ENGINE ASSEMBLY > INSTALLATION

for Preparation Click here


HINT:
Perform "Inspection After Repair" after replacing the engine assembly (Click here).


1. INSTALL ENGINE HANGERS


    A337908E01
  1. Install the No. 1 engine hanger with the bolt as shown in the illustration.

    Text in Illustration 
    *1
    No. 1 Engine Hanger
    *2
    No. 2 Engine Hanger
    *a
    Stopper
    *b
    Rib

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

    NOTICE:
    Make sure to install the No. 1 engine hanger with the stopper contacting the rib of the cylinder head sub-assembly as shown in the illustration.

    HINT:
    Item
    Part No.
    No. 1 Engine Hanger
    12281-0V010
    No. 2 Engine Hanger
    12282-0V010
    Bolt
    90105-C0170
  1. Install the No. 2 engine hanger with the bolt as shown in the illustration.

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

    NOTICE:
    Make sure to install the No. 2 engine hanger with the stopper positioned between the ribs of the cylinder head sub-assembly as shown in the illustration.
  1. Using an engine sling device and engine lift, secure the engine assembly with transaxle.

    NOTICE:
    1. Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
    2. Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.


2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
  1. Remove the engine assembly from the engine stand.



3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    A337180E01
  1. Using SST, hold the crankshaft.

    SST
    09213-54015  
    09330-00021  

    HINT:
    Part number of installation bolt for SST (crankshaft pulley holding tool): 91551-80650 (quantity: 2)
  1. Clean the 8 bolts and the bolt holes.



    A337178
  1. Install the front drive plate spacer.

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


    A337179E01
  1. Install the drive plate and ring gear sub-assembly and rear drive plate spacer to the crankshaft.

    Text in Illustration 
    *1
    Drive Plate and Ring Gear Sub-assembly
    *2
    Rear Drive Plate Spacer
    V100135
    Transaxle Side


    A192239E20
  1. Apply adhesive to 2 or 3 threads at the end of each of the 8 bolts.

    Text in Illustration 
    *a
    Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent


    A337181E01
  1. Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration.

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

    NOTICE:
    Do not start the engine for at least 1 hour after installing the drive plate and ring gear sub-assembly.


4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


    C317166E01
  1. Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

    Text in Illustration 
    *1
    Crankshaft
    *a
    Torque Converter Assembly Centerpiece
    V100135
    Clutch Spline Grease

    Clutch Spline Grease:
    Toyota Genuine Clutch Spline Grease or equivalent

    Maximum Grease Amount:
    Approximately 1 g (0.0353 oz)


    C317167E01
  1. Confirm that the knock pins are installed to the engine assembly and are not damaged.

    Text in Illustration 
    *1
    Knock Pin
  1. While keeping the engine assembly and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the 9 bolts shown in the illustration.

    Bolt
    Bolt Length
    Torque
    (A)
    55 mm (2.17 in.)
    64 N*m (653 kgf*cm, 47 ft.*lbf)
    (B)
    50 mm (1.97 in.)
    46 N*m (469 kgf*cm, 34 ft.*lbf)
    (C)
    32 mm (1.26 in.)
    44 N*m (449 kgf*cm, 32 ft.*lbf)
    33 mm (1.30 in.)
    43 N*m (438 kgf*cm, 32 ft.*lbf)

    NOTICE:
    1. When tightening the bolts, make sure that the contact surfaces of the engine assembly and automatic transaxle assembly are in close contact with one another.
    2. Do not use excessive force when installing the automatic transaxle assembly.
    3. Check that the torque converter assembly rotates.
    4. Make sure that the wire harness and other similar items are not pinched between the contact surfaces.
    5. In order to protect the automatic transaxle oil pan sub-assembly, place attachments on the transmission jack.
    6. Make sure that the attachments and automatic transaxle oil pan sub-assembly are centered on the transmission jack.
    7. To prevent the automatic transaxle oil pan sub-assembly from being deformed, do not place any attachments under the automatic transaxle oil pan sub-assembly.
    8. Secure the automatic transaxle assembly to the transmission jack using a belt, etc. to prevent it from falling.


