CAUTION:
As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.
Tech Tips
w/ Canister Pump Module:
Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, cylinder head LH, camshaft, No. 2 camshaft, No. 3 camshaft sub-assembly, No. 4 camshaft sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring Click here.
INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for AWD)
Tech Tips
Only perform this procedure when replacement of the engine mounting insulator is necessary.
Install the rear No. 1 engine mounting insulator to the engine mounting bracket with the bolt.
Install the engine mounting bracket to the transfer with the bolt.
INSTALL REAR ENGINE MOUNTING BRACKET (for 2WD)
Install the rear engine mounting bracket to the automatic transmission assembly with the 4 bolts.
INSTALL REAR ENGINE MOUNTING INSULATOR (for 2WD)
*a | Claw |
Front of the Vehicle |
Install the rear engine mounting insulator to the rear engine mounting bracket with the 4 bolts.
Tech Tips
Make sure the claw is facing towards the front of the vehicle.
INSTALL FRONT ENGINE MOUNTING INSULATOR
Tech Tips
Only perform this procedure when replacement of the engine mounting insulator is necessary.
for 2WD:
Install the front engine mounting insulator RH and LH with the 2 nuts.
for AWD:
Install the front engine mounting insulator RH and LH with the 4 nuts.
INSTALL ENGINE HANGER
Install the 2 No. 1 engine hangers with the 4 bolts as shown in the illustration.
Tech Tips
No. 1 engine hanger | 12281 - 31070 |
Bolt | 91671 - F0822 |
REMOVE ENGINE STAND
Attach an engine sling device and hang the engine with a chain block.
Note
Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
Lift the engine and remove it from the engine stand.
Note
With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
Place the engine onto a work bench.
INSTALL FRONT FRAME ASSEMBLY (for AWD)
Install the front frame assembly with the 2 bolts.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)
Install the front suspension crossmember sub-assembly with the 2 bolts.
INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for AWD)
Support the differential carrier assembly with a jack. Temporarily install the differential carrier assembly to the engine assembly with the 3 bolts.
Tighten the 3 bolts to install the differential carrier assembly.
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for AWD)
Coat the spline of the inboard joint shaft assembly with MP grease No. 2.
Set the shaft snap ring with the opening side facing down.
*a | Snap Ring Opening is Facing Downwards |
Align the shaft splines and install the drive shaft assembly LH with a brass bar and hammer.
Note
Make sure that the snap ring opening is facing downwards when installing the front drive shaft.
Be careful not to damage the drive shaft dust cover, boot and oil seal.
Move the drive shaft assembly while keeping it level.
Tech Tips
Whether or not the inboard joint shaft is in contact with the pinion shaft can be determined from the sound and feeling when tapping in the shaft.
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for AWD)
Align the shaft splines and install the drive shaft assembly RH.
Note
Move the drive shaft assembly while keeping it level.
Using water pump pliers, install a new drive shaft bearing bracket hole snap ring.
Note
Do not damage the boot and oil seal.
Install a new No. 1 drive shaft bearing bracket setting bolt.
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft pulley.
Clean the 8 bolts and 8 bolt holes.
*1 | Pin Hole |
*2 | Pin |
Install the front drive plate spacer.
Tech Tips
Align the pin of the front drive plate spacer with the pin hole of the crankshaft.
*1 | Drive Plate |
*2 | Rear Drive Plate Spacer |
Transmission |
Install the drive plate and ring gear sub-assembly and rear drive plate spacer onto the crankshaft.
Apply a few drops of adhesive to 2 or 3 threads of the 6 bolt tips.
Adhesive |
---|
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent |
In several steps, uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
INSTALL AUTOMATIC WITH TRANSFER TRANSMISSION ASSEMBLY
INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
INSTALL REAR ENGINE MOUNTING MEMBER
for 2WD:
Install the engine rear mounting member to the automatic transmission assembly with the 4 nuts.
for AWD:
Install the engine rear mounting member to the automatic transmission assembly with the 3 nuts.
INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
for 2WD Click here
for AWD Click here
INSTALL FLYWHEEL HOUSING SIDE COVER
Install the flywheel housing side cover to the engine assembly.
Note
Make sure that the flywheel housing side cover is securely installed.
INSTALL STARTER ASSEMBLY
Install the starter with the 2 bolts.
Connect the starter cable with the nut, and then attach the terminal cap.
Connect the starter connector.
INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for AWD)
Completely remove any oil or the like and clean the constant velocity universal joint washers and the contact surfaces of the front propeller shaft assembly, transfer and front differential.
Align the matchmarks on the transfer companion flange and the front propeller shaft assembly.
*a | Matchmark |
Clean off oil and other foreign matter completely |
Temporarily tighten the front propeller shaft assembly with the 6 bolts and 2 constant velocity universal joint washers.
Note
Completely remove any oil or the like and clean the contact surfaces of the bolt.
Align the matchmarks on the differential companion flange and the front propeller shaft assembly.
*a | Matchmark |
Clean off oil and other foreign matter completely |
Temporarily tighten the front propeller shaft assembly with the 6 bolts and 2 constant velocity universal joint washers.
Note
Completely remove any oil or the like and clean the contact surfaces of the bolt.
