ENGINE ASSEMBLY INSTALLATION

INSTALL FRONT ENGINE MOUNTING BRACKET LH
1. Install the mounting bracket with the 4 bolts.
  
  Torque:
  
  51 N*m { 520 kgf*cm, 38 ft.*lbf }
INSTALL FRONT ENGINE MOUNTING BRACKET RH
1. Install the mounting bracket with the 4 bolts.
  
  Torque:
  
  51 N*m { 520 kgf*cm, 38 ft.*lbf }
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE
1. Apply a coat of engine oil to a new O-ring.
2. Install the O-ring to the oil control valve.
3. Install the oil control valve with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL CRANKSHAFT POSITION SENSOR
1. Apply a light coat of engine oil to the O-ring of the sensor.
2. Install the sensor with the bolt.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
3. Install the connector to the connector bracket.
4. Attach the harness clamp.
5. Connect the sensor connector.
INSTALL CAMSHAFT POSITION SENSOR
1. Apply a coat of engine oil to a new O-ring.
2. Install the O-ring to the sensor.
3. Install the sensor with the bolt.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
1. Using a 19 mm deep socket wrench, install a new gasket and the sensor.
INSTALL KNOCK SENSOR
1. Install the sensor so that it is horizontal as shown in the illustration. Then install the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Tech Tips
  
  It is acceptable for the sensor to be tilted +-10°.
2. Connect the sensor connector.
INSTALL NO. 1 WATER BY-PASS PIPE
1. Install a new gasket and the water by-pass pipe with the 2 nuts.
  
  Torque:
  
  17.5 N*m { 178 kgf*cm, 13 ft.*lbf }
INSTALL OIL PRESSURE SWITCH
1. Apply adhesive to 2 or 3 threads of the oil pressure switch.
  
  Adhesive
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
2. Install the oil pressure switch.
  
  Torque:
  
  15 N*m { 153 kgf*cm, 11 ft.*lbf }
  
  Note
  
  Do not start the engine for at least 1 hour after installation of the switch.
3. Connect the oil pressure switch connector.
4. Start the engine and check for engine oil leaks.
INSTALL NO. 1 IDLER PULLEY
1. Install the spacer, idler pulley and pulley plate with the bolt.
  
  Torque:
  
  43 N*m { 439 kgf*cm, 32 ft.*lbf }
INSTALL THERMOSTAT
1. Install a new gasket to the thermostat.
  
  Tech Tips
  
  When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.
2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.
  
  Tech Tips
  
  The jiggle valve may be set within 10°of either side of the prescribed position.
INSTALL WATER INLET
1. Install the inlet with the 2 nuts and bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect the connector.
INSTALL DRIVE BELT TENSIONER
1. Temporarily install the belt tensioner with the 3 bolts.
  
  Tech Tips
  
  Make sure the flanges of the bolts are contacting the tensioner surface.
2. Install the tensioner by tightening the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf, for bolt 1 }
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf, for bolt 2 }
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf, for bolt 3 }
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
Note

Install the No. 1 compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.
1. Temporarily install the No. 1 compressor mounting bracket with the 3 bolts.
  
  Tech Tips
  
  Temporarily install the No. 1 compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.
2. Push the No. 1 compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf, for bolt B }
  
  Tech Tips
  
  Make sure there is no clearance between the cylinder block and No. 1 compressor mounting bracket as shown in the illustration.
3. Uniformly tighten the 4 bolts in the order shown in the illustration.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf, for bolt A }
  
  24.5 N*m { 250 kgf*cm, 18 ft.*lbf, for bolt C }
INSTALL IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)
1. Temporarily install the idle pulley assembly with the bolt.
  
  Note
  
  Do not use any tools.
2. Tighten the bolt.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
INSTALL EXHAUST MANIFOLD (w/o Secondary Air Injection System)
1. Install a new gasket and the exhaust manifold with the 6 nuts.
  