5. INSTALL FRONT ENGINE MOUNTING BRACKET
  1. Install the front engine mounting bracket to the transaxle housing with the 3 bolts.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }


6. INSTALL WIRE HARNESS CLAMP BRACKET
  1. Install the wire harness clamp bracket to the transaxle housing with the bolt.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }
  1. Engage the 4 clamps to connect the wire harness to the wire harness clamp bracket.

  1. Connect the oxygen sensor connector.

  1. Install the clamp to the wire harness clamp bracket.

  1. Connect the transmission breather hose sub-assembly to the clamp.



7. INSTALL ENGINE MOUNTING BRACKET RH
  1. Install the engine mounting bracket RH with the 3 bolts.

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


8. INSTALL DRIVE SHAFT BEARING BRACKET
  1. Install the drive shaft bearing bracket with the 3 bolts.

    Torque:
    64 N*m{ 650 kgf*cm , 47 ft.*lbf }


9. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
  1. Temporarily install the front engine mounting insulator with the 3 nuts.



10. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

HINT:
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
  1. Temporarily install the engine mounting insulator LH with the 3 nuts.



11. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

HINT:
Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
  1. Temporarily install the engine mounting insulator RH with the 3 nuts.



12. INSTALL FRONT FRAME ASSEMBLY
  1. Install the engine mounting insulator LH with the nut.

    Torque:
    95 N*m{ 969 kgf*cm , 70 ft.*lbf }
  1. Install the front engine mounting insulator with the bolt.

    Torque:
    87 N*m{ 887 kgf*cm , 64 ft.*lbf }
  1. Install the engine mounting insulator RH with the nut.

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


  1. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators.


    A338542E01


    Text in Illustration 
    *1
    Front Engine Mounting Insulator
    *2
    Engine Mounting Insulator RH
    *3
    Engine Mounting Insulator LH
    -
    -

    Torque:
    Nut (A):
    58 N*m{ 591 kgf*cm , 43 ft.*lbf }
    Nut (B):
    99 N*m{ 1010 kgf*cm , 73 ft.*lbf }

    HINT:
    Perform this procedure only when replacement of the engine mounting insulators is necessary.


  1. Install the 4 hole plugs.


    A256545E12


    Text in Illustration 
    *1
    Engine Mounting Insulator RH
    *2
    Engine Mounting Insulator LH

    HINT:
    Perform this procedure only when replacement of the engine mounting insulators is necessary.


13. INSTALL GENERATOR ASSEMBLY
  1. Install the generator assembly with the 2 bolts.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }
  1. Install the wire harness clamp bracket to the generator assembly with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
  1. Connect the wire harness to terminal B with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }
  1. Close the terminal cap.

  1. Connect the generator assembly connector.



14. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    E305926E01
  1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

  1. Tighten the 2 stud bolts.

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

    HINT:
    Tighten the stud bolts in the order shown in the illustration.


    E305925E01
  1. Install the compressor assembly with pulley and bracket with the 2 bolts and 2 nuts.

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

    HINT:
    Tighten the bolts and nuts in the order shown in the illustration.


15. INSTALL V-RIBBED BELT


    A337564E01
  1. Set the V-ribbed belt onto each part as shown in the illustration except the engine water pump pulley.

    Text in Illustration 
    *1
    Crankshaft Pulley
    *2
    V-ribbed Belt Tensioner Assembly
    *3
    Generator Assembly
    *4
    Engine Water Pump Assembly
    *5
    Compressor Assembly with Pulley
  1. Loosen the V-ribbed belt by turning the belt tensioner clockwise.

  1. Set the V-ribbed belt onto the engine water pump pulley.

    NOTICE:
    Make sure that the V-ribbed belt is securely fitted into the grooves of each pulley.