*a | Turn |
*b | Hold |
Using a screwdriver or an equivalent, hold the transfer companion flange.
Using a socket hexagon wrench 6 mm, fully tighten the front propeller shaft assembly with the 6 bolts.
Note
Be careful not to damage the front propeller shaft.
*a | Turn |
*b | Hold |
Using a screwdriver or an equivalent, hold the transfer companion flange.
Using a socket hexagon wrench 6 mm, fully tighten the front propeller shaft assembly with the 6 bolts.
Note
Be careful not to damage the front propeller shaft.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
*1 | Protrusion |
*a | Front |
Install a new gasket as shown in the illustration.
*a | Front |
Install the exhaust manifold sub-assembly LH with 6 new nuts.
Note
Do not damage the stud bolts when installing the exhaust manifold.
Be sure to tighten either the nut labeled A or B in the illustration first.
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
*1 | Protrusion |
*a | Front |
Install a new gasket as shown in the illustration.
*a | Front |
Install the exhaust manifold sub-assembly RH with 6 new nuts.
Note
Do not damage the stud bolts when installing the exhaust manifold.
Be sure to tighten either the nut labeled A or B in the illustration first.
INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH
Install the engine under cover sub-assembly LH.
INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH
Install the engine under cover sub-assembly RH.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Install a new O-ring to the engine oil level dipstick guide.
Apply a light coat of engine oil to the O-ring.
Push in the engine oil level dipstick guide end into the guide hole.
Install the engine oil level dipstick guide with the bolt.
for AWD:
Connect the clamp.
INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
Install a new O-ring to the No. 2 oil level dipstick guide.
Install the No. 2 oil level dipstick guide with the bolt.
Install the oil level dipstick.
INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for AWD)
Set the engine on an engine lifter.
Note
Place wooden blocks or plate lift attachments so that the engine is level.
With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
Remove the 4 bolts and 2 No. 1 engine hangers.
Operate the engine lifter and install the engine to the vehicle.
Note
Make sure that the engine is clear of all wiring and hoses.
Install the engine and transmission assembly with crossmember with the 6 bolts and 2 nuts.
Bolt | |
Nut |
Install the rear engine mounting member with the 4 bolts.
Connect the wire harness with the bolt.
INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)
Set the engine on an engine lifter.
Note
Place wooden blocks or plate lift attachments so that the engine is level.
With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
Remove the 4 bolts and 2 No. 1 engine hangers.
Operate the engine lifter and install the engine to the vehicle.
Note
Make sure that the engine is clear of all wiring and hoses.
Install the engine and transmission assembly with crossmember with the 6 bolts, 4 new bolts and 2 nuts.
Bolt | |
Nut |
Install the rear engine mounting member with the 4 bolts.
Connect the wire harness with the nut.
INSTALL FRONT SUSPENSION MEMBER BRACE (for AWD)
Install the 2 front suspension member braces with the 4 bolts.
INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD)
Install the front lower suspension member protector with the 4 bolts.
INSTALL NO. 2 FRAME CROSSMEMBER ASSEMBLY (for AWD)
Install the No. 2 frame crossmember assembly with the 3 bolts.
INSTALL NO. 1 FRAME CROSSMEMBER ASSEMBLY (for AWD)
Install the No. 1 frame crossmember assembly with the 3 bolts.
INSTALL FRONT NO. 2 UPPER SUSPENSION MEMBER (for 2WD)
Install the 2 front No. 2 upper suspension members with the 6 bolts.
CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for AWD)
Connect the floor shift gear shifting rod sub-assembly to the transmission control shaft lever LH with the pin.
Install a new clip.
Turn the transmission control shaft lever LH of the park/neutral position switch assembly counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position.
Temporarily install the floor shift gear shifting rod sub-assembly with the nut.
Tighten the nut while lightly pushing the lever rearward.
*a | Rear |
Note
Do not push the shift lever too hard.
CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
Turn the transmission control shaft lever RH of the park/neutral position switch assembly counterclockwise until it stops, and then turn it clockwise 2 notches to set it to the N position.
Temporarily install the floor shift gear shifting rod sub-assembly with the nut.
Tighten the nut while lightly pushing the lever rearward.
*a | Rear |
Note
Do not push the shift lever too hard.
CONNECT POWER STEERING LINK WIRE HARNESS
for 2WD:
Connect the wire harness connector (C) to the power steering link assembly and securely lock the connector.
Front |
Connect the 2 wire harness connectors (A) and (B) to the power steering link assembly.
Connect the 2 wire harness clamps to the bracket.
for AWD:
Connect the wire harness connector (C) to the power steering link assembly and securely lock the connector.
Front |
Connect the 2 wire harness connectors (A) and (B) to the power steering link assembly.
Connect the 2 wire harness clamps to the front frame assembly.
Connect the wire harness bracket with the bolt.
CONNECT FRONT AXLE ASSEMBLY LH (for AWD)
Install the front axle hub sub-assembly and front disc brake dust cover with the 4 bolts.
Install the front drive shaft assembly to the front axle hub sub-assembly.
Note
Be careful not to damage the front drive shaft boot.
