ENGINE ASSEMBLY INSTALLATION


  1. INSTALL ENGINE HANGERS


    1. A019JNJ
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 and No. 2 engine hangers with the 2 bolts.

      Part No.
      Item Part No.
      No. 1 engine hanger 12281-36020
      No. 2 engine hanger 12282-36020
      Bolt 91552-81040, 91552-81025
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    2. Attach the sling device to the engine hangers and chain block.

  2. REMOVE ENGINE STAND


    1. Using a chain block and engine sling device, secure the engine assembly.

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

    2. Remove the engine stand from the engine.

  3. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine with transaxle.

  4. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A019NX0E02

      Using SST, hold the crankshaft.

      SST
      09213-54015
      09330-00021

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

    2. Clean the bolts and their installation holes.

    3. A019NMT

      Install the front drive plate spacer.

      Tech Tips

      Align the pin of the front drive plate spacer with the pin hole of the crankshaft.

    4. A019N52E03
      Text in Illustration
      *1 Drive Plate and Ring Gear Sub-assembly
      *2 Rear Drive Plate Spacer
      A019NE4 Transaxle Side

      Install the drive plate and ring gear sub-assembly and rear drive plate spacer to the crankshaft.

    5. A019MWWE03
      Text in Illustration
      *1 Adhesive 1324

      Apply a few drops of adhesive to 2 or 3 threads of the bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A019KG1E01

      Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

      Note


      • Do not strike or damage the drive plate installation bolts. Be sure to handle them carefully.

      • Do not start the engine for at least an hour after installing the drive plate.

  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. A019LBQE01
      Text in Illustration
      *1 Knock Pin

      Confirm that the 2 knock pins are on the automatic transaxle contact surface of the engine cylinder block before automatic transaxle installation.

    2. Apply clutch spline grease to the circumference of the crankshaft contact surface (*a) with the torque converter assembly centerpiece.

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      Approximately 1 g (0.0353 oz)
    3. A019NP9E01
      Text in Illustration
      *2 Crankshaft
      *a Crankshaft Contact Surface

      Keeping the engine and automatic transaxle in a horizontal position, align the knock pins with each hole on the automatic transaxle and tighten the 9 bolts shown in the illustration.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      Bolt C
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Bolt Length
      Bolt Length [mm (in.)]
      A 55 (2.17)
      B 50 (1.97)
      C 33 (1.30)

      Note


      • Do not twist or apply excessive force to the automatic transaxle.

      • Check that the torque converter assembly rotates smoothly after installation of the automatic transaxle.

  6. INSTALL DRIVE SHAFT BEARING BRACKET


    1. A019MZA

      Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 649 kgf*cm, 47 ft.*lbf }

  7. INSTALL ENGINE MOUNTING BRACKET RH


    1. A019KDY

      Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  8. TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR RH


    1. A019L1B

      Temporarily install the engine mounting insulator RH with the 3 nuts.

      Tech Tips

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

  9. TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR LH


    1. A019LCI

      Temporarily install the engine mounting insulator LH with the 3 nuts.

      Tech Tips

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

  10. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR


    1. A019LTP

      Temporarily install the front engine mounting insulator with the 3 nuts.

      Tech Tips

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

  11. INSTALL STARTER ASSEMBLY


    1. A019LZI

      Install the starter with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    2. A019K4AE01

      Connect the starter connector.

    3. Install the starter wire with the nut and cover the nut with the cap.

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

  12. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH


    1. A019NURE01
      Text in Illustration
      *1 Stud bolt
      *2 Bolt

      Using a "TORX" socket wrench (E8), install the 2 stud bolts.

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

    2. Temporarily install the compressor assembly with pulley with the 2 stud bolts and 2 bolts.

  13. INSTALL FRONT FRAME ASSEMBLY


    1. A019MPZ

      Install the engine mounting insulator RH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    2. A019KRR

      Install the engine mounting insulator LH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    3. A019OTY

      Install the front engine mounting insulator with the bolt.

      Torque:
      87 N*m  { 888 kgf*cm, 65 ft.*lbf }

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.