16. INSTALL ENGINE WIRE
  1. Install the engine wire to the engine assembly with transaxle.



17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
  1. Set the engine assembly with transaxle on an engine lifter.

    NOTICE:
    1. Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.
    2. To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.
    3. Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.

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

    NOTICE:
    1. Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.
    2. Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
    3. While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.


    A338965E01
  1. Install the frame side rail plate sub-assembly RH and frame side rail plate sub-assembly LH with the 4 bolts and 2 nuts.

    Text in Illustration 
    V100135
    Bolt
    V100136
    Nut

    Torque:
    Bolt (A):
    85 N*m{ 867 kgf*cm , 63 ft.*lbf }
    Bolt (B) and Nut:
    32 N*m{ 329 kgf*cm , 24 ft.*lbf }
  1. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH with the 4 bolts and 2 nuts.

    Torque:
    Bolt (A):
    85 N*m{ 867 kgf*cm , 63 ft.*lbf }
    Bolt (B) and Nut:
    32 N*m{ 329 kgf*cm , 24 ft.*lbf }

    HINT:
    Perform "Inspection After Repair" after replacing the engine assembly.


18. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT


    C295661E01
  1. Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts.

    Text in Illustration 
    *a
    Adhesive

    Adhesive:
    Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    NOTICE:
    In order to ensure proper sealing of the 6 drive plate and torque converter assembly setting bolts, apply adhesive to the 6 drive plate and torque converter assembly setting bolts and install them within 10 minutes of adhesive application.
  1. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

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

    NOTICE:
    First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.


19. INSTALL FLYWHEEL HOUSING UNDER COVER
  1. Install the flywheel housing under cover.



20. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY


    C238511E02
  1. Align the matchmarks and install the steering intermediate shaft to the steering link assembly.

    Text in Illustration 
    *a
    Matchmark
  1. Install the bolt.

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


21. INSTALL FRONT DRIVE SHAFT ASSEMBLY
(Click here)


22. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)


    A077857E03
  1. Using a vernier caliper, measure the free length of the 2 compression springs.

    Minimum Free Length
    40.5 mm (1.59 in.)
    If the free length is less than the minimum, replace the compression spring.
  1. Temporarily install a new exhaust pipe gasket to the exhaust manifold converter sub-assembly (TWC: Front Catalyst).



    A181728E40
  1. Using a plastic hammer and wooden block, tap in the exhaust pipe gasket until its surface is flush with the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

    Text in Illustration 
    *1
    Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
    *2
    Exhaust Pipe Gasket
    *a
    Wooden Block

    NOTICE:
    1. Be careful with the installation direction of the gasket.
    2. Do not reuse the gasket.
    3. Do not damage the gasket.
    4. Do not push in the gasket by using the exhaust pipe when connecting it.
  1. Install a new exhaust pipe gasket to the front exhaust pipe assembly (TWC: Rear Catalyst).

  1. Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.



  1. Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and center exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.

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

    HINT:
    A258941E01
    After installation, check that the space between the flanges of the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and front exhaust pipe assembly (TWC: Rear Catalyst) is consistent front-to-rear and left-to-right.
    Text in Illustration 
    *1
    Exhaust Manifold Converter Sub-assembly (TWC: Front Catalyst)
    *2
    Front Exhaust Pipe Assembly (TWC: Rear Catalyst)
    *3
    Exhaust Pipe Gasket
    *a
    Space between Flanges: 8.5 mm (0.335 in.)
  1. Connect the heated oxygen sensor connector.



23. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
  1. Connect the fuel vapor feed hose assembly to the floor tube (Click here).

  1. Install the EFI fuel pipe clamp.



24. CONNECT FUEL TUBE SUB-ASSEMBLY
  1. Connect the 2 fuel tube sub-assemblies to the 2 fuel tubes (Click here).

  1. Install the 2 EFI fuel pipe clamps (Click here).



25. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE
  1. Remove the vinyl tape from the No. 1 cooler refrigerant suction hose and compressor assembly with pulley.

