ENGINE ASSEMBLY INSTALLATION

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

INSTALL ENGINE WIRE

1. Connect the 4 connectors and 6 clamps, and install the engine wire to the automatic transaxle assembly with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL GENERATOR ASSEMBLY

INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

INSTALL V-RIBBED BELT

1. 

   Text in Illustration

   *1	V-ribbed Belt Tensioner Assembly
   *2	Generator
   *3	Water Pump
   *4	Cooler Compressor
   *5	Crankshaft
   *6	Idler

   Set the V-ribbed belt onto each part as shown in the illustration.

2. Using SST, slowly turn the V-ribbed belt tensioner assembly clockwise and install the V-ribbed belt.

   SST

   09216-42010

   Note

   
   

   • Make sure that SST and other tools are set to the V-ribbed belt tensioner assembly securely.

   • When compressing the V-ribbed belt tensioner assembly, slowly turn the V-ribbed belt tensioner assembly.

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 EXHAUST PIPE ASSEMBLY

CONNECT FUEL TUBE SUB-ASSEMBLY

1. 

   Text in Illustration

   *1	Fuel Pipe
   *2	Fuel Tube Connector
   *3	Nylon Tube
   *4	O-ring
   *5	Retainer

   Push the fuel tube connector to the fuel pipe until the fuel tube connector makes a "click" sound.

   Note

   
   

   • Before connecting the fuel tube connector and fuel pipe, check that there is no damage or foreign matter on the connecting part of the fuel pipe.

   • After connecting the fuel tube connector and fuel pipe, check that they are securely connected by trying to pull them apart.

2. Install the fuel tube sub-assembly to the fuel hose clamp.

3. Install the No. 1 fuel pipe clamp.

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 to 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 }

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. Install the bracket with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

6. Connect the 2 connectors.

7. Engage the 2 clamps.

INSTALL STARTER ASSEMBLY

1. Install the starter assembly with the 2 bolts.

   Torque:

   37 N*m  { 377 kgf*cm, 27 ft.*lbf }

2. Connect the connector.

3. Connect the starter wire and install the nut, close the terminal cap.

   Torque:

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

CONNECT UNION TO VACUUM TUBE HOSE

1. Connect the union to vacuum tube hose to the intake manifold.

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

1. Install the air cleaner filter element to the air cleaner case sub-assembly.

2. 

   Text in Illustration

   *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.

   Note

   
   

   • 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.

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

4. Install the air cleaner cap sub-assembly and tighten the 2 bolts.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

5. Connect the wire harness clamp.

6. Connect the mass air flow meter connector.

7. Connect the purge line hose to the 2 clamps.

8. Connect the 2 vacuum switching valve vacuum hoses.

9. Connect the vacuum switching valve connector.

INSTALL FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

1. Install the front outer cowl top panel sub-assembly with the 10 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Engage the 2 clamps to install the wire harness to the front outer cowl top panel sub-assembly.

ADD ENGINE OIL

1. Add new engine oil.

   Standard Oil Grade
   Oil Grade Oil Viscosity (SAE) API grade SL "Energy-Conserving", SM "Energy-Conserving", SN "Resource-Conserving" or ILSAC multigrade engine oil 5W-30 10W-30 API grade SL, SM or SN multigrade engine oil 15W-40 20W-50

   Standard Oil Capacity
   Item Standard Condition Drain and refill with oil filter change 4.3 liters (4.5 US qts., 3.8 Imp. qts.) Drain and refill without oil filter change 4.1 liters (4.3 US qts., 3.6 Imp. qts.) Dry fill 5.0 liters (5.3 US qts., 4.4 Imp. qts.)

2. Install the oil filler cap.

ADD ENGINE COOLANT

1. Tighten the radiator drain cock plug by hand.

2. Slowly fill the radiator assembly with the engine coolant.

   Standard capacity
   6.6 liters (7.0 US qts, 5.8 Imp. 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. Remove the reserve tank cap.

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

5. 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.

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

7. 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 engine 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 No. 2 radiator hose.

   2. Maintain the engine speed at 2000 to 2500 rpm.

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

      CAUTION:

      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.

      Note

      
      

      • 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.

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

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

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

WARM UP ENGINE

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note

   To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

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 and ECT / Active Test / Control the Fuel Pump / Speed.

   4. Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly 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 FOR 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 AUTOMATIC TRANSMISSION FLUID LEVEL

1. 

   Text in Illustration

   *a	OK if hot
   *b	Add if hot

   Park the vehicle on a level surface and apply the parking brake.

2. With the engine idling and the brake pedal depressed, move the shift lever to all positions from P to L. Then return it to P.

3. Pull out the dipstick and wipe it clean.

4. Push the dipstick back fully into the pipe.

5. Pull the dipstick out again and check that the fluid level is within the HOT range. If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add a proper amount of new fluid and recheck the fluid level.

   Note

   Use Toyota Genuine ATF WS.

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.

      • Inspect the idle speed with the cooling fans off.

      • 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

      *a

      DLC3

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

      SST

      09843-18030

      Note

      
      

      • Confirm the terminal before connecting them. Connecting the wrong terminal 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 DTCs Click here.

   2. See the table below for possible causes, and then inspect and correct the applicable parts 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. Incorrect valve clearance 3. Leaky intake and exhaust valves 4. 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.

INSPECT SHIFT LEVER POSITION

1. When the shift lever is moved from P to R with the ignition switch ON and brake pedal depressed, make sure that the shift lever moves smoothly and correctly into the position.

2. Start the engine and make sure that the vehicle moves forward when the shift lever is moved from N to D and moves rearward when the shift lever is moved to R.