  Torque:
  
  36 N*m { 367 kgf*cm, 27 ft.*lbf }
INSTALL EXHAUST MANIFOLD (w/ Secondary Air Injection System)
1. Install a new gasket and the exhaust manifold with the 8 nuts.
  
  Torque:
  
  36 N*m { 367 kgf*cm, 27 ft.*lbf }
INSTALL AIR SWITCHING VALVE (w/ Secondary Air Injection System)
1. Install the air switching valve with 2 new nuts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Install 2 new gaskets and the intake pipe insulator with 4 new nuts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Check that the nuts are tightened to the torque specification.
  
  Note
  
  Tightening the nuts only once is not enough to tighten them to the torque specification.
INSTALL EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)
1. Install the heat insulator with the 5 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL EXHAUST MANIFOLD HEAT INSULATOR (w/ Secondary Air Injection System)
1. Install the heat insulator with the 5 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL INTAKE MANIFOLD
1. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
2. Connect the crankshaft position sensor to the clamp.
INSTALL INJECTOR
1. Install a new insulator to the injector.
2. Apply a light coat of grease or gasoline to a new O-ring and install it to the injector.
3. Apply a light coat of grease or gasoline on the place where the delivery pipe touches the O-ring.
4. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back and forth.
  Note
  - Be careful not to twist the O-ring.
  - After installing the fuel injector, check that it turns smoothly. If not, reinstall it with a new O-ring.
5. Position the injector connector so that it faces downward.
INSTALL FUEL DELIVERY PIPE
1. Install the 4 spacers to the cylinder head.
2. Install the delivery pipe together with the 4 injectors and 4 spacers with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
3. Connect the 4 injector connectors.
4. Connect the 4 clamps and wire harness to the delivery pipe.
5. Connect the vacuum hose.
INSTALL THROTTLE BODY
1. Install a new gasket on the intake manifold.
  
  Tech Tips
  
  Align the protrusion of the gasket with the groove of the intake manifold.
2. Install the throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
3. Connect the 2 water by-pass hoses to the throttle body.
4. Connect the throttle position sensor and control motor connector.
INSTALL ENGINE WIRE
1. Connect the wire harness (engine ground wire) to the engine rear side with the 2 bolts so that it is within the specified range shown in the illustration.
  
  Torque:
  
  31 N*m { 316 kgf*cm, 23 ft.*lbf }
2. Connect the oil pressure sensor connector.
3. Connect the noise filter connector.
4. Connect the camshaft position sensor connector.
5. Connect the 4 injector connectors.
6. Connect the crankshaft position sensor connector.
7. Connect the OCV connector.
8. Connect the purge VSV connector.
9. Connect the throttle body connector.
10. Connect the ECT sensor connector.
11. Connect the knock sensor connector.
12. Connect the wire harness to the clamps.
INSTALL GENERATOR
1. Install the generator with the 2 bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
2. Install the generator wire with the bolt and nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
3. Connect the connector.
INSTALL VENTILATION PIPE
1. Install the ventilation pipe with the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL SPARK PLUG
INSTALL IGNITION COIL
1. Install the ignition coil with the bolt.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Connect the 4 ignition coil connectors.
REMOVE ENGINE FROM ENGINE STAND
INSTALL ENGINE ASSEMBLY
1. Attach the engine sling device and chain block to the engine hangers.
2. Slowly lower the engine assembly into the engine compartment.
3. Install the engine mounting brackets with the 4 bolts and 4 nuts.
  
  Torque:
  
  38 N*m { 388 kgf*cm, 28 ft.*lbf }
INSTALL REAR END PLATE
1. Install the end plate with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL DRIVE PLATE (for Automatic Transmission)
Tech Tips
- The mounting bolts are tightened in 2 progressive steps.
- If any of the mounting bolts is broken or deformed, replace it.
1. Apply adhesive to 2 or 3 threads of the mounting bolt end.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the drive plate.
3. Fix the crankshaft in place with SST.
  