CONNECT FRONT AXLE ASSEMBLY RH (for AWD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH (for AWD)
Connect the front lower ball joint assembly with the 2 bolts.
CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH (for AWD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)
Install the steering knuckle to the lower ball joint with the 2 bolts.
CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH (for AWD)
Connect the absorber and absorber bracket. Then install the bolt.
CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH (for AWD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
Install the bolt on the lower side of the front shock absorber while holding the nut.
CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT TIE ROD ASSEMBLY LH (for AWD)
Connect the tie rod assembly LH to the steering knuckle with the nut.
Install a new clip.
CONNECT TIE ROD ASSEMBLY RH (for AWD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH (for AWD)
Using a chisel and hammer, stake the axle shaft nut.
INSTALL FRONT AXLE SHAFT NUT RH (for AWD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT FRONT SPEED SENSOR LH (for AWD)
Install the speed sensor to the steering knuckle with the 2 bolts.
Note
Prevent foreign matter from adhering to the speed sensor.
Be careful not to damage the speed sensor.
Do not twist the sensor wire when installing the speed sensor.
CONNECT FRONT SPEED SENSOR RH (for AWD)
Tech Tips
Install the RH side following the same procedure as for the LH side.
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD)
*a | Matchmark |
Align the matchmarks and connect the No. 2 steering intermediate shaft to the steering link.
Install the bolt.
CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD without VGRS)
*a | Matchmark |
*b | Vehicle Interior |
Align the matchmark on the steering sliding with shaft yoke with the matchmark on the power steering link and install the bolt.
Tighten the bolt closest to the vehicle interior.
CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD with VGRS)
Align the matchmarks and correct the steering sliding with shaft yoke sub-assembly to the power steering gear assembly.
Install the 2 bolts.
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)
Apply grease to the flexible coupling centering bushings.
Grease |
---|
Molybdenum disulphide lithium base NLGI No. 2 |
Completely remove any oil or the like and clean the contact surfaces of the differential companion flange and flexible coupling.
Remove SST from the transmission.
Insert the yoke of the intermediate shaft into the transmission.
Note
Be careful not to damage the oil seal.
Align the matchmarks on the differential companion flange and flexible coupling.
Install and tighten the 3 bolts, 3 washers and 3 nuts.
Note
Be careful not to damage the flexible coupling centering bushings.
Tech Tips
The bolts should be installed from the propeller intermediate shaft assembly side.
Temporarily install the 2 bolts with the 2 washers.
Tech Tips
Use the adjusting washers which were removed.
Adjust the distance (A) between the surface of the center support bearing and the surface of the cushion to 11.5 to 13.5 mm (0.453 to 0.531 in.) as shown in illustration.
Distance (A) |
---|
11.5 to 13.5 mm (0.453 to 0.531 in.) |
Check that the center line of the bracket is at right angles to the shaft axial direction.
*a | 90° |
Tighten the 2 bolts.
INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for AWD)
Note
Measure the joint angle when the vehicle is raised using a four-post lift or when using a pit.
Tech Tips
If any vibration or noise occurs, perform the joint angle check as follows and replace the No. 2 center support bearing washer with a proper one.
Stabilize the propeller shaft and differential.
Turn the propeller shaft several times by hand to stabilize the center support bearing.
Using a jack, raise and lower the differential to stabilize the differential mounting cushion.
Check the No. 2 and No. 3 joint angles.
*a | No. 2 Joint Angle | *b | No. 3 Joint Angle |
Using SST, measure the installation angle of the propeller intermediate shaft assembly and propeller shaft assembly.
Tech Tips
SST should be set directly underneath the shaft.
Using SST, measure the installation angle of the differential.
Tech Tips
Measure the installation angle by placing SST in the positions shown in the illustration.
Calculate the No. 2 joint angle.
No. 2 joint angle |
---|
A - B = -1°30' to -0°30' |
A |
---|
Propeller intermediate shaft installation angle |
B |
---|
Propeller shaft assembly installation angle |
Calculate the No. 3 joint angle.
No. 3 joint angle |
---|
B - C = 0°30' to 1°30' |
B |
---|
Propeller shaft assembly installation angle |
C |
---|
Differential installation angle |
If the measured angle is not within the specified range, adjust it with the center support bearing washers.
Adjust the No. 2 joint angle.
Select the center support bearing washers for adjustment.
Center Support Bearing Washer | ||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Note
Make sure to use a washer of the same thickness on both the right and left sides.
Do not use 2 or more washers on a bolt.
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 2WD)
Apply grease to the flexible coupling centering bushings.
Grease |
---|
Molybdenum disulphide lithium base NLGI No. 2 |
Completely remove any oil or the like and clean the contact surfaces of the transmission companion flange and flexible coupling.
Completely remove any oil or the like and clean the contact surfaces of the differential companion flange and flexible coupling.
Align the matchmarks on the transmission companion flange and flexible coupling.
Install and tighten the 3 bolts, 3 washers and 3 nuts.
Note
Be careful not to damage the flexible coupling centering bushings.
Tech Tips
The bolts should be installed from the propeller intermediate shaft assembly side.
Align the matchmarks on the differential companion flange and flexible coupling.
Install and tighten the 3 bolts, 3 washers and 3 nuts.
