ENGINE ASSEMBLY INSTALLATION

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

1. Install a new front drive shaft hole snap ring LH.

   Note

   Face the end gap of the front drive shaft hole snap ring downward.

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

INSTALL GENERATOR ASSEMBLY

INSTALL COMPRESSOR AND PULLEY

INSTALL V-RIBBED BELT

1. 

   Text in Illustration

   *1	Crankshaft
   *2	Tensioner
   *3	Generator
   *4	Water Pump
   *5	Cooler Compressor

   Set the V-ribbed belt onto each part as shown in the illustration except the water pump pulley.

2. Loosen the V-ribbed belt by turning the belt tensioner clockwise.

3. Set the V-ribbed belt onto the water pump pulley.

   Note

   Make sure that the belt is attached to each pulley. In particular, make sure that the belt is securely fitted into the grooves of the crankshaft pulley.

CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

1. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks and install the steering intermediate shaft to the steering link assembly.

2. Install the bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

INSTALL FRONT AXLE ASSEMBLY LH

1. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

   Note

   Be careful not to damage the drive shaft boot or speed sensor rotor.

INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

1. Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

   Torque:

   75 N*m  { 765 kgf*cm, 55 ft.*lbf }

INSTALL TIE ROD ASSEMBLY LH

1. Connect the tie rod assembly LH to the steering knuckle with the nut.

   Torque:

   49 N*m  { 500 kgf*cm, 36 ft.*lbf }

2. Install a new cotter pin.

   Note

   Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

INSTALL FRONT SPEED SENSOR LH

1. Install the front speed sensor and front flexible hose to the front shock absorber assembly with the bolt and clamp.

   Torque:

   19 N*m  { 192 kgf*cm, 14 ft.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

   Tech Tips

   Install the speed sensor harness bracket first and then the front flexible hose.

2. Install the front speed sensor to the steering knuckle with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

INSTALL FRONT STABILIZER LINK ASSEMBLY LH

INSTALL FRONT AXLE SHAFT NUT LH

1. Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using a non-residue solvent.

   Note

   
   

   • Be sure to perform this work even, when using a new front drive shaft assembly.

   • Keep the threaded parts free of oil and foreign matter.

2. Using a socket wrench (30 mm), install the front axle hub shaft nut.

   Torque:

   294 N*m  { 2998 kgf*cm, 217 ft.*lbf }

   Note

   Stake the nut after inspecting for looseness and runout in the following steps.

   Tech Tips

   Keep depressing the brake pedal to prevent the front drive shaft from rotating.

INSTALL FRONT EXHAUST PIPE ASSEMBLY

INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the attached vinyl tape from the hose.

2. 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

3. Install the O-ring onto the No. 1 cooler refrigerant discharge hose.

4. Install the No. 1 cooler refrigerant discharge hose onto the compressor assembly with pulley with the bolt.

   Torque:

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

5. Connect the 2 connectors.

6. Install the bolt.

INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE

1. Remove the attached vinyl tape from the hose.

2. 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

3. Install the O-ring onto the No. 1 cooler refrigerant suction hose.

4. Install the No. 1 cooler refrigerant suction hose onto the compressor assembly with pulley with the bolt.

   Torque:

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

5. Connect the 2 connectors.

6. Install the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL STARTER ASSEMBLY (for 1.6 kW Type)

1. Install the starter assembly with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the starter connector.

3. Install the terminal nut and cover the nut with the cap.

   Torque:

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

INSTALL STARTER ASSEMBLY (for 1.7 kW Type)

1. Install the starter assembly with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the starter connector.

3. Install the terminal nut and cover the nut with the cap.

   Torque:

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

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

1. Install the air cleaner cap sub-assembly with the 2 clamps.

2. Install the air cleaner hose with the hose clamp.

3. Connect the ventilation hose to the cylinder head cover.

4. Install the fuel vapor feed hose to the air cleaner hose.

5. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly.

6. Connect the vacuum switching valve assembly to the air cleaner hose.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. 

   Text in Illustration

   *a

   Code Mark

   Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

   Specified capacity

   Code Mark "M"	6.9 liters (7.3 US qts, 6.1 lmp. qts)
   Code Mark "G"	7.0 liters (7.4 US qts, 6.2 lmp. 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).

3. Slowly pour coolant into the radiator reserve tank assembly until it reaches the full line.

4. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

   If the coolant level is low, add coolant.

5. Install the radiator cap sub-assembly and reserve tank cap.

6. Bleed air from the cooling system.

   Note

   
   

   • 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.

   
   

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

      Tech Tips

      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 hose.

   2. Maintain the engine speed at 2500 to 3000 rpm.

   3. Squeeze the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:

      When squeezing the radiator hoses:

      
      

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the cooling fans.

      Note

      
      

      • Make sure that the radiator reserve tank assembly still has some coolant in it.

      • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

      • If there is not enough coolant, the engine may overheat or be seriously damaged.

      • If the radiator reserve tank assembly does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reserve tank assembly is filled to the full line.

7. Stop the engine and wait until the engine coolant cools down.

8. Add engine coolant to the full line on the radiator reserve tank assembly.

CHARGE WITH REFRIGERANT

INSPECT FOR FUEL LEAK

1. Check fuel pump operation.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch to ON and turn the intelligent tester on.