  1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

    Compressor Oil:
    ND-OIL 8 or equivalent
  1. Install the O-ring to the No. 1 cooler refrigerant suction hose.

  1. Connect the No. 1 cooler refrigerant suction hose to the compressor assembly with pulley with the bolt.

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


26. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
  1. Remove the vinyl tape from the No. 1 cooler refrigerant discharge hose and compressor assembly with pulley.

  1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

    Compressor Oil:
    ND-OIL 8 or equivalent
  1. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

  1. Connect the No. 1 cooler refrigerant discharge hose to the compressor assembly with pulley with the bolt.

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

  1. Connect each connector.

  1. Connect the wire harness with the bolt.

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


27. CONNECT UNION TO CHECK VALVE HOSE
  1. Connect the union to check valve hose to the vacuum pump assembly, and slide the clip to secure it.



28. INSTALL ENGINE MOVING CONTROL ROD

HINT:
Perform this procedure only when replacement of the engine moving control rod is necessary.
  1. Temporarily install the engine moving control rod and No. 3 engine mounting stay RH to the engine moving control rod bracket with the bolt.



29. INSTALL ENGINE MOVING CONTROL ROD BRACKET


  1. When replacing the engine moving control rod.



      A338527E01
    1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

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

      NOTICE:
      Temporarily tighten bolt (A) and bolt (B), and then fully tighten the 4 bolts in the order of bolt (D), bolt (C), bolt (A) and bolt (B).


    2. A348191E01
    3. Using SST and a union nut wrench (14 mm), tighten the bolt.

      Text in Illustration 
      *a
      Torque Wrench Fulcrum Length
      *b
      Union Nut Wrench
      SST
      09961-00950  

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

      NOTICE:
      1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (Click here).
      2. When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 260 mm (10.2 in.)): 33 N*m (337 kgf*cm, 24 ft.*lbf)


  1. When not replacing the engine moving control rod.



      A338527E01
    1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

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

      NOTICE:
      Temporarily tighten bolt (A) and bolt (B), and then fully tighten the 4 bolts in the order of bolt (D), bolt (C), bolt (A) and bolt (B).


30. INSTALL NO. 2 ENGINE MOUNTING STAY RH
  1. Install the No. 2 engine mounting stay RH with the 2 bolts.

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


31. INSTALL EARTH WIRE
  1. Install the earth wire with the 2 bolts.

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


32. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
  1. Move the shift lever to N.

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

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }
  1. Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.



33. INSTALL NO. 1 AIR CLEANER BRACKET
  1. Install the No. 1 air cleaner bracket to the battery carrier with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
  1. Connect the 2 wire clamps.



34. CONNECT ENGINE WIRE


    A338537
  1. Engage the 2 wire harness clamps.

  1. Push down the lock lever to connect the ECM connector.

    NOTICE:
    1. When connecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting part of the ECM connector.
    2. Be sure to securely connect the ECM connectors.
  1. Engage the claw to connect the engine wire to the engine room relay block assembly.

  1. Install the nut to the engine room relay block assembly.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
  1. Connect the 4 connectors to the engine room relay block assembly.

  1. Engage the wire harness clamp.

  1. Install the engine wire with the bolt.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
  1. Install the No. 1 relay block cover to the engine room relay block assembly.



35. INSTALL STARTER ASSEMBLY
  1. Install the starter assembly with the 2 bolts.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }
  1. Connect the starter assembly connector.

  1. Connect terminal 30 with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }
  1. Close the terminal cap.



36. CONNECT OUTLET NO. 1 OIL COOLER HOSE
  1. Connect the outlet No. 1 oil cooler hose to the automatic transaxle assembly and slide the clip to secure it.



37. CONNECT INLET NO. 1 OIL COOLER HOSE
  1. Connect the inlet No. 1 oil cooler hose to the automatic transaxle assembly and slide the clip to secure it.