Note
Be careful not to damage the flexible coupling centering bushings.
Tech Tips
The bolts should be installed from the propeller shaft assembly side.
Temporarily install the 2 bolts with the 2 washers.
Tech Tips
Use the adjusting washers which were removed.
FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY (for 2WD)
*a | 90° |
Adjust the distance (A) between the surface of the center support bearing and the surface of the cushion to 11.5 to 13.5 mm (0.453 to 0.531 in.) as shown in illustration.
Distance (A) |
---|
11.5 to 13.5 mm (0.453 to 0.531 in.) |
Check that the center line of the bracket is at right angles to the shaft axial direction.
Tighten the 2 bolts.
*a | Turn |
*b | Hold |
Using SST, tighten the adjusting nut.
Tech Tips
Use a torque wrench with a fulcrum length of 34.5 cm (13.6 in.).
INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE (for 2WD)
Note
Measure the joint angle when the vehicle is raised using a four-post lift or when using a pit.
Tech Tips
If any vibration or noise occurs, perform the joint angle check as follows and replace the No. 2 center support bearing washer with a proper one.
Stabilize the propeller shaft and differential.
Turn the propeller shaft several times by hand to stabilize the center support bearing.
Using a jack, raise and lower the differential to stabilize the differential mounting cushion.
Check the No. 2 and No. 3 joint angles.
*a | No. 2 Joint Angle | *b | No. 3 Joint Angle |
Using SST, measure the installation angle of the propeller intermediate shaft assembly and propeller shaft assembly.
Tech Tips
SST should be set directly underneath the shaft.
Using SST, measure the installation angle of the differential.
Tech Tips
Measure the installation angle by placing SST in the positions shown in the illustration.
Calculate the No. 2 joint angle.
No. 2 joint angle |
---|
A - B = -0°30' to 0°30' |
A |
---|
Propeller intermediate shaft installation angle |
B |
---|
Propeller shaft assembly installation angle |
Calculate the No. 3 joint angle.
No. 3 joint angle |
---|
B - C = 0°42' to 1°42' |
B |
---|
Propeller shaft assembly installation angle |
C |
---|
Differential installation angle |
If the measured angle is not within the specified range, adjust it with the center support bearing washers.
Adjust the No. 2 joint angle.
Select the center support bearing washers for adjustment.
Center Support Bearing Washer | ||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Note
Make sure to use a washer of the same thickness on both the right and left sides.
Do not use 2 or more washers on a bolt.
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
Install the front No. 1 floor heat insulator with the 4 nuts.
INSTALL NO. 1 FUEL TANK PROTECTOR
Install the No. 1 fuel tank protector with the 4 nuts and tighten the nuts in the order shown in the illustration.
INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY (for 2WD)
Install the front center floor brace sub-assembly with the 4 bolts.
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
w/ Protector:
Tech Tips
Only perform this procedure when replacement of the front No. 1 exhaust pipe protector is necessary.
Install the front No. 1 exhaust pipe protector and exhaust pipe protector stay with the 2 bolts and 2 nuts.
Install the clamp with the bolt.
Using a vernier caliper, measure the free length of the compression springs.
Minimum free length |
---|
38.5 mm (1.52 in.) |
Tech Tips
If the free length is less than the minimum, replace the compression spring.
Install the 2 new gaskets to the front exhaust pipe assembly.
*1 | Front Exhaust Pipe Assembly |
*2 | Gasket |
*3 | Wooden Block |
Using a plastic-faced hammer and wooden block, tap in the new gasket until its surface is flush with the front exhaust pipe 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.
Install 2 new gaskets and the front exhaust pipe with 4 new nuts, 8 bolts and the 4 compression springs.
CONNECT HEATED OXYGEN SENSOR
for Bank 2 Sensor 2:
Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 4 turns.
*A | for 2WD |
*B | for AWD |
*1 | Fulcrum Length |
Using SST, connect the heated oxygen sensor to the front exhaust pipe assembly.
Tech Tips
Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.
Make sure SST and the wrench are connected in a straight line
After installing the sensor, check that the sensor wire is not twisted.
If the sensor wire is twisted, reinstall sensor.
for AWD:
Connect the grommet and attach the 2 clips of the heated oxygen sensor.
for 2WD:
Connect the grommet of the heated oxygen sensor.
for Bank 1 Sensor 2:
Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 4 turns.
*1 | Fulcrum Length |
Using SST, connect the heated oxygen sensor to the front exhaust pipe assembly.
Tech Tips
Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.
Make sure SST and the wrench are connected in a straight line.
After installing the sensor, check that the sensor wire is not twisted.
If the sensor wire is twisted, reinstall the sensor.
Connect the grommet of the heated oxygen sensor.
INSTALL FRONT CENTER FLOOR BRACE
Install the front center floor brace with the 2 clips, 6 bolts and 2 nuts.
INSTALL REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY
Install the No. 2 rear floor board sub-assembly with the 4 grommets and 7 clips.
INSTALL REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY
Install the No. 1 rear floor board sub-assembly with the 4 grommets and 7 clips.
INSTALL FRONT FLOOR COVER LH (for AWD)
Install the front floor cover LH with the 3 nuts and 3 grommets.