      Note

      Do not start the engine.

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

   4. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.

2. Inspect for fuel leaks.

   
   

   1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs. If there is a fuel leak, repair or replace parts as necessary.

3. Turn the ignition switch off.

4. Disconnect the intelligent tester from the DLC3.

INSPECT FOR COOLANT LEAK

INSPECT REFRIGERANT LEAK

1. After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.

2. Carry out the test under the following conditions:

   
   

   • Turn the engine switch off.

   • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

     Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm², 57 to 85 psi)

   • Ensure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).

   • Repeat the inspection 2 or 3 times.

3. Remove the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

4. Remove the front bumper assembly Click here.

5. Remove the radiator side deflector RH Click here.

6. 

   Text in Illustration

   *a	Check for leaks
   *b	Halogen Leak Detector Sensor
   *c	Distance between Sensor and Joint to be Checked: 10 mm or less
   *d	Halogen Leak Detector Sensor Moving Speed: 25 to 50 mm/sec.

   How to check for refrigerant leaks in pipe joints:

   Note

   Gas leaking from a joint can be dissipated by even the slightest breeze. Move the halogen leak detector sensor 360° around each joint instead of keeping it in one spot when checking.

7. Using a halogen leak detector, check for refrigerant leaks at the pipe joints shown in the illustration.

   

   Text in Illustration

   *a	Area to be Checked	*b	Service Valve (High)
   *c	Service Valve (Low)	*d	Pipe Joint
   *e	Air Conditioner Pressure Sensor Joint	*f	Cooler Expansion Valve Joint
   *g	Condenser Joint (Inlet)	*h	Condenser Joint (Outlet)
   *i	Compressor Joint (Inlet)	*j	Compressor Joint (Outlet)

   Tech Tips

   
   

   • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

   • Disconnect the pressure sensor connector and leave it for approximately 20 minutes.

   • When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

   Standard
   There are no refrigerant leaks from the joints.

   If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

8. 

   Text in Illustration

   *1	Drain Cooler Hose
   *a	Halogen Leak Detector

   Bring the halogen leak detector sensor close to the drain cooler hose with the detector turned off, and then turn the detector on.

   Note

   Keep water away from the halogen leak detector to prevent malfunction.

   Tech Tips

   
   

   • After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

   • When bringing the halogen leak detector sensor close to the drain cooler hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow checking for leaks.

   Standard
   Refrigerant is not leaking from the drain cooler hose.

   If refrigerant is leaking, check for refrigerant leaks from the No. 1 cooler evaporator sub-assembly.

9. Remove the blower motor with fan sub-assembly Click here.

10. 

    Text in Illustration

    *1	No. 1 Cooler Evaporator Sub-assembly
    *a	Halogen Leak Detector

    Insert the halogen leak detector sensor into the air conditioning unit assembly, bring the sensor close to the No. 1 cooler evaporator sub-assembly and check for refrigerant leaks.

    Tech Tips

    After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

    Standard
    Refrigerant is not leaking from the No. 1 cooler evaporator sub-assembly.

    If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

11. Install the blower motor with fan sub-assembly Click here.

12. Install the radiator side deflector RH Click here.

13. Install the front bumper assembly Click here.

14. Install the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

INSPECT IGNITION TIMING

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.

      Note

      
      

      • Switch off all accessories and the A/C before connecting the intelligent tester.

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

   2. Race the engine at 2500 rpm for approximately 90 seconds.

   3. Turn the intelligent tester main switch on.

   4. Enter the following menus: Powertrain / Engine / Data List / Engine Speed.

      Standard idle speed
      610 to 710 rpm

      Tech Tips

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

      If the idle speed is not as specified, check the air intake system.

   5. Disconnect the intelligent tester from the DLC3.

3. When not using the intelligent tester:

   
   
   1. 

      Text in Illustration

      *1

      DLC3

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

      SST

      09843-18030

      Note

      
      

      • Confirm the terminals before connecting them. Connecting the wrong terminals may result in damage to electrical components.

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

      • Inspect the idle speed with the cooling fans off.

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

   2. Race the engine at 2500 rpm for approximately 90 seconds.

   3. Check the idle speed.

      Standard idle speed
      610 to 710 rpm

      If the speed is not as specified, check the air intake system.

   4. Disconnect the tachometer probe from the DLC3.

INSPECT CO/HC

1. Start the engine.

2. Keep the engine speed 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 during idling.

4. Immediately check CO/HC concentration at idle and 2500 rpm.

   Tech Tips

   
   

   • When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.

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

   
   

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

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

      CO	HC	Symptom	Causes
      Normal	High	Rough idle	1. Faulty ignition Incorrect timing Plugs are contaminated or shorted, or gaps are defective 2. Leaky intake and exhaust valves 3. Leaky cylinder
      Low	High	Rough idle (Fluctuating HC reading)	1. Vacuum leaks PCV hose 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. Faulty SFI system Faulty pressure Defective ECT sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty MAF sensor

INSTALL COOL AIR INTAKE DUCT SEAL

1. Install the cool air intake duct seal with the 9 clips.