38. CONNECT HEATER OUTLET WATER HOSE
  1. Connect the heater outlet water hose to the EGR cooler assembly and slide the clip to secure it.



39. CONNECT HEATER INLET WATER HOSE
  1. Connect the heater inlet water hose to the cylinder head sub-assembly and slide the clip to secure it.

  1. Engage the clamp to connect the heater inlet water hose.



40. CONNECT NO. 2 RADIATOR HOSE
  1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.



41. CONNECT NO. 1 RADIATOR HOSE
  1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.



42. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    A338529E01
  1. Insert the projection of the air cleaner case sub-assembly into the hole of the No. 1 air cleaner bracket as shown in the illustration.

    Text in Illustration 
    *a
    Hole
    *b
    Projection
  1. Install the 2 bolts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }
  1. Connect the wire harness clamp.



43. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
  1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

    NOTICE:
    Install the air cleaner filter element sub-assembly with the printed side facing the vehicle left.


44. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
  1. Connect the air cleaner cap with air cleaner hose to the throttle body with motor assembly.

  1. Install the air cleaner cap with air cleaner hose with the 2 guides and 2 air cleaner cap clamps.

  1. Tighten the hose clamp.

  1. Connect the union to connector tube hose to the air cleaner hose sub-assembly.

  1. Engage the wire harness clamp.

  1. Connect the mass air flow meter sub-assembly connector.

  1. Engage the ventilation hose clamp.

  1. Connect the ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.



45. INSTALL BATTERY
  1. Install the battery and battery tray.

  1. Install the battery clamp with the bolt and nut.

    Torque:
    Bolt:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }
    Nut:
    3.5 N*m{ 36 kgf*cm , 31 in.*lbf }
  1. Connect the cable to the positive (+) battery terminal with the nut.

    Torque:
    6.5 N*m{ 66 kgf*cm , 58 in.*lbf }


46. INSTALL INLET AIR CLEANER ASSEMBLY
  1. Install the inlet air cleaner assembly with the 2 bolts.

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


47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
  1. Connect the cable to the negative (-) battery terminal with the nut.

    Torque:
    6.5 N*m{ 66 kgf*cm , 58 in.*lbf }

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


48. ADD ENGINE OIL
  1. Add clean engine oil and install the oil filler cap sub-assembly.

    Standard Oil Grade:

    Oil Grade
    Oil Viscosity (SAE)
    API grade SL "Energy-Conserving", SM "Energy- Conserving", SN "Resource-Conserving" or ILSAC multigrade engine oil
    1. 0W-20
    1. 5W-20
    1. 5W-30
    1. 10W-30
    API grade SL, SM or SN multigrade engine oil
    1. 15W-40

    Standard Capacity:

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


49. ADD ENGINE COOLANT
  1. Tighten the radiator drain cock plug by hand.

  1. Slowly fill the radiator assembly with engine coolant.

    Specified Capacity:
    7.3 liters (7.7 US qts, 6.4 Imp. qts)

    NOTICE:
    Do not substitute plain water for engine coolant.

    HINT:
    TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damaging 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).
  1. Remove the reserve tank cap.

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

  1. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
    If the engine coolant level is low, add engine coolant.

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

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the heater control to the maximum hot setting.
    3. Adjust the blower speed to the low setting.

    1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the engine coolant for several minutes.

      HINT:
      The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose.
    2. Maintain the engine speed at 2500 to 3000 rpm.

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

      CAUTION:
      When squeezing the No. 1 radiator hose and No. 2 radiator hose:
      1. Wear protective gloves.
      2. Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.
      3. Keep your hands away from the fan and No. 2 fan.

      NOTICE:
      1. If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.
      2. Make sure that the radiator reserve tank assembly still has some engine coolant in it.
      3. If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.
      4. If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly is filled to the full line.
  1. Stop the engine, and wait until the engine coolant cools down.