CONNECT FUEL TUBE SUB-ASSEMBLY
Connect the fuel tube sub-assembly Click here.
Install the fuel pipe clamp.
CONNECT NO. 2 FUEL HOSE
Connect the No. 2 fuel hose and clamp.
CONNECT FUEL TUBE SUB-ASSEMBLY
Connect the fuel tube sub-assembly Click here.
Install the fuel pipe clamp.
CONNECT ENGINE WIRE (for LHD)
Engine Room LH Side:
Connect the wire harness clamp and engine wire to the ECM box Click here.
Engine Room RH Side:
Install the bolt, clamp and No. 3 engine wire.
Connect the 2 wire harness clamps.
Connect the No. 4 engine wire to the No. 1 engine room junction block with the nut.
Install the No. 1 engine room relay block cover.
Connect the clamp.
Connect the No. 2 engine wire and engine room main wire to the positive (+) battery terminal. Then, install it with the nut.
CONNECT ENGINE WIRE (for RHD)
Engine Room LH Side:
Connect the wire harness clamp and engine wire to the ECM box Click here.
Connect the 2 wire harness clamps.
Connect the No. 4 engine wire to the No. 1 engine room junction block with the nut.
Install the No. 1 engine room relay block cover.
Connect the clamp.
Connect the No. 2 engine wire and engine room main wire to the positive (+) battery terminal. Then, install it with the nut.
Engine Room RH Side:
Install the bolt, clamp and No. 3 engine wire.
INSTALL ECM COVER
Install the ECM cover with the 3 bolts.
Note
Make sure that the wire harness does not get caught between the parts.
CONNECT SUCTION HOSE
Remove the attached vinyl tape from the suction hose.
Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the cooler compressor assembly.
Compressor oil |
---|
ND-OIL 8 or equivalent |
Install the O-ring on the suction hose.
Install the suction hose on the cooler compressor assembly with the bolt.
CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.
Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the cooler compressor assembly.
Compressor oil |
---|
ND-OIL 8 or equivalent |
Install the O-ring on the No. 1 cooler refrigerant discharge hose.
Install the No. 1 cooler refrigerant discharge hose on the cooler compressor assembly with the bolt.
CONNECT OUTLET HEATER WATER HOSE
Connect the outlet heater water hose.
CONNECT INLET HEATER WATER HOSE
Connect the inlet heater water hose.
CONNECT RADIATOR RESERVOIR TANK HOSE
Install the clamp and connect the radiator reservoir tank hose.
CONNECT NO. 2 OIL COOLER OUTLET HOSE (w/ Transmission Oil Cooler)
Connect the No. 2 oil cooler outlet hose to the radiator assembly and secure it with the hose clamp.
Attach the flexible hose clamp.
CONNECT NO. 2 OIL COOLER INLET HOSE (w/ Transmission Oil Cooler)
Connect the No. 2 oil cooler inlet hose to the radiator assembly and secure it with the hose clamp.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and secure it with the clip.
CONNECT NO. 1 RADIATOR HOSE
Install the clamp and connect the No. 1 radiator hose.
CONNECT PURGE LINE HOSE
Install the clamp and connect the purge line hose.
CONNECT UNION TO CHECK VALVE HOSE
Connect the hose to the surge tank.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
*1 | Pin |
*2 | Grommet |
Insert the pin on the lower side of the air cleaner case into the grommet.
Install the air cleaner case, clamp and 2 bolts.
Note
During removal, do not lose the grommet on the underside of the air cleaner case.
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
Install the air cleaner cap with air cleaner hose assembly with the 4 clamps and hose clamp.
Tech Tips
Fit the protrusion on the air cleaner hose into the hole of the hose clamp on the throttle valve side.
Connect the VSV hose to the air cleaner hose.
for RHD:
Connect the union to check valve hose.
Connect the mass air flow meter connector and clamp to the air cleaner.
INSTALL NO. 1 AIR CLEANER INLET
Install the No. 1 air cleaner inlet with the bolt.
ADD ENGINE OIL
Add clean engine oil.
Note
Do not allow engine oil to 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 | ||||||
---|---|---|---|---|---|---|
|
Standard Oil Grade (for Korea) | ||||||
---|---|---|---|---|---|---|
|
Standard Capacity | ||||||||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
|
Install the oil filler cap.
ADD DIFFERENTIAL OIL (for AWD)
*a | 0 to 5 mm (0 to 0.196 in.) |
Add differential oil so that the oil level is within 5 mm (0 to 0.196 in.) of the bottom lip of the differential filler plug hole.
Note
Too much or too little oil will lead to differential problems.
After changing the oil, drive the vehicle and then check the oil level again.
for Front Differential:
Oil type |
---|
Hypoid gear oil API GL-5 or equivalent |
Recommended Viscosity | ||||||
---|---|---|---|---|---|---|
|
Standard Differential Oil Capacity |
---|
0.65 to 0.75 liters (0.69 to 0.79 US qts, 0.58 to 0.66 Imp. qts) |
Using a 10 mm hexagon wrench, install a new gasket and the filler plug.
