ENGINE ASSEMBLY INSTALLATION


  1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A019OAPE01

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021

    2. Clean the 8 bolts and 8 bolt holes.

    3. A019N87

      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. A019PG0E01

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

    5. A019ME0E06
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    6. A019KZPE01

      In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      83 N*m  { 846 kgf*cm, 61 ft.*lbf }

  2. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A019KW3

      Install the rear engine mounting bracket with the 3 bolts.

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

  3. INSTALL ENGINE MOUNTING BRACKET RH


    1. A019LBY

      Install the engine mounting bracket RH with the 3 bolts.

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

  4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    1. A019KZ1E04
      Text in Illustration
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece

      Apply clutch spline grease to the round of the crankshaft contact surface with the torque converter assembly centerpiece.

      Clutch spline grease
      Toyota Genuine Clutch Spline Grease or equivalent
      Maximum spread
      About 1 g (0.0353 oz.)
    2. A019K1YE01

      Keeping the engine and automatic transaxle assembly in a horizontal position, align the knock pins with each hole on the automatic transaxle assembly and tighten the 11 bolts shown in the illustration.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt C
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      Bolt D
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

      Note


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

      • Do not forcibly pry on the automatic transaxle assembly.

      • Check that the torque converter assembly rotates.

      Tech Tips

      Bolt length:


      • Bolt A: 55 mm (2.17 in.)

      • Bolt B: 50 mm (1.97 in.)

      • Bolt C: 41 mm (1.61 in.)

      • Bolt D: 33 mm (1.30 in.)

  5. INSTALL TRANSFER STIFFENER PLATE RH


    1. A019MNOE01

      Install the transfer stiffener plate RH with the 4 bolts.

      Torque:
      Bolt A
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
      Bolt B
      78 N*m  { 796 kgf*cm, 58 ft.*lbf }

  6. INSTALL MANIFOLD STAY


    1. A019JQF

      Install the manifold stay with the bolt and nut.

      Torque:
      Bolt
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
      Nut
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  7. INSTALL RADIATOR PIPE CLAMP


    1. A019LMZ

      Install the radiator pipe clamp with the bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Install the sensor wire and the breather plug hose to the radiator pipe clamp.

  8. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. A019PBN

      Install the rear engine mounting insulator assembly with the 2 bolts.

      Torque:
      52 N*m  { 531 kgf*cm, 39 ft.*lbf }

      Tech Tips

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

    2. Install the 2 hole plugs.

  9. INSTALL ENGINE MOUNTING INSULATOR RH


    1. A019L1B

      Install the engine mounting insulator RH with the 3 nuts.

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

      Tech Tips

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

    2. Install the 2 hole plugs.

  10. INSTALL ENGINE MOUNTING INSULATOR LH


    1. A019LCI

      Install the engine mounting insulator LH with the 3 nuts.

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

      Tech Tips

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

    2. Install the 2 hole plugs.

  11. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. A019MUE

      Install the front engine mounting insulator with the 3 nuts.

      Torque:
      52 N*m  { 531 kgf*cm, 39 ft.*lbf }

      Tech Tips

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

    2. Install the 2 hole plugs.

  12. INSTALL ENGINE WIRE


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

  13. 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 terminal nut and cover the nut with the cap.

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

  14. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH


    1. for Standard Bolt:


      1. A019MM7E01
        Text in Illustration
        *1 Bracket

        Temporarily install the compressor and magnetic clutch and the bracket with the 4 bolts.

    2. for Stud Bolt:


      1. A019M5TE01
        Text in Illustration
        *1 Bracket
        *2 Stud bolt
        *2 Bolt

        Temporarily install the compressor and magnetic clutch and the bracket with the 2 stud bolts and 2 bolts.

  15. INSTALL COMPRESSOR AND MAGNETIC CLUTCH


    1. for Standard Bolt:


      1. A019N95E01

        Install the compressor and magnetic clutch with the 4 bolts.

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }

        Note

        Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

    2. for Stud Bolt:


      1. A019M2Q

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

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      2. A019M2LE01

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

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }

        Note

        Tighten the bolts and nuts in the order shown in the illustration to install the compressor and magnetic clutch.