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



50. ADD AUTOMATIC TRANSAXLE FLUID
(Click here)


51. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
  1. Perform vacuum purging using a vacuum pump or appropriate equipment.



  1. Charge the air conditioning system with refrigerant.

    Refrigerant type:
    HFC-134a (R134a)


    E143108E14


    Text in Illustration 
    *a
    Sub-cool System
    *b
    High Pressure
    *c
    Refrigerant Amount
    *d
    Standard charge amount
    *e
    Charge additional 100 g (3.5 oz)
    *f
    Point where bubbles disappear
    *g
    Mean value in proper range
    *h
    Overcharged
    *i
    +/-50 g (+/-1.76 oz)
    -
    -

    Standard charge amount:
    450 to 550 g (15.9 to 19.4 oz)
    SST
    09985-20010   (09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150)

    NOTICE:
    1. Do not turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.
    2. The refrigerant amount should be checked by quantity (weight).

    HINT:
    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 air conditioning system.


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

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


53. INSPECT FOR FUEL LEAK
(Click here)


54. INSPECT FOR ENGINE OIL LEAK
  1. Start the engine. Make sure that there are no engine oil leaks from the area that was worked on.



55. INSPECT FOR COOLANT LEAK
  1. Remove the radiator cap sub-assembly.



    A255285E01
  1. Fill the radiator assembly with engine coolant, and then install a radiator cap tester.

    Text in Illustration 
    *a
    Radiator Cap Tester
  1. Warm up the engine.

  1. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm2, 17 psi), and then check that the pressure does not drop.

    1. If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
    2. If there are no signs of external engine coolant leaks, check the heater core, cylinder block sub-assembly and cylinder head sub- assembly.
  1. Remove the radiator cap tester.

  1. Install the radiator cap sub-assembly.



56. INSPECT FOR EXHAUST GAS LEAK
If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
  1. Perform Inspection After Repair after repairing an exhaust gas leak (Click here).



57. INSPECT FOR REFRIGERANT LEAK
  1. After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.

  1. Carry out the test under the following conditions:

    1. Turn the engine switch off.
    2. Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.
      Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)
    3. Ensure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).
    4. Repeat the inspection 2 or 3 times.
  1. Remove the front outer cowl top panel sub-assembly (Click here for LHD or Click here for RHD).

  1. Remove the front bumper assembly (Click here).

  1. Remove the radiator side deflector RH (Click here).



    E280082E01
  1. How to check for refrigerant leaks in pipe joints:

    Text in Illustration 
    *a
    Check for leaks
    *b
    Halogen Leak Detector Sensor
    *c
    Distance between Sensor and Joint to be Checked:
    10 mm or less
    *d
    Halogen Leak Detector Sensor Moving Speed:
    25 to 50 mm/sec.

    NOTICE:
    Gas leaking from a joint can be dissipated by even the slightest breeze. Move the halogen leak detector sensor 360° around each joint instead of keeping it in one spot when checking.


  1. Using a halogen leak detector, check for refrigerant leaks at the pipe joints shown in the illustration.


    E288035E01


    Text in Illustration 
    *a
    Area to be Checked
    *b
    Service Valve (High)
    *c
    Service Valve (Low)
    *d
    Pipe Joint
    *e
    Air Conditioner Pressure Sensor Joint
    *f
    Cooler Expansion Valve Joint
    *g
    Condenser Joint (Inlet)
    *h
    Condenser Joint (Outlet)
    *i
    Compressor Joint (Inlet)
    *j
    Compressor Joint (Outlet)

    HINT:
    1. After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
    2. Disconnect the pressure sensor connector and leave it for approximately 20 minutes.
    3. When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

    Standard:
    There are no refrigerant leaks from the joints.
    If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.


    E280081E01
  1. Bring the halogen leak detector sensor close to the drain cooler hose with the detector turned off, and then turn the detector on.

    Text in Illustration 
    *1
    Drain Cooler Hose
    *a
    Halogen Leak Detector

    NOTICE:
    Keep water away from the halogen leak detector to prevent malfunction.