Install the engine under cover.
for Rear Differential:
Oil type and viscosity |
---|
Toyota genuine differential gear oil LT 75W-85 GL-5 or equivalent |
Standard Differential Oil Capacity | ||||||
---|---|---|---|---|---|---|
|
Install a new gasket and the filler plug.
ADD AUTOMATIC TRANSMISSION FLUID
for 2WD Click here
for AWD Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
PERFORM INITIALIZATION
ADJUST SHIFT LEVER POSITION
for 2WD Click here
for AWD Click here
INSPECT SHIFT LEVER POSITION
for 2WD Click here
for AWD Click here
ADD ENGINE COOLANT
Tighten the radiator drain cock plug by hand.
Tighten the 2 cylinder block drain cock plugs.
Add TOYOTA Super Long Life Coolant (SLLC) to the water outlet sub-assembly opening.
Standard Capacity | ||||||
---|---|---|---|---|---|---|
|
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).
Slowly pour coolant into the radiator reservoir tank until it reaches the full line.
Press 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.
Install the radiator cap.
Bleed air from the cooling system.
Note
Before starting the engine to warm up the engine, turn the A/C switch off.
Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
CAUTION:
When pressing the radiator hoses:
Wear protective gloves.
Be careful as the radiator hoses are hot.
Keep your hands away from the radiator fans.
Tech Tips
The thermostat open timing can be confirmed by pressing the No. 1 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
Maintain the engine speed at 2000 to 2500 rpm.
Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.
CAUTION:
When pressing the radiator hoses:
Wear protective gloves.
Be careful as the radiator hoses are hot.
Keep your hands away from the radiator fans.
Stop the engine, and wait until the engine coolant cools down to ambient temperature.
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.
Check the coolant level in the radiator reservoir tank.
If the coolant level is low, add SLLC to the radiator reservoir tank full line.
CHARGE REFRIGERANT
Tech Tips
Charge refrigerant in accordance with the equipment manual.
Perform vacuum purging using a vacuum pump.
Charge refrigerant HFC-134a (R134a).
Standard |
---|
500 +/-50 g (17.64 +/-1.76 oz) |
*a | Amount to be charged | *b | Charge 100 g (3.53 oz) |
*c | Mean value in proper range | *d | Point where bubbles disappear |
*e | Overcharged | *f | Pressure |
*g | Sub-cool system | *h | Refrigerant amount |
Note
Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
The system may need to be charged with approximately 100 g (3.53 oz) of refrigerant after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
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.
Fill the radiator with coolant and attach a radiator cap tester.
Warm up the engine.
Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 20 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.
INSPECT FOR OIL LEAK
Start the engine. Make sure that no oil leaks from the connection point of the oil filter cap.
INSPECT FOR FUEL LEAK
Connect the GTS to the DLC3.
Turn the engine switch on (IG).
Note
Do not start the engine.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
Check the fuel pump operation.
Check for pressure in the fuel inlet tube from the fuel line. Check that sound of fuel flowing in the fuel tank can be heard.
If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.
Inspect for fuel leaks.
Check that there are no fuel leaks anywhere on the system after performing maintenance.
If there is a fuel leak, repair or replace parts as necessary.
INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
Tech Tips
If an exhaust gas leak has been repaired, perform an inspection following the repair Click here.
INSPECT FOR REFRIGERANT LEAK
After recharging the refrigerant, check for refrigerant gas leakage using a halogen leak detector.
Perform the operation observing the following instructions:
Stop the engine.
Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
Repeat the test 2 or 3 times.
Make sure that some refrigerant remains in the refrigeration system.
Tech Tips
When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).
*1 | Halogen Leak Detector |
*a | Check for Leakage |
Using a halogen leak detector, check the refrigerant line for leakage.
If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.
Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.
INSTALL FRONT WHEEL
PLACE FRONT WHEELS FACING STRAIGHT AHEAD
CHECK AND ADJUST FRONT WHEEL ALIGNMENT
VARIABLE GEAR RATIO STEERING SYSTEM CALIBRATION (w/ VGRS)
ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)
*1 | Approx. 10 m |
*2 | Approx. 14 m |
Note
Perform measurements on a level surface.
Make sure that no large pieces of metal are within a 10 m (32.8 ft.) x 14 m (45.9 ft.) area in front of the vehicle. If possible, the surrounding area should also be free of large metal objects.
Before adjusting the radar beam axis, prepare the vehicle as follows.
Remove all excess weight from the vehicle (luggage, heavy objects, etc.).
Check the tire pressure and adjust it if necessary Click here.
*1 | Level |
Check and adjust the vertical direction of the radar sensor.
Remove dust, oil and foreign matter from the radar sensor's level rack.
Set a level on the radar sensor's level rack.
*1 | Level |
*2 | Air Bubble |
*3 | Bolt A |
*a | FR |
*b | LH |
Check that the level's air bubble is within the red frame.
OK |
---|
Level's air bubble is within the red frame. |
If the bubble is not within the red frame, use a screwdriver to adjust bolt A until the air bubble is within the red frame.
Tech Tips
The adjustable range within the level's red frame is +/- 0.2°.
The target angle is +0.2° (upward angle of 0.2°).
Adjustment | |||||||
---|---|---|---|---|---|---|---|
|
*1 | Millimeter Wave Radar Sensor |
Adjust the reflector height.