    3. Engage each clamp.

    4. Connect each connector.

  16. INSTALL GENERATOR ASSEMBLY


    1. A019NEV

      Install the wire harness clamp stay with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }
    2. A019O7M

      Connect the wire harness clamp.

    3. Install the generator assembly to the cylinder block with the generator bracket, bolt and nut.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    4. A019KOS

      Install the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    5. A019MQ0

      Connect the generator connector to the generator assembly.

    6. Install the generator wire with the nut.

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

    7. Install the terminal cap.

    8. Connect the wire harness clamps.

    9. Connect the magnetic clutch connector to the compressor and magnetic clutch.

  17. INSTALL V-RIBBED BELT


    1. A019OSRE02
      Text in Illustration
      *1 Water Pump
      *2 Idler
      *3 Generator
      *4 Crankshaft
      *5 V-ribbed belt Tensioner
      *6 A/C Compressor

      Install the V-ribbed belt.

    2. A019NA3

      Turn the V-ribbed belt tensioner counterclockwise and remove a 5 mm bi-hexagon wrench.

    3. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.

  18. 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. A019OWR

      Install the front engine mounting insulator with the bolt.

      Torque:
      87 N*m  { 888 kgf*cm, 65 ft.*lbf }
    4. A019MQ8

      Connect the wire clamp and connector.

    5. A019LRC

      Install the rear engine mounting insulator assembly with the 2 bolts.

      Torque:
      78 N*m  { 795 kgf*cm, 57 ft.*lbf }

  19. INSTALL STEERING LINK ASSEMBLY


    1. A019N4D

      Install the power steering link assembly with the 2 bolts and 2 nuts.

      Torque:
      70 N*m  { 713 kgf*cm, 51 ft.*lbf }

      Note


      • Make sure to tighten the bolts starting from the steering link assembly pinion shaft side.

      • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

  20. INSTALL FRONT STABILIZER BAR

  21. INSTALL FRONT NO. 1 STABILIZER BRACKET LH


    1. A019KPI

      Install the front No. 1 stabilizer bracket LH to the front frame assembly with the 2 bolts.

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

  22. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    Perform the same procedure as for the LH side.

  23. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on the 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.

      Tech Tips

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

    2. A019KKGE12

      Remove the 4 bolts, No. 1 and No. 2 engine hangers.

    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. A019PC4E02
      Text in Illustration
      *1 Nut
      *2 Bolt A
      *3 Bolt B

      Install the frame side rail 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 }

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    1. A019O0IE01

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    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. A019O2A

      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.

  25. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. A019L20

      Install the flywheel housing under cover with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  26. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING


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

  27. 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. A019L24E10
      Text in Illustration
      *1 Matchmark

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

  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH


    1. Install the front drive shaft assembly RH.

    2. A019L7E

      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. A019JQBE01
      Text in Illustration
      *1 Matchmark

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

  29. 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 }

  30. INSTALL FRONT LOWER SUSPENSION ARM RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. 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.

  32. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  33. 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.

  34. CONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  35. 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.

  36. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  37. 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.

  38. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  39. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY LH (w/ Air Suspension)


    1. A019ODT

      Install the height control sensor link sub-assembly LH with the nut.

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

  40. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY RH (w/ Air Suspension)

    Tech Tips

    Perform the same procedure as for the LH side.

  41. 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 }

  42. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. A019L6PE01

      Remove SST from the transaxle.

    2. Install the propeller with center bearing shaft assembly.

      Note


      • Be careful not to damage the oil seal.

      • Be careful not to damage the universal joint boot when installing the propeller shaft.

    3. A019N0IE01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the rear propeller shaft and the electromagnetic control coupling assembly and install the 4 nuts and 4 No. 2 center support bearing washers.

      Note

      Do not allow grease to adhere to the bolts or washers.

    4. A019M7FE03

      Temporarily install the propeller with center bearing shaft assembly with the 4 bolts, and 4 No. 2 center support bearing washers.

      Note


      • Reuse the No. 2 center support bearing washers.

