cover sub-assembly with the 2 nuts.
Be sure to perform this procedure after removing and reinstalling the throttle with motor body assembly or any throttle with motor body assembly components.
Perform the following procedure after replacing the throttle with motor body assembly or any throttle with motor body assembly components. The following procedure should also be performed if the throttle with motor body assembly is cleaned.
Turn the ignition switch to ON without operating the accelerator pedal sensor assembly.
If the accelerator pedal sensor assembly is operated, perform the above step again.
Connect the intelligent tester to the DLC3 and clear the DTCs Click here.
Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range with the A/C switch off.
Be sure to perform this step with all accessories off.
Make sure that the shift lever is in N.
Enter the following menus: Powertrain / Engine and ECT / Data List / Gas Throttle / Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more.
Perform a road test and confirm that there are no abnormalities.