      Tech Tips

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

      A019OTPE04
      Text in Illustration
      *a Front Engine Mounting Insulator *b Engine Mounting Insulator RH
      *c Engine Mounting Insulator LH - -
      Torque:
      A
      52 N*m  { 531 kgf*cm, 38 ft.*lbf }
      Torque:
      B
      87 N*m  { 888 kgf*cm, 64 ft.*lbf }

    5. Install the 5 hole plugs.

      Tech Tips

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

      A019LJGE02
      Text in Illustration
      *a Front Engine Mounting Insulator *b Engine Mounting Insulator RH
      *c Engine Mounting Insulator LH - -

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on an engine lifter.

      Note


      • Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.

      • Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

      • To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.

      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.

    2. Remove the engine hangers Click here.

    3. Install the engine assembly with transaxle to the vehicle.

      Note

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

      Tech Tips


      • 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.

    4. A019K24E02
      Text in Illustration
      *1 Nut
      *2 Bolt A
      *3 Bolt B

      Install the frame side plates RH and LH with the 6 bolts and 2 nuts.

      Torque:
      Nut
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt A
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt B
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
    5. A019KKWE02
      Text in Illustration
      *1 Nut
      *2 Bolt C
      *3 Bolt D

      Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.

      Torque:
      Nut
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt C
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt D
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  15. INSTALL COMPRESSOR AND MAGNETIC CLUTCH


    1. A019NGHE01

      Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

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

      Note

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

    2. A019OD6E02
      Text in Illustration
      *1 Nut
      *2 Bolt A
      *3 Bolt B

      Install the frame side plate RH with the 3 bolts and nut.

      Torque:
      Nut
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt A
      32 N*m  { 327 kgf*cm, 24 ft.*lbf }
      Bolt B
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  16. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A019NX0E02

      Using SST, hold the crankshaft pulley.

      SST
      09213-54015
      09330-00021

      Tech Tips

      SST (Crankshaft pulley holding tool) Fixing bolt part No. : 91551-80650(2 pcs)

    2. A019MFOE05
      Text in Illustration
      *1 Adhesive 1324

      Apply a few drops of adhesive to 2 or 3 threads of the 6 drive plate and torque converter assembly setting bolt tips.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A019N5D

      Tighten the 6 drive plate and torque converter assembly setting bolts.

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

      Note

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

  17. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. A019N9W

      Install the flywheel housing under cover .

  18. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


    1. A019OIF

      Using a snap ring expander, install a new drive shaft hole snap ring RH.

      Note

      Install the drive shaft hole snap ring RH securely.

  19. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. A019N6T

      Align the shaft splines and install the drive shaft assembly LH with a brass bar and a hammer.

      Note


      • Set the shaft snap ring with the opening facing down.

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

      • When inserting the drive shaft assembly, keep it level.

    2. A019L24E11
      Text in Illustration
      *a Matchmark

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

  20. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH


    1. Install the front drive shaft assembly RH.

    2. A019O4L

      Install a new bearing bracket hole snap ring and the bolt.

      Torque:
      32 N*m  { 330 kgf*cm, 24 ft.*lbf }

      Note


      • Do not damage the boot or oil seal.

      • When inserting the drive shaft assembly, keep it level.

    3. A019JQBE03
      Text in Illustration
      *a Matchmark

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

  21. INSTALL FRONT LOWER SUSPENSION ARM LH


    1. A019L7M

      Install the front lower suspension arm to the front lower ball joint with the bolt and 2 nuts.

      Torque:
      92 N*m  { 938 kgf*cm, 68 ft.*lbf }

  22. INSTALL FRONT LOWER SUSPENSION ARM RH

    Tech Tips

    Perform the same procedure as for the LH side.

  23. CONNECT FRONT STABILIZER LINK ASSEMBLY LH


    1. A019MGY

      Install the front stabilizer link assembly to the front shock absorber 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 hexagon wrench (6 mm) to hold the stud bolt.

  24. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  25. CONNECT TIE ROD ASSEMBLY LH


    1. A019K8D

      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.

  26. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  27. CONNECT FRONT SPEED SENSOR LH


    1. A019L39E04
      Text in Illustration
      *1 Hole
      *2 Resin Clamp

      Install the resin clamp and front speed sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note


      • Prevent foreign matter from attaching to the sensor tip.