      • Do not allow grease to adhere to the bolts or washers.

    5. A019K6PE01

      Fully tighten the 4 nuts.

      Torque:
      74 N*m  { 750 kgf*cm, 54 ft.*lbf }

  43. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. Depress the brake pedal and hold it.

    2. A019KFJ

      Remove the piece of cloth or equivalent from the universal joint.

    3. Using a hexagon wrench (6 mm), tighten the 6 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    4. A019OQRE01

      With the vehicle unloaded, adjust the dimension between the rear side of the cover and shaft as shown in the illustration.

      Length (A)
      65.5 to 70.5 mm (2.57 to 2.78 in.)

    5. With the vehicle unloaded, adjust the front and rear dimensions between the edge surface of the center support bearing and the edge surface of the cushion respectively as shown in the illustration, and then tighten the bolts.

      A019P79E02
      Text in Illustration
      *1 No. 2 Center Support Bearing Assembly (for Front Side) *2 No. 2 Center Support Bearing Assembly (for Rear Side)
      Length (A)
      11.5 to 13.5 mm (0.453 to 0.532 in.)

    6. Fully tighten the 4 bolts.

      Torque:
      74 N*m  { 750 kgf*cm, 54 ft.*lbf }

    7. Check that the center line of the bracket is at a right angle to the shaft axial direction.

  44. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. A019NU3

      Install the No. 1 exhaust pipe support bracket with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  45. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket to the front exhaust pipe assembly.

    2. A019OPWE01

      Install the front exhaust pipe assembly with the 2 nuts and 2 bolts (B).

      Torque:
      Bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Nut
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }

    3. Tighten the bolt (A).

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A019OUN

      Connect the No. 2 oxygen sensor connector (for Bank 2 Sensor 2).

  46. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY


    1. A019NK3

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

      Minimum length
      41.5 mm (1.64 in.)

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

    2. Fully insert a new gasket to the front No. 3 exhaust pipe sub-assembly.

    3. A019K0PE15
      Text in Illustration
      *1 Front No. 3 Exhaust Pipe 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 front No. 3 exhaust pipe sub-assembly.

      Note


      • Be sure to install the gasket in the correct direction.

      • 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 2 new gaskets to the front No. 3 exhaust pipe sub-assembly.

    5. A019N5K

      Install the front No. 3 exhaust pipe sub-assembly with the 4 bolts, 2 compression springs and 2 nuts.

      Torque:
      Bolt
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }
      Nut
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }
    6. A019KHL

      Connect the 3 clamps and oxygen sensor connector (for Bank 1 Sensor 2).

  47. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil to a new O-ring.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the suction hose sub-assembly.

    4. A019PJZ

      Connect the suction hose sub-assembly with the nut.

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

      Note

      Be sure to hold the suction hose while tightening the nut so that the suction hose is not deformed.

  48. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil to a new O-ring.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the discharge hose sub-assembly.

    4. A019LEG

      Connect the discharge hose sub-assembly with the nut.

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

      Note

      Be sure to hold the discharge hose while tightening the nut so that the discharge hose is not deformed.

  49. INSTALL NO. 3 ENGINE MOUNTING STAY RH

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine moving stay RH is necessary.


    1. A019PE4E02
      Text in Illustration
      *1 Engine moving control rod
      *2 No. 3 engine moving stay RH
      *3 Engine moving control rod bracket

      Temporarily install the engine moving control rod and No. 3 engine moving stay RH to the engine moving control rod bracket with the 2 bolts.

    2. Tighten the bolt A.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  50. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. A019KYYE01

      When replaced the engine moving control rod or No. 3 engine moving stay RH.


      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. A019OWI

      When not replaced the engine moving control rod or No. 3 engine moving stay RH.


      1. Install the engine moving control rod bracket with the 4 bolts.

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

  51. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A019MSW

      Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

      Torque:
      Bolt
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Nut
      23 N*m  { 234 kgf*cm, 17 ft.*lbf }

  52. CONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. A019L8P

      Connect the union to check valve hose.

  53. CONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. A019O41

      Connect the union to check valve hose.

  54. 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.