Adjust the reflector so that the center of SST reflector is the same height as the millimeter wave radar sensor.
Tech Tips
Prepare a 10 m (32.8 ft.) string, a string with a sharp-pointed weight (plumb bob), and a 5 m (16.4 ft.) tape measure.
Place the reflector.
Hang the string (with weight) from the center of the vehicle's rear emblem. Mark the vehicle's rear center point on the ground. Repeat for the front of the vehicle.
*a | Adjust Center By Moving String To Right And Left |
*b | Extend String Through Front Center Mark |
Set one end of the 10 m (32.8 ft.) string on the vehicle's rear center point. Run the string over the vehicle's front center point to a position 5 m (16.4 ft.) beyond the vehicle's front center point as shown in the illustration. Mark the 5 m (16.4 ft.) position.
Place the reflector (SST) at the marked position.
Note
Perform the operation as precisely as possible.
*a | Reflector (SST) Placement Point | *b | Millimeter Wave Radar Sensor Position |
*c | 16.4 ft. | *d | 0.516 in. |
Check the radar beam axis.
When using the GTS:
Connect the GTS to the DLC3.
Turn the engine switch on (IG).
Turn the GTS on, and turn the cruise control main switch on.
Select "Connect to Vehicle".
Select each item on the display screen and proceed to the next screen.
Under "System Selection Menu", select "Radar Cruise".
Select "Utility".
Select "Beam Axis Adjustment" and proceed to the next screen.
Tech Tips
A buzzer will sound for 1 second.
Follow the GTS display, and continue with the adjustment.
Note
Turn the cruise control main switch on before pressing "Next".
Make sure there is at least 20 cm (7.87 in.) between the radar sensor and any nearby individuals.
Check the following items on the radar cruise divergence data screen.
Note
While using the GTS beam axis adjustment mode, the actual direction and angle of the radar sensor may be different from the GTS data. In such a case, the deviation is displayed on the multi-information display in the combination meter.
Confirm that the distance value is approximately 5 m (16.4 ft.).
Tech Tips
A value between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.) should be indicated.
If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).
Confirm that the left/right side value is between 0.0 m (0.0 ft.) and 6.3 m (20.7 ft.).
Tech Tips
If the distance is 0.0 m (0.0 ft.), the sensor cannot detect the target. Reconfirm that there is no metal in the specified area in front of the vehicle (refer to the Notice at the beginning of this adjustment procedure).
Check and adjust the horizontal direction of the radar sensor.
Check that the divergence of the radar beam axis is 0°.
Standard |
---|
0° (Both right and left) |
If the axis is not as specified, use a screwdriver to adjust bolt B until the divergence of the radar beam axis is 0°.
*1 | Bolt B |
Based on the measured divergence of the beam axis, turn and adjust bolt B for horizontal adjustment of the millimeter wave radar sensor using a screwdriver.
Adjustment | |||||||
---|---|---|---|---|---|---|---|
|
Tech Tips
If the value does not change to 0°, it is possible that the sensor is aiming at something different. Reconfirm that there are no reflective materials in the surrounding area.
Select "Next". The driving learning value is automatically reset.
Tech Tips
A buzzer will sound for 10 seconds or more.
Disconnect the GTS from the DLC3.
Recheck and readjust the vertical direction of the radar sensor.
*1 | Level |
Set a level on the radar sensor's level rack.
*1 | Level |
*2 | Air Bubble |
*3 | Bolt A |
*a | FR |
*b | LH |
Check that the level's air bubble is within the red frame.
OK |
---|
Level's air bubble is within the red frame. |
If the bubble is not within the red frame, use a screwdriver to adjust bolt A until the level's air bubble is within the red frame.
Tech Tips
The adjustable range within the red frame is +/- 0.2°.
The target angle is + 0.2° (upward angle of 0.2°).
Adjustment | |||||||
---|---|---|---|---|---|---|---|
|
INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY
w/ Canister Pump Module:
Note
Perform the following procedure after replacing the throttle body with motor assembly or any throttle body components. The following procedure should also be performed if the throttle body with motor assembly is cleaned.
Turn the engine switch on (IG) without operating the accelerator pedal.
Note
If the accelerator pedal is operated, perform the above steps again.
Connect the GTS to the DLC3 and clear the DTCs Click here.
Perform the "Inspection After Repairs" Click here.
Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range when the A/C is switched off.
Standard | ||||
---|---|---|---|---|
|
Note
Be sure to perform this step with all accessories off.
Make sure that the shift lever is in neutral.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Throttle Sensor Position. Sensor Output. Fully depress the accelerator pedal and check that the value is 60% or more.
Perform a road test and confirm that there are no abnormalities.
w/o Canister Pump Module:
Note
Be sure to perform this procedure after reassembling the throttle body with motor assembly or removing and reinstalling any throttle body component.
Perform the following procedure after replacing the throttle body with motor assembly or any throttle body components. The following procedure should also be performed if the throttle body with motor assembly is cleaned.
Be sure to perform this procedure after reconnecting the battery cable or replacing the ECM.
Disconnect the cable from the negative (-) battery terminal. Wait at least 60 seconds and reconnect the cable.
Note
After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.
Turn the engine switch on (IG) without operating the accelerator pedal.