  SST
  
  09213-54015 ( 91651-60855 )
  
  09330-00021
4. Install and uniformly tighten the 10 mounting bolts in several passes in the order shown in the illustration.
  
  Torque:
  
  74 N*m { 755 kgf*cm, 55 ft.*lbf }
INSTALL FLYWHEEL (for Manual Transmission)
Tech Tips
- The mounting bolts are tightened in 2 progressive steps.
- If any of the mounting bolts is broken or deformed, replace it.
1. Apply adhesive to 2 or 3 threads of the mounting bolt end.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
2. Install the flywheel.
3. Fix the crankshaft in place with SST.
  
  SST
  
  09213-54015 ( 91651-60855 )
  
  09330-00021
4. Install and uniformly tighten the 10 mounting bolts in several passes in the order shown in the illustration.
  
  Torque:
  
  26.5 N*m { 270 kgf*cm, 20 ft.*lbf }
  
  If any of the mounting bolts does not meet the torque specification, replace the mounting bolts.
5. Mark the mounting bolts with paint.
6. Retighten the mounting bolts by 90° in the numerical order shown in the illustration.
7. Check that the painted marks are now at a 90° angle to the position.
INSTALL CLUTCH DISC (for Manual Transmission)
1. Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.
  
  SST
  
  09301-00110
  
  Note
  
  Take care not to insert the clutch disc facing the wrong direction.
INSTALL CLUTCH COVER (for Manual Transmission)
1. Align the matchmarks on the clutch cover and flywheel.
2. Tighten the 6 bolts as described below.
  1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
  2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
    
    Torque:
    
    19 N*m { 195 kgf*cm, 14 in.*lbf }
3. Lightly move SST up and down, and right and left.
  
  SST
  
  09301-00110
4. Check that the disc is in the center, and then tighten the bolts.
INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (A343E)
1. Install the automatic transmission assembly Click here.
INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (A343F)
1. Install the automatic transmission assembly Click here.
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (R150 / R151)
1. Install the manual transmission unit assembly Click here.
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (R150F / R151F)
1. Install the manual transmission unit assembly Click here.
INSTALL HOOD ASSEMBLY
1. Install the hood with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Connect the washer nozzle hose.
3. Adjust the hood Click here.
INSTALL COOLER COMPRESSOR (w/ Air Conditioning System)
1. Loosely install the bolt labeled A to install the compressor.
2. Install the compressor completely by tightening the 4 bolts in the order shown in the illustration.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
  
  Note
  
  In order to prevent misalignment, which causes belt rattle, tightening of the bolts must be performed in the order shown.
3. Connect the suction hose with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
4. Connect the compressor connector.
INSTALL OIL DIPSTICK GUIDE
1. Install a new O-ring and the dipstick guide with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL OIL DIPSTICK
INSTALL VANE PUMP
1. Install the vane pump with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Connect the PS oil pressure switch connector.
CONNECT ENGINE WIRE
1. Connect the 2 engine room junction block connectors and connect the wire clamp.
2. Connect the cable to the engine room junction block with the nut.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
3. Install the engine room relay block cover (upper).
4. Install the engine room relay block cover (side).
5. Connect the ground wire with the bolt and clamp.
  
  Torque:
  
  31 N*m { 316 kgf*cm, 23 ft.*lbf }
6. Connect the ground wire to the frame with the bolt so that it is within the range shown in the illustration.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
7. Push the engine wire through the dash panel into the cabin. The wire should be within the range shown in the illustration.
8. For unleaded gasoline specification vehicle:
  
  Install the sensor clamp with the bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
9. Connect the ECM connectors.
  1. Connect the 4 ECM connectors.
  2. Install the glove compartment door.
  3. 4WD:
    