  55. CONNECT NO. 1 OUTLET OIL COOLER HOSE


    1. A019OTS

      Connect the No. 1 outlet oil cooler hose.

  56. 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. A019OMS

      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.

  57. CONNECT OUTLET HEATER WATER HOSE


    1. A019K50

      Connect the outlet heater water hose.

  58. CONNECT INLET HEATER WATER HOSE


    1. A019OK2

      Connect the inlet heater water hose.

  59. CONNECT NO. 1 RADIATOR HOSE


    1. A019P36

      Install the No. 1 radiator hose to the radiator pipe clamp.

    2. Connect the No. 1 radiator hose.

  60. CONNECT NO. 2 RADIATOR HOSE


    1. A019KL5

      Connect the No. 2 radiator hose.

  61. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A019NY6

      Connect the No. 1 fuel vapor feed hose.

  62. 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.

  63. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (for RHD)


    1. A019K8O

      Install the brake master cylinder reservoir sub-assembly with the 2 bolts.

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

    2. Connect the connector.

  64. CONNECT ENGINE WIRE


    1. A019LXT

      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 }

  65. INSTALL NO. 1 RELAY BLOCK COVER


    1. A019NPK

      Install the No. 1 relay block cover.

  66. INSTALL RESERVOIR BRACKET (for LHD)


    1. A019MMB

      Install the reservoir bracket with the 2 bolts.

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

  67. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (for LHD)


    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.

  68. 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.

  69. INSTALL AIR CLEANER ASSEMBLY


    1. A019M7QE01
      Text in Illustration
      *1 Tab
      *2 Hole

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

    2. A019JQO

      Install the air cleaner assembly with the 2 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }
    3. A019L8LE01
      Text in Illustration
      *1 Ventilation Hose
      *2 Fuel Vapor Feed Hose

      Connect the air cleaner hose to the throttle body with the hose clamp.

    4. Connect the ventilation hose and the fuel vapor feed hose.

    5. A019LU3

      Connect the 2 vacuum hoses.

    6. A019KSB

      Connect the 2 wire harness clamps and vacuum switching valve connector.

    7. A019LPG

      Connect the vacuum hose to the intake air surge tank assembly.

    8. Install the hose to the hose clamp.

    9. A019K7G

      Connect the mass air flow meter connector and wire harness clamp.

  70. 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 }

  71. INSTALL NO. 1 AIR CLEANER INLET


    1. A019ND6

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

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

    2. Connect the vacuum hose clamp to the No. 1 air cleaner inlet.

  72. INSTALL NO. 2 AIR CLEANER INLET


    1. A019O60

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

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

    2. Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.

  73. INSPECT VACUUM HOSES


    1. Inspect the vacuum hoses.

      A019K2M

  74. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A019OCLE01

      Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.

      Torque:
      Nut*1
      85 N*m  { 867 kgf*cm, 63 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 }
    2. A019O7N

      Engage the grommet and clamp to install the wire harness.

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

  75. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A019OF3E01

      Install the outer cowl top panel sub-assembly with the 4 bolts, 4 nuts*1 and 2 nuts*2.

      Torque:
      Nut*1
      85 N*m  { 867 kgf*cm, 63 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 }
    2. A019N0P

      Engage the grommet and clamp to install the wire harness.

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

  76. INSTALL FRONT SHOCK ABSORBER CAP (w/ Air Suspension)


    1. A019N7O

      Install the front shock absorber cap with the 3 nuts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  77. 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.

  78. 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.

  79. 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.

  80. 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.

  81. INSTALL FRONT WIPER ARM HEAD CAP


    1. A019O2C

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

  82. 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.

  83. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

    Tech Tips

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

  84. 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.

  85. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

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

  86. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)


    1. Install the suspension tower damper with the 4 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  87. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  88. INSTALL FRONT WHEEL

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

  89. ADD ENGINE OIL


    1. A019KNY

      Add clean engine oil and install the oil filler cap.

      Note

      Do not allow engine oil adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

      If engine oil is on the location indicated by the arrow, replace the belt tensioner.