      • Firmly insert the sensor body into the knuckle before tightening the bolt.

      • After installing the sensor to the knuckle, make sure that there is no clearance between the sensor stay and knuckle. Also make sure that no foreign matter is stuck between the parts.

      • To prevent interference between the sensor and magnetic rotor, do not rotate the sensor body during or after the insertion of the sensor body to the knuckle.

  28. CONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. INSTALL FRONT AXLE SHAFT NUT LH


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

      Tech Tips


      • Be sure to perform this work for a new drive shaft.

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

    2. A019MP3

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

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

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

  30. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A019JU2

      Align the matchmarks on the steering intermediate shaft assembly and power steering link assembly.

    2. Install the bolt.

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

  32. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A019NK3

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

      Minimum 41.5 mm (1.64 in.)

      Tech Tips

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

    2. Fully insert a new gasket to the exhaust manifold converter sub-assembly.

    3. A019K0PE17
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Gasket
      *3 Wooden Block

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

      Note


      • Be careful with the installation direction of the gasket.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      48 N*m  { 490 kgf*cm, 35 ft.*lbf }

  33. INSTALL ENGINE MOVING CONTROL ROD


    1. A019N81

      Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.

      Tech Tips

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  34. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. A019M02E01
      Text in Illustration
      *1 Bolt A
      *2 Bolt B
      *3 Bolt C
      *4 Bolt D
      *5 Bolt E

      When the engine moving control rod has been replaced.


      1. Temporarily install the engine moving control rod and engine moving control rod bracket with the 4 bolts.

      2. Install the engine moving control rod bracket with the bolts except A.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

      3. Tighten the bolt A.

        Torque:
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    2. A019L0LE01
      Text in Illustration
      *1 Bolt B
      *2 Bolt C
      *3 Bolt D
      *4 Bolt E

      When the engine moving control rod has been reused.


      1. Temporarily install the engine moving control rod bracket with the 4 bolts.

      2. Fully tighten the engine moving control rod bracket with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  35. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A019LSS

      Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  36. CONNECT UNION TO CHECK VALVE HOSE


    1. A019MV7

      Connect the union to check valve hose.

  37. CONNECT NO. 1 INLET OIL COOLER HOSE


    1. A019NI7E01
      Text in Illustration
      *A for Straight Type
      *B for Elbow Type

      Connect the No. 1 inlet oil cooler hose.

  38. CONNECT NO. 1 OUTLET OIL COOLER HOSE


    1. A019OTS

      Connect the No. 1 outlet oil cooler hose.

  39. CONNECT FUEL MAIN TUBE


    1. A019MZM

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

      Note


      • Check that there is no damage or foreign objects on the fuel tube connector.

      • After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

    2. A019MSU

      Install the No. 1 EFI fuel pipe clamp.

      Tech Tips

      The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.

  40. CONNECT OUTLET HEATER WATER HOSE


    1. A019NI3

      Connect the outlet heater water hose.

  41. CONNECT INLET HEATER WATER HOSE


    1. A019L9W

      Connect the inlet heater water hose.

  42. CONNECT NO. 1 RADIATOR HOSE


    1. A019KFY

      Connect the No. 1 radiator hose.

  43. CONNECT NO. 2 RADIATOR HOSE


    1. A019LBV

      Connect the No. 2 radiator hose.

  44. INSTALL GENERATOR ASSEMBLY


    1. A019LIQ

      Install the generator with the 2 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    2. A019JY8

      Install the wire harness clamp bracket with the bolt.

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

    3. Connect the generator wire with the nut.

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

    4. Install the terminal cap.

    5. Connect the generator connector.

    6. Connect the wire harness clamp.

  45. INSTALL V-RIBBED BELT


    1. A019N3FE03
      Text in Illustration
      *1 Generator
      *2 Tensioner
      *3 Crankshaft
      *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.

  46. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Install a new clip to the control cable bracket.

    2. A019MFEE03
      Text in Illustration
      *1 Claw (A)
      *2 Claw (B)
      *3 Control Cable

      Install the control cable to the control cable bracket.