    Connect the 4WD control ECU connector.
10. Connect the wire clamp to the engine mounting bracket front LH with the bolt.
CONNECT FUEL HOSE
1. Connect the No. 2 fuel hose to the pressure regulator.
2. Connect the No. 1 fuel hose to the pulsation damper.
  1. Check that there is no damage or contamination in the connected part of the pipe.
  2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of fresh engine oil on the tip of the pipe.
  3. After having finished the connection, try to pull apart the pipe and the connector and confirm that they are securely connected.
  4. Attach the lock claws to the connector by pushing down on the cover, as shown in the illustration.
CONNECT HOSE
1. Connect the vacuum hose (for brake master cylinder).
2. For unleaded gasoline specification vehicle:
  
  Connect the purge line hose.
INSTALL RADIATOR ASSEMBLY
1. Install the radiator with the 4 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. Attach the 4 clamps to the radiator side as shown in the illustration.
3. Connect the 2 airbag sensor front connectors.
INSTALL FAN PULLEY
INSTALL FAN SHROUD
1. Install the fan pulley to the water pump.
2. Place the shroud together with the fluid coupling fan between the radiator and engine.
  
  Note
  
  Be careful not to damage the radiator core.
3. Temporarily install the coupling fan to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.
4. Attach the shroud's claws to the radiator as shown in A in the illustration.
5. Install the shroud with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
6. Connect the reservoir hose to the radiator tank upper.
7. Install the drive belt Click here.
8. Tighten the 4 nuts of the fluid coupling fan.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL DRIVE BELT
1. Install the drive belt to the pulleys except the drive belt tensioner pulley.
2. Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and then install the drive belt to the tensioner pulley.
  Note
  - The backside of the drive belt should face the tensioner pulley.
  - Check that the drive belt is properly set to each pulley.
3. After a new belt has been installed, check that the tensioner indicator mark is within range A shown in the illustration.
CONNECT RADIATOR OUTLET HOSE
CONNECT RADIATOR INLET HOSE
INSTALL RADIATOR GRILLE
1. Attach the 6 claws to install the radiator grille.
2. Install the 2 screws and 2 clips.
INSTALL INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY
1. Install the air cleaner and intake air connector assembly with the 4 bolts, and tighten the hose clamp.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf, for air cleaner }
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf, for intake air connector }
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf, for hose clamp }
2. Connect the MAF meter connector and harness clamps.
3. Connect the No. 2 ventilation hose.
4. Connect the vacuum hose.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Adhesive
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

ADD ENGINE OIL

Clean and install the oil drain plug with a new gasket.

Torque:

37.5 N*m { 382 kgf*cm, 28 ft.*lbf }

Add fresh engine oil.

Standard capacity

Item	Capacity
Drain and refill with oil filter change	5.6 liters (5.9 US qts, 4.9 Imp. qts)
Drain and refill without oil filter change	5.3 liters (5.6 US qts, 4.7 Imp. qts)
Dry fill	6.3 liters (6.7 US qts, 5.5 Imp. qts)

Install the oil filler cap.

ADD ENGINE COOLANT

Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Torque:: 13 N*m { 133 kgf*cm, 10 ft.*lbf, for cylinder block drain cock plug }

Standard capacity

Item	Specified Condition
Manual transmission	w/ Heater	7.8 liters (8.2 US qts, 6.9 Imp. qts)
Manual transmission	w/o Heater	7.0 liters (7.4 US qts, 6.2 Imp. qts)
Automatic transmission	w/ Heater	8.1 liters (8.6 US qts, 7.1 Imp. qts)
Automatic transmission	w/o Heater	7.3 liters (7.7 US qts, 6.4 Imp. qts)

Fill the radiator reservoir with TOYOTA Super Long Life Coolant (SLLC) to the F line.
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).
- Please contact your TOYOTA dealer for further details.
  
  Note
  
  Never use water as a substitute for engine coolant.
Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level drops below the F line, add TOYOTA SLLC to the F line.
Install the radiator cap.
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.
2. Maintain the engine speed at 2,500 to 3,000 rpm.
3. Press the inlet and outlet 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 fan.
Stop the engine and wait until the 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.

If the coolant level is below the L line, add SLLC to the reservoir F line.