Note
If the accelerator pedal is operated, perform the above steps again.
Connect the GTS to the DLC3 and clear the DTCs Click here.
Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range when the A/C is switched off.
Standard | ||||
---|---|---|---|---|
|
Note
Be sure to perform this step with all accessories off.
Make sure that the shift lever is in neutral.
Enter the following menus: Powertrain / Engine and ECT / Data List / All Data / Throttle Sensor Position. Sensor Output. Fully depress the accelerator pedal and check that the value is 60% or more.
Perform a road test and confirm that there are no abnormalities.
INSPECT IGNITION TIMING
Warm up the engine and stop the engine.
Note
A warmed up engine should have an engine coolant temperature of over 80°C (176°F), and an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.
When using the GTS:
Connect the GTS to the DLC3.
Start the engine and idle it.
Turn the GTS on.
Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance.
Standard ignition timing |
---|
8 to 18° BTDC at idle |
Note
When checking the ignition timing, the transmission should be in neutral.
Tech Tips
Refer to the GTS operator's manual for further details.
Check that the ignition timing advances immediately when the engine speed is increased.
Enter the following menus: Powertrain / Engine / Active Test / Connect the TC and TE1.
Monitor IGN Advance.
Perform the Active Test.
Standard ignition timing |
---|
8 to 12° BTDC at idle |
Note
When checking the ignition timing, the transmission should be in neutral or park.
Tech Tips
Refer to the GTS operator's manual for further details.
When not using the GTS:
Remove the V-bank cover sub-assembly.
Connect the tester probe of a timing light to the wire of the ignition connector for No. 1 cylinder.
Note
Use a timing light which can detect the primary signal.
*a | Front view of DLC3 |
Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
Note
Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
When checking the ignition timing, the transmission should be in neutral.
Using a timing light, check the ignition timing.
Standard ignition timing |
---|
8 to 12° BTDC at idle |
Remove SST from the DLC3.
Check the ignition timing.
Standard ignition timing |
---|
8 to 18° BTDC at idle |
Check that the ignition timing advances immediately when the engine speed is increased.
Disconnect the timing light from the engine.
Install the V-bank cover sub-assembly.
INSPECT ENGINE IDLE SPEED
Warm up and stop the engine.
Note
A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.
When using the GTS:
Connect the GTS to the DLC3.
Note
Switch off all accessories and A/C before connecting the GTS.
Race the engine at 2500 rpm for approx. 90 seconds.
Turn the GTS on.
Enter the following menus: powertrain / Engine and ECT / Data list / Engine Speed.
Standard idle speed |
---|
600 to 700 rpm |
Note
When checking the idle speed, the transmission should be in neutral.
Tech Tips
Refer to the GTS operator's manual for further details.
If the idle speed is not as specified, check the air intake system.
Disconnect the GTS from the DLC3.
When not using the GTS:
*a | Front view of DLC3 |
Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3.
Note
Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
Race the engine at 2500 rpm for approx. 90 seconds.
Check the idle speed.
Standard idle speed (Transmission neutral position) |
---|
600 to 700 rpm |
Note
When checking the idle speed, the transmission should be in neutral.
If the speed is not as specified, check the air intake system.
Disconnect the tachometer from the DLC3.
INSPECT CO/HC
Tech Tips
This is a check for determining whether or not the idle CO / HC complies with regulations.
Start the engine.
Keep the engine speed at 2500 rpm for approx. 180 seconds.
Insert the CO / HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling.
Immediately check CO / HC concentration at idle and/or 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.
Check the DTCs Click here.
See the table below for possible causes, then inspect and correct the applicable causes if necessary.
CO | HC | Symptom | Causes |
---|---|---|---|
Normal | High | Rough idle |
|
Low | High | Rough idle (Fluctuating HC reading) |
|
High | High | Rough idle (Black smoke from exhaust) |
|
INSPECT ENGINE OIL LEVEL
Warm up and stop the engine, and then wait for 5 minutes. The oil level should be between the dipstick's low level mark and full level mark.
If 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.
INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)
Install the No. 2 engine under cover with the 4 screws.
INSTALL FRONT SUSPENSION MEMBER BRACE (for 2WD)
Install the front suspension member brace with the clip and 4 bolts.
INSTALL REAR ENGINE UNDER COVER LH
Install the rear engine under cover LH with the screw.
INSTALL REAR ENGINE UNDER COVER RH
Tech Tips
Install the RH side following the same procedure as for the LH side.
INSTALL ENGINE UNDER COVER
for 2WD:
Install the engine under cover with the 13 screws and 3 clips.
for AWD:
Install the engine under cover with the 10 screws and 3 clips.
INSTALL V-BANK COVER SUB-ASSEMBLY
*1 | Tip (Round Portion) |
Attach the 3 clips in the order shown in the illustration to install the V-bank cover.
Note
Securely attach the clips.
If the clips are forcibly attached or struck with an object, they may be damaged.
Do not apply any oil to the tips (round portions).
INSTALL COOL AIR INTAKE DUCT SEAL
Install the cool air intake duct seal with the 7 clips.
INSTALL ENGINE ROOM SIDE COVER
Install the engine room side cover with the 4 clips.