      Note


      • Make sure that the claws (A) on the clip are securely fit into the bracket holes.

      • Make sure that the cable is securely installed inside of the claws (B) of the clip.

    3. A019OKV

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

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

      Note

      Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.

  47. CONNECT ENGINE WIRE


    1. A019OYF

      Connect the 2 wire clamps.

    2. A019JS5

      Connect the connector to the ECU with the lock lever.

    3. A019MWX

      Connect the engine wire to the engine room junction block.

    4. A019OPF

      Install the engine wire with the nut and 3 connectors.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    5. A019NA7

      Connect the 2 wire clamps.

    6. A019OIS

      Install the earth wire with the 2 bolts.

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

  48. INSTALL RESERVOIR BRACKET


    1. A019MMB

      Install the reservoir bracket with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  49. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    1. A019PHG

      Install the brake master cylinder reservoir sub-assembly with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the connector to the brake master cylinder reservoir sub-assembly.

  50. INSTALL NO. 1 RELAY BLOCK COVER


    1. A019NPK

      Install the No. 1 relay block cover.

  51. INSTALL AIR CLEANER BRACKET


    1. A019PFR

      Install the air cleaner bracket with the 2 bolts.

      Torque:
      13 N*m  { 132 kgf*cm, 10 ft.*lbf }

    2. Connect the engine wire clamp.

  52. INSTALL AIR CLEANER ASSEMBLY


    1. A019KVSE01
      Text in Illustration
      *a A side view
      *b Front of the vehicle
      *c 11 to 14 mm (0.433 to 0.551 in.)

      Install the air cleaner hose with the hose clamp.

      Note

      Install the air cleaner hose clamp so that the orientation is as shown in the illustration.

    2. A019M7QE02
      Text in Illustration
      *a Tab
      *b Hole

      Insert the tab of the air cleaner assembly to the hole of the vehicle body as shown in the illustration.

    3. Install the air cleaner assembly with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    4. A019LTQE02
      Text in Illustration
      *a Light blue paint mark

      Connect the vacuum hose to the 2 clamps of the air cleaner hose.

      Note

      Align the light blue paint mark of the vacuum hose with the clamp of the air cleaner hose.

    5. Connect the vacuum hose.

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

    7. Connect the vacuum switching valve connector and install the vacuum hose to the 2 clamps.

    8. Connect the No. 2 fuel vapor feed hose to the vacuum switching valve and clamp of the air cleaner hose.

    9. Connect the mass air flow meter connector and install the wire harness clamp to the air cleaner assembly.

    10. Connect the vacuum switching valve connector and install the wire harness clamp to the air cleaner assembly.

  53. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. A019LTJ

      Install the battery clamp with the bolt and nut.

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

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

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  54. INSTALL NO. 1 AIR CLEANER INLET


    1. A019LTK

      Install the No. 1 air cleaner inlet with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  55. INSTALL NO. 2 AIR CLEANER INLET


    1. A019ODB

      Install the No. 2 air cleaner inlet with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  56. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Place the front tires on the ground.

    2. Remove the 4 nuts used to support the front shock absorber.

    3. A019OF3E01

      Install the outer cowl top panel sub-assembly with the 4 bolts and 6 nuts.

      Torque:
      Nut*1
      85 N*m  { 866 kgf*cm, 62 ft.*lbf }
      Nut*2
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
      Bolt
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    4. Engage the grommet and clamp to install the wire harness.

    5. Connect the connector (w/ Windshield Deicer).

  57. INSTALL HOSE BRACKET (for LHD)


    1. A019P7C

      Install the hose bracket to the outer cowl top panel sub-assembly with the 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  58. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    1. A019K93

      Install the windshield wiper motor and link assembly with the 5 bolts.

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

      Note

      Be careful not to damage the windshield when installing the windshield wiper motor and link assembly.

    2. A019NAG

      w/o Deicer:


      1. Engage the clamp.

      2. Connect the connector.

    3. A019JXV

      w/ Deicer:


      1. Engage the clamp.

      2. Connect each connector.

  59. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Engage the 10 guides.