CHECK FOR FUEL LEAKS
1. Connect the intelligent tester to the DLC3.
  1. Turn the ignition switch ON.
    
    Note
    
    Do not start the engine.
  2. Push the intelligent tester main switch ON.
  3. Select the Active Test and enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.
2. Check for fuel leaks.
  1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system.
CHECK FOR OIL LEAKS
1. Start the engine, and check that there are no oil leaks after performing maintenance.
CHECK FOR COOLANT LEAKS
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.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17.1 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 cylinder block and head.
INSTALL NO. 1 ENGINE UNDER COVER
1. Install the No. 1 under cover with the 4 bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
CHECK IDLE SPEED AND IGNITION TIMING
1. Warm up and stop the engine.
  
  Note
  
  A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.
2. Check the idle speed control system.
  1. Using SST, connect terminals TC and CG of the DLC3.
    
    SST
    
    09843-18040
  2. Start the engine at idle.
    
    Note
    
    Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
    
    Turn off all electrical systems before connecting the terminals.
    
    When checking ISC function, the transmission should be in the neutral position.
  3. After connecting terminals (TC and CG), check that the engine speed changes to approximately 1,000 to 1,500 rpm for 5 seconds, and then returns to idle speed.
    
    If the result is not as specified, check the throttle body, DTC Click here and wire harness.

CHECK CO/HC

Start and warm up the engine.
Run the engine at 2,500 rpm for approximately 180 seconds and idle the engine.
Insert CO/HC meter testing probe at least 40 cm (1.3 ft.) into the tailpipe.
Check CO/HC concentration at idle.

Standard idle CO concentration

0 to 0.5 %

Standard idle HC concentration

Applicable local regulation

Standard idle CO concentration
0 to 0.5 %

Standard idle HC concentration
Applicable local regulation

If the CO/HC concentration is not as specified, perform troubleshooting in the order given below.

Check the heated oxygen sensor operation Click here.

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

CO	HC	Problems	Causes
Normal	High	Rough idle	Faulty ignitions: Incorrect timing Plugs are contaminated, shorted or gaps are defective Incorrect valve clearance Leaks in intake and exhaust valves Leaks in cylinders
Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
High	High	Rough idle (Black smoke from exhaust)	Restricted air filter Plugged PCV valve Faulty SFI system: Faulty pressure regulator Defective ECT sensor Defective Mass Air Flow (MAF) meter Faulty ECM Faulty injectors Faulty throttle position sensor

Problems

Causes

Normal

High

Rough idle

Faulty ignitions:

Incorrect timing
Plugs are contaminated, shorted or gaps are defective

Incorrect valve clearance
Leaks in intake and exhaust valves
Leaks in cylinders

Low

High

Rough idle

(Fluctuating HC reading)

Vacuum leaks:

PCV hoses
Intake manifold
Throttle body
Brake booster line

Lean mixture causing misfire

High

Rough idle

(Black smoke from exhaust)

Restricted air filter
Plugged PCV valve
Faulty SFI system:

Faulty pressure regulator
Defective ECT sensor
Defective Mass Air Flow (MAF) meter
Faulty ECM
Faulty injectors
Faulty throttle position sensor

CHECK FUNCTION OF THROTTLE BODY
1. Check the throttle control motor operating sound.
  1. Turn the ignition switch ON.
  2. When pressing the accelerator pedal, check the operating sound of the running motor. Make sure that no friction noises emit from the motor.
    
    If friction noise is heard, replace the throttle body.
2. Check the throttle position sensor.
  1. Connect the intelligent tester to the DLC3.
  2. Turn the ignition switch ON.
  3. Under Current Data, check that the throttle valve opening percentage (Throttle Pos) is within the standard.
    
    Standard throttle valve opening percentage
    
    60% or more
    
    Note
    
    When checking the standard throttle valve opening percentage, the shift lever should be in the N position.
    
    If the percentage is less than 60%, replace the throttle body.
PERFORM INITIALIZATION
1. Perform initialization Click here.
  
  Note
  
  Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.