      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 Grade (Destination package for Europe, Australia)
      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 Standard Condition
      Drain and refill with oil filter change 6.1 liters (6.4 US qts, 5.4 lmp. qts)
      Drain and refill without oil filter change 5.7 liters (6.0 US qts, 5.0 lmp. qts)
      Dry fill 7.1 liters (7.5 US qts, 6.2 lmp. qts)

  90. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Remove the radiator cap.

    4. Loosen the air drain cock plug on the water inlet housing.

    5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

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

      Standard capacity
      9.5 liters (10.0 US qts, 8.3 lmp. 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).

      • Contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    7. Tighten the air drain plug.

    8. A019MVWE01
      Text in Illustration
      *1 FULL Line

      Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

    9. Install the radiator cap.

    10. 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.

    11. 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 reservoir 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 reservoir 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 reservoir is filled to the FULL line.

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

    13. Add engine coolant to the FULL line on the radiator reservoir.

  91. ADD TRANSFER OIL

  92. INSPECT TRANSFER OIL


    1. A019JV1

      Remove the No. 1 transfer case plug and gasket.

    2. A019MRF

      Check that the oil level is between 0 and 5 mm (0 and 0.197 in.) from the bottom lip of the case plug hole.

      Note


      • When inspecting the transfer oil, make sure that the vehicle is level.

      • An excessively large or small amount of oil may cause damage.

      • After adding oil, drive the vehicle and recheck the oil level.

    3. Check for oil leakage if the oil level is low.

    4. Install a new gasket onto the No. 1 transfer case plug and then tighten the plug.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  93. ADD AUTOMATIC TRANSAXLE FLUID

    Tech Tips

    Click here.)

  94. WARM UP ENGINE

  95. INSPECT ENGINE OIL LEVEL


    1. Warm up and stop the engine, then wait for 5 minutes. The oil level should be between the low level and full level marks on the engine oil level dipstick.

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

      Note

      Do not add engine oil to above the full level mark.

  96. INSPECT 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.

  97. CHARGE WITH REFRIGERANT


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A019MUNE05
      Standard (for Suction Pipe Separate Type)
      450 to 550 g (15.9 to 19.4 oz.)
      Standard (except Suction Pipe Separate Type)
      500 to 600 g (17.6 to 21.2 oz.)
      SST
      09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

      Note


      • Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

      Tech Tips

      Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

  98. INSPECT FOR FUEL LEAK

    Tech Tips

    Click here.)

  99. 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. A019MDJ

      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.

  100. INSPECT FOR OIL LEAK

  101. INSPECT FOR EXHAUST GAS LEAK

  102. INSPECT IGNITION TIMING


    1. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

    2. When using the intelligent tester:

      Check the ignition timing.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine and run it at idle.

      3. Turn the intelligent tester main switch on.

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

        Standard ignition timing
        9.5 to 24.5° BTDC at idle

        Note


        • Check the ignition timing with the cooling fans off.

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

        • When checking the ignition timing, the transaxle should be in neutral or park.

        Tech Tips

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

      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.

      7. Monitor IGN Advance.

      8. Perform the Active Test.

        Standard ignition timing
        8 to 12° BTDC at idle

        Note

        When checking the ignition timing, the transaxle should be in neutral or park.

        Tech Tips

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

    3. When not using the intelligent tester:


      1. A019MASE14

        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.

        • Check the ignition timing with the cooling fans off.

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

        • When checking the ignition timing, the transaxle should be in neutral or park.

      2. Remove the engine room side cover Click here.

      3. Remove the engine room side cover LH Click here.

      4. Remove the cool air intake duct seal Click here.

      5. Remove the V-bank cover sub-assembly Click here.

      6. Connect the timing light tester probe to the ignition coil wire for No. 1 cylinder.

        Note

        Use a timing light that detects primary signals.

      7. Check the ignition timing at idle.

        Standard ignition timing
        8 to 12° BTDC at idle

        Note

        When checking the ignition timing, the transaxle should be in neutral or park.

        Tech Tips

        Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed.