      A019KO1E01

    2. Engage the 6 claws and guide <A> as shown in the illustration.

    3. Install the 2 clips to cowl top ventilator louver sub-assembly.

  60. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    1. A019LY2E05
      Text in Illustration
      *1 Wiper Arm Serration
      *2 Wire Brush
      *3 Wiper Pivot Serration

      When reusing the front wiper arm and blade assembly LH:


      1. Clean the wiper arm serrations.

    2. When reusing the windshield wiper link assembly:


      1. Clean the wiper pivot serrations with a wire brush.

    3. A019LK0E01
      Text in Illustration
      *1 Ceramic Dot

      Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Hold the wiper arm by hand while tightening the nut.

    4. Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

  61. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    1. Operate the wiper and stop the windshield wiper motor at the automatic stop position.

    2. A019LY2E06
      Text in Illustration
      *1 Wiper Arm Serration
      *2 Wire Brush
      *3 Wiper Pivot Serration

      When reusing the front wiper arm and blade assembly RH:


      1. Clean the wiper arm serrations.

    3. When reusing the windshield wiper link assembly:


      1. Clean the wiper pivot serrations with a wire brush.

    4. A019PK0E01
      Text in Illustration
      *1 Ceramic Dot

      Install the front wiper arm and blade assembly RH with the 2 nuts to the position shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Tech Tips

      While holding the tip of the wiper blade on the glass at approximately 20 mm above the ceramic dot, press down on the wiper arm and tighten the nut. Then raise and lower the wiper arm a few times to confirm that it has settled to the specified position.

  62. INSTALL FRONT WIPER ARM HEAD CAP


    1. A019O2C

      Engage the 3 claws to install the front wiper arm head cap.

  63. INSTALL FRONT FENDER TO COWL SIDE SEAL LH


    1. Wipe off any tape adhesive residue with cleaner.

    2. A019KT9E01
      Text in Illustration
      *1 Double-Sided Tape

      Engage the 2 claws and install a new front fender to cowl side seal LH.

  64. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  65. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH


    1. A019O73

      Engage the 3 clips and 2 guides.

    2. Install the front fender top reinforcement sub-assembly LH with the clip.

    3. A019ND4E01
      Text in Illustration
      *1 Hood to Cowl Top Seal

      Engage the clip to the hood to cowl top seal to the front fender top reinforcement sub-assembly LH.

  66. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure for the RH side and LH side.

  67. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  68. INSTALL FRONT WHEEL

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

  69. ADD ENGINE OIL


    1. Add new 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

      • 0W-20


      • 5W-20


      • 5W-30


      • 10W-30
      API grade SL, SM or SN multigrade engine oil

      • 15W-40


      • 20W-50
      Standard Capacity
      Item Specified Condition
      Drain and refill with oil filter change 4.4 liters (4.6 US qts, 3.9 Imp. qts)
      Drain and refill without oil filter change 4.0 liters (4.2 US qts, 3.5 Imp. qts)
      Dry fill 5.3 liters (5.6 US qts, 4.7 Imp. qts)

    2. Install the oil filler cap.

  70. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock by hand.

    2. Remove the radiator cap.

    3. Loosen the air drain valve.

    4. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain valve hole. Then tighten the air drain valve.

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

      Standard Capacity
      6.7 liters (7.1 US qts, 5.9 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.

    6. A019N61E02
      Text in Illustration
      *a Full Line

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

    7. Install the radiator cap.

    8. 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.

    9. Bleed air from the cooling system.


      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 checking when the engine coolant starts to flow inside the hose.

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

      3. Squeeze the inlet and 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 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 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 radiator reserve tank is filled to the full line.

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

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

  71. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  72. WARM UP ENGINE

  73. INSPECT ENGINE OIL LEVEL


    1. Warm up and stop the engine, then wait for 5 minutes.

    2. Check that the oil level is between the low level and full level marks on the level dipstick.

      If the level is low, check for leakage and add oil up to the full level mark.

      Note

      Do not fill the engine with oil to above the full level mark.

  74. INSPECT FOR ENGINE COOLANT LEVEL


    1. A019MVWE02
      Text in Illustration
      *1 Full Line
      *2 Low Line

      Check that the engine coolant level is between the low and full lines when the engine is cold.