    HINT:
    1. After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
    2. When bringing the halogen leak detector sensor close to the drain cooler hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow checking for leaks.

    Standard:
    Refrigerant is not leaking from the drain cooler hose.
    If refrigerant is leaking, check for refrigerant leaks from the No. 1 cooler evaporator sub-assembly.
  1. Remove the blower motor with fan sub-assembly (Click here).



    E288039E01
  1. Insert the halogen leak detector sensor into the air conditioning unit assembly, bring the sensor close to the No. 1 cooler evaporator sub-assembly and check for refrigerant leaks.

    Text in Illustration 
    *1
    No. 1 Cooler Evaporator Sub-assembly
    *a
    Halogen Leak Detector

    HINT:
    After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

    Standard:
    Refrigerant is not leaking from the No. 1 cooler evaporator sub-assembly.
    If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.
  1. Install the blower motor with fan sub-assembly (Click here).

  1. Install the radiator side deflector RH (Click here).

  1. Install the front bumper assembly (Click here).

  1. Install the front outer cowl top panel sub-assembly (Click here for LHD or Click here for RHD).



58. INSPECT IGNITION TIMING
  1. Warm up and stop the engine.

  1. When using the GTS:

    1. Connect the GTS to the DLC3.

    2. Start the engine and run it at idle.

    3. Turn the GTS on.

    4. Enter the following menus: Powertrain / Engine / Data List / Ignition Timing Cylinder #1.

      Standard Ignition Timing:
      5 to 15° BTDC at idle

      NOTICE:
      1. Check the ignition timing with the cooling fans off.
      2. Turn off all electrical systems and the A/C.
      3. When checking the ignition timing, the transaxle should be in neutral or park.
    5. Check that the ignition timing advances immediately when the engine speed is increased.

    6. Enter the following menus: Powertrain / Engine / Active Test / Activate the TC Terminal / ON.

    7. Monitor Ignition Timing Cylinder #1.

    8. Perform the Active Test.

      Standard Ignition Timing:
      8 to 12° BTDC at idle

      NOTICE:
      1. Check the ignition timing with the cooling fans off.
      2. Turn off all electrical systems and the A/C.
      3. When checking the ignition timing, the transaxle should be in neutral or park.


  1. When not using the GTS:



      A122830E44
    1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      Text in Illustration 
      *a
      DLC3
      SST
      09843-18040  

      NOTICE:
      1. Confirm the terminal numbers before connecting them. Connecting the wrong terminals may damage electrical components.
      2. Check the ignition timing with the cooling fans off.
      3. Turn off all electrical systems and the A/C.
      4. When checking the ignition timing, the transaxle should be in neutral or park.
    2. Remove the No. 1 engine cover sub-assembly (Click here).



    3. A338458
    4. Connect the clip of a timing light to the ignition coil wire for the No. 1 cylinder.

      NOTICE:
      Use a timing light that detects primary signals.
    5. Start the engine and run it at idle.

    6. Check the ignition timing at idle.

      Standard Ignition Timing:
      8 to 12° BTDC at idle

      NOTICE:
      1. Check the ignition timing with the cooling fans off.
      2. Turn off all electrical systems and the A/C.
      3. When checking the ignition timing, the transaxle should be in neutral or park.
    7. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

    8. Check the ignition timing at idle.

      Standard Ignition Timing:
      5 to 15° BTDC at idle

      NOTICE:
      1. Check the ignition timing with the cooling fans off.
      2. Turn off all electrical systems and the A/C.
      3. When checking the ignition timing, the transaxle should be in neutral or park.
    9. Confirm that the ignition timing advances immediately when the engine speed is increased.