      8. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

      9. Check the ignition timing at idle.

        Standard ignition timing
        9.5 to 24.5° BTDC at idle

      10. Confirm that the ignition timing advances immediately when the engine rpm is increased.

      11. Remove the timing light from the engine.

      12. Install the V-bank cover sub-assembly Click here.

      13. Install the cool air intake duct seal Click here.

      14. Install the engine room side cover LH Click here.

      15. Install the engine room side cover Click here.

  103. INSPECT ENGINE IDLE SPEED


    1. Warm up and stop the engine.

      Tech Tips

      A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

    2. When using the intelligent tester:

      Check the idle speed.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine and run it at idle.

      3. Turn the intelligent tester main switch on.

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

      5. Read the value displayed on the tester.

        Standard idle speed
        600 to 700 rpm

        Note


        • Check the idle speed with the cooling fans off.

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

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

        Tech Tips


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

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

    3. When not using the intelligent tester:


      1. A019MASE15

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

        SST
        09843-18030

      2. Check the idle speed.

        Standard idle speed
        600 to 700 rpm

        Note


        • Check the idle speed with the cooling fans off.

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

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

        Tech Tips

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

  104. 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 idle.

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

      Tech Tips

      When performing the 2 mode (with the engine idling/running at 2500 rpm) test, follow the measurement order determined by applicable local regulations.

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


      1. Check the DTCs Click here.

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

        CO HC Problem Cause
        Normal High Rough idle

        1. Faulty ignitions:


          • Incorrect valve timing

          • Fouled, shorted or improperly gapped plugs

        2. Incorrect valve clearance (valve lash adjuster)

        3. Leaks in intake or exhaust valves

        4. Leaks in cylinders
        Low High

        Rough idle

        (Fluctuating HC reading)

        1. Vacuum leaks:


          • PCV hoses

          • Intake manifold

          • Throttle body assembly

          • Brake booster line

        2. Lean mixture causing misfire
        High High

        Rough idle

        (Black smoke from exhaust)

        1. Restricted air cleaner filter element sub-assembly

        2. Plugged PCV valve

        3. Faulty SFI system:


          • Faulty fuel pressure regulator

          • Defective engine coolant temperature sensor

          • Defective mass air flow meter

          • Faulty ECM

          • Faulty injector assemblies

          • Faulty throttle position sensor (built in throttle body assembly)

  105. CHECK FOR SPEED SENSOR SIGNAL

    Tech Tips

    Click here.)

  106. 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.

  107. CHECK VEHICLE HEIGHT (w/ Air Suspension)

    Note

    If the height control sensor link has been removed and reinstalled, check the vehicle height.


    1. Change the height control switch from the "NORM" position to the "HIGH" position and back to the "NORM" position.

    2. Measure the vehicle height ( Click here).

  108. ADJUST VEHICLE HEIGHT (w/ Air Suspension)

    Note

    If the height control sensor has been replaced, be sure to adjust the vehicle height.


    1. Adjust the vehicle height ( Click here).

  109. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Tech Tips

    Click here.)

  110. 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).

  111. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A019LVN

      Fit the 4 retainers and install the V-bank cover sub-assembly.

  112. INSTALL FRONT FENDER APRON SEAL LH


    1. A019O6T

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

  113. INSTALL FRONT FENDER APRON SEAL RH


    1. A019O37

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

  114. INSTALL FRONT FENDER LINER LH

  115. INSTALL FRONT FENDER LINER RH

  116. INSTALL NO. 2 ENGINE UNDER COVER

  117. INSTALL NO. 1 ENGINE UNDER COVER

  118. INSTALL FRONT FLOOR COVER LH


    1. A019OFY

      Connect the 3 clips.

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

  119. PERFORM INITIALIZATION


    1. Perform initialization ( Click here)

      Note

      Some systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

  120. ADJUST HEADLIGHT ASSEMBLY (w/ Air Suspension)


    1. Adjust the headlight Click here.

  121. INSTALL COOL AIR INTAKE DUCT SEAL


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

  122. INSTALL ENGINE ROOM SIDE COVER


    1. Engage the guide.

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

  123. INSTALL ENGINE ROOM SIDE COVER LH


    1. Engage the guide.

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