      If the engine coolant level is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the full line.

      Note

      Do not substitute plain water for engine coolant.

  75. INSPECT FOR FUEL LEAK

    Click here

  76. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. Remove the radiator cap.

    2. A019MH7

      Fill the radiator with coolant and attach a radiator cap tester.

    3. Warm up the engine.

    4. Using the radiator cap tester, increase the pressure inside the radiator 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 and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    5. Remove the radiator cap tester.

    6. Install the radiator cap.

  77. INSPECT FOR OIL LEAK

  78. INSPECT FOR EXHAUST GAS LEAK

  79. INSPECT IGNITION TIMING


    1. Warm up and stop the engine.

    2. When using the 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 / Data List / IGN Advance.

        Standard ignition timing
        5 to 15° BTDC at idle

        Tech Tips

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

        If the ignition timing is not as specified, check the valve timing.

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

      6. Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1 / ON.

      7. Monitor IGN Advance of the Data List.

        Standard ignition timing
        8 to 12° BTDC at idle

        Tech Tips

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

        If the ignition timing is not as specified, check the valve timing.

      8. Enter the following menus: Connect the TC and TE1 / OFF.

      9. Turn the engine switch off.

      10. Disconnect the intelligent tester from the DLC3.

    3. When not using the intelligent tester:


      1. Remove the No. 1 engine cover sub-assembly.

      2. A019P7D

        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. A019MASE37
        Text in Illustration
        *1 DLC3

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

        SST
        09843-18040

        Note


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

        • When checking the ignition timing, the transmission should be in neutral.

      4. Using a timing light, check the ignition timing.

        Standard ignition timing
        8 to 12° BTDC at idle

      5. Remove SST from the DLC3.

      6. Check the ignition timing.

        Standard ignition timing
        5 to 15° BTDC at idle

        If the ignition timing is not as specified, check the valve timing.

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

      8. Disconnect the timing light from the engine.

      9. Install the No. 1 engine cover sub-assembly.

  80. 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.

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

      3. Turn the intelligent tester 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.

        Note

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

        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. A019MASE38
        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.

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

      3. Check the idle speed.

        Standard idle speed
        610 to 710 rpm

        Note


        • 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.

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

      4. Disconnect the tachometer probe from the DLC3.

  81. INSPECT CO/HC

    Tech Tips

    This check determines whether or not the idle CO/HC complies with regulations.


    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 causes if necessary.

        CO HC Symptom Cause
        Normal High Rough idle

        • 1. Faulty ignitions


          • 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

  82. CHECK FOR SPEED SENSOR SIGNAL

    Click here

  83. INSPECT SHIFT LEVER POSITION


    1. When moving the shift lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and correctly into position.

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

  84. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  85. INSPECT AUTOMATIC TRANSAXLE SYSTEM

    Note

    If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary ( Click here).

  86. INSTALL NO.1 ENGINE COVER SUB-ASSEMBLY


    1. A019KNK

      Fit the 3 retainers and install the No. 1 engine cover sub-assembly.

  87. INSTALL FRONT FENDER APRON SEAL LH


    1. A019O6T

      Install the front fender apron seal LH with the 2 bolts and clip.

  88. INSTALL FRONT FENDER APRON SEAL RH


    1. A019O37

      Install the front fender apron seal RH with the 2 bolts and clip.

  89. INSTALL FRONT FENDER LINER LH

  90. INSTALL FRONT FENDER LINER RH

  91. INSTALL NO. 2 ENGINE UNDER COVER

  92. INSTALL NO. 1 ENGINE UNDER COVER

  93. INSTALL FRONT FLOOR COVER LH


    1. A019OFYE01
      Text in Illustration
      *1 Bolt
      *2 Screw

      Connect the 2 clips (B).

    2. Install the front floor cover LH with the 2 screws and 4 bolts.

    3. Install the clip (A).

  94. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 6 clips.

  95. INSTALL ENGINE ROOM SIDE COVER


    1. Engage the guide.

    2. Install the engine room side cover with the 4 clips.

  96. INSTALL ENGINE ROOM SIDE COVER LH


    1. Engage the guide.

    2. Install the engine room side cover LH with the 4 clips.