    10. Disconnect the clip of the timing light from the ignition coil wire for the No. 1 cylinder.

    11. Install the No. 1 engine cover sub-assembly (Click here).



59. INSPECT ENGINE IDLE SPEED
  1. Warm up and stop the engine.

  1. When using the GTS:

    1. Connect the GTS to the DLC3.

    2. Start the engine and run it at idle.

    3. Turn the GTS 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

      NOTICE:
      1. Check the engine idle speed with the cooling fans off.
      2. Turn off all electrical systems and the A/C.
      3. When checking the engine idle speed, the transaxle should be in neutral or park.


  1. When not using the GTS:



      A122830E45
    1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.

      Text in Illustration 
      *a
      DLC3
      SST
      09843-18030  

      NOTICE:
      Be sure to connect the tachometer probe to the correct terminal. Connecting the wrong terminals can cause damage to electrical components.
    2. Start the engine and run it at idle.

    3. Inspect the engine idle speed.

      Standard Idle Speed:
      600 to 700 rpm

      NOTICE:
      1. Check the engine idle speed with the cooling fans off.
      2. Turn off all electrical systems and the A/C.
      3. When checking the engine idle speed, the transaxle should be in neutral or park.
    4. Turn the engine switch off.

    5. Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.



60. INSPECT CO/HC

HINT:
This check determines whether or not the idle CO/HC complies with regulations.
  1. Start the engine.

  1. Run the engine at 2500 rpm for approximately 180 seconds.

  1. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idle.

  1. Immediately check the CO/HC concentration during idle and when the engine is running at 2500 rpm.

    HINT:
    When performing a 2 mode (with the engine idling/running at 2500 rpm) test, the measurement procedures are 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 for DTCs (Click here).

    2. See the following table for possible causes, then inspect the applicable parts and repair them if necessary.

      CO
      HC
      Problem
      Cause
      Normal
      High
      Rough idle
      1. Faulty ignition:
        1. Incorrect valve timing
        2. Fouled, shorted or improperly gapped spark plugs
      2. Incorrect valve clearance (valve lash adjuster assembly)
      3. Leaks in intake or exhaust valves
      4. Leaks in cylinders
      5. Faulty EGR
      Low
      High
      Rough idle
      (Fluctuating HC reading)
      1. Vacuum leaks:
        1. PCV hoses
        2. Intake manifold
        3. Throttle with motor body assembly
        4. Brake booster line
      2. Lean mixture causing misfire
      3. Faulty EGR
      High
      High
      Rough idle (Black smoke from exhaust)
      1. Restricted air cleaner filter element sub-assembly
      2. Plugged PCV valve
      3. Faulty SFI system:
        1. Fuel pressure regulator assembly
        2. Engine coolant temperature sensor
        3. Mass air flow meter sub-assembly
        4. ECM
        5. Fuel injector assemblies
        6. Throttle position sensor (built into throttle with motor body assembly)
      4. Faulty EGR


61. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
  1. Engage the 3 grommets to install the No. 1 engine cover sub-assembly.



62. INSTALL COOL AIR INTAKE DUCT SEAL
  1. Install the cool air intake duct seal with the 9 clips.



63. INSPECT SHIFT LEVER POSITION
(Click here)


64. INSTALL FRONT FENDER APRON SEAL LH
  1. Install the front fender apron seal LH with the 2 bolts and clip.



65. INSTALL FRONT FENDER APRON SEAL RH
  1. Install the front fender apron seal RH with the 2 bolts and clip.



66. INSTALL ENGINE UNDER COVER LH
  1. Install the engine under cover LH with the 3 screws and 2 clips.



67. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
  1. Install the front wheel opening extension pad LH with the 3 screws.



68. INSTALL ENGINE UNDER COVER RH
  1. Install the engine under cover RH with the 3 screws and 3 clips.



69. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
  1. Install the front wheel opening extension pad RH with the 3 screws.



70. INSTALL FRONT WHEELS

Torque:
103 N*m{ 1049 kgf*cm , 76 ft.*lbf }


71. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(Click here)


72. INSPECT SPEED SENSOR SIGNAL
(Click here)