OIL PUMP > INSTALLATION

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1. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

  1. Apply seal packing in a continuous bead to the engine unit as shown in the following illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent
    Seal diameter:
    5.0 to 5.5 mm (0.197 to 0.217 in.)

    NOTICE:
    1. Be sure to clean and degrease the contact surfaces, especially 7 areas indicated by C in the illustration.
    2. When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.
    3. Install the cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    4. Do not start the engine for at least 2 hours after installing.


      A106259E02



  1. Apply seal packing in a continuous bead to the timing chain cover as shown in the following illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent
    Seal packing:
    Part No. 08826-00100 or equivalent

    NOTICE:
    1. When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.
    2. Install the cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.


    Apply seal packing as follows:

    Area
    		Seal Packing Diameter
    		Application Position from Inside Seal Line
    Continuous Line Area
    		3.5 to 4.0 mm (0.138 to 0.158 in.)
    		3.0 to 4.0 mm (0.118 to 0.158 in.)
    Alternate Long and Short Dashed Line Area
    		3.5 to 4.0 mm (0.138 to 0.158 in.)
    		2.0 to 3.0 mm (0.079 to 0.118 in.)
    Dashed Line Area
    		4.0 to 5.0 mm (0.158 to 0.197 in.)
    		1.0 to 2.0 mm (0.039 to 0.079 in.)



    A106260E02



    A108817

  1. Install a new gasket.



    A094904E01

  1. Align the oil pump drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.



    A106153E01

  1. Install the timing chain cover with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf } for bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for except bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for nut

    NOTICE:
    Make sure that there is no oil on the bolt threads.



    A108825

  1. Install the wiring harness bracket with the bolt.

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



2. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH (for Bank 1)


A094646E02

  1. Apply seal packing as shown in the illustration.

    Seal packing:
    08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the crankcase within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.

  1. Install the gasket to the head cover.



    A095596E02

  1. Install the head cover with the 14 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } for bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolts except A



3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (for Bank 2)


A094647E02

  1. Apply seal packing as shown in the illustration.

    Seal packing:
    08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the crankcase within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.

  1. Install the gasket to the head cover.



    A094649E02

  1. Install the head cover with the 14 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } for bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolts except A



4. INSTALL NO. 2 OIL PIPE


A109709

  1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

  1. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install oil pipe (on the head cover side).

  1. Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil check valve bolt.

  1. Tighten the oil pipe union (on the head cover side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }

  1. Tighten the oil check valve bolt (on the cylinder head side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }



5. INSTALL NO. 1 OIL PIPE


A109708

  1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

  1. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install oil pipe (on the head cover side).

  1. Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil check valve bolt.

  1. Tighten the oil pipe union (on the head cover side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }

  1. Tighten the oil check valve bolt (on the cylinder head side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }



6. INSTALL IGNITION COIL ASSEMBLY

  1. Install the 6 ignition coils with the 6 bolts.

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



7. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY


  1. Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown in the illustration.


    A106023E01

    NOTICE:
    1. Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
    2. Check that the installation directions of the No. 1 and No. 2 backup rings are correct.
    3. Make sure the backup rings and O-ring are installed in the correct order.
    4. Check that the alignment openings of the backup rings are not overlapped or stretched as shown in the illustration.
    5. After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.
    6. Check that the No. 3 fuel pipe installation end is not contaminated with foreign matter and is not damaged.

  1. Apply gasoline to the O-ring and connect the fuel pipe to the delivery pipe.

    NOTICE:
    Do not install the bolt at this time.



8. INSTALL HIGH PRESSURE SIDE FUEL PUMP


    A104008E01

  1. Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

    HINT:
    When installing the fuel pump using the procedure described above: By not using the crankshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.

  1. Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.



    A104009E02

  1. Apply a coat of engine oil to the pump activation cam and pump lifter part.



    A104010E01

  1. Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set it on the insulator.

    NOTICE:
    Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.

  1. Install the union nut of the No. 1 fuel pipe without damaging its seal surface. Tighten the nut as much as possible by hand.



    A104011

  1. Install the 2 nuts and tighten them in several passes.

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

  1. Connect the fuel hose.



9. INSTALL FUEL MAIN TUBE


A108621E01

NOTICE:
Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.

  1. Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.



    A109549E01

  1. Check that the connector and fuel main pipe are securely connected by trying to pull them apart.



    A103961

  1. Install the fuel pipe clamp.



10. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY


    A103981

  1. Install the No.1 fuel pipe with the 2 bolts.

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

  1. Connect the fuel pipe hose.



11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY


A103978E01

  1. Install a new gasket to the intake air surge tank.

  1. Install the intake air surge tank with the 2 nuts.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }

  1. Using a hexagon socket wrench 5, install the 7 bolts.

    Torque:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }

  1. Install the 2 surge tank stays with the 4 bolts.

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

  1. Install the intake manifold stay with the 2 bolts.

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



12. INSTALL OIL STRAINER SUB-ASSEMBLY


  1. Using an E6 "torx" socket, install the stud bolts as shown in the illustration.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }



    A095995E03



    A094463E02

  1. Install a new gasket and the oil strainer with the 3 nuts.

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

  1. Install 2 new O-rings.



13. INSTALL OIL PAN SUB-ASSEMBLY


A109786E02

  1. When replacing a stud bolt, install it by using an E6 "torx" socket wrench.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }



    A109751E04

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3.0 to 4.0 mm (0.118 to 0.156 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the crankcase within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.



    A109706E03

  1. Install the oil pan with the 16 bolts and 2 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } for bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolts except A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for nut



14. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


A109753E04

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3.0 to 4.0 mm (0.118 to 0.156 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the crankcase within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.



    A095044E03

  1. Install the oil pan with the 15 bolts and 2 nuts.

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

  1. Install a new gasket and the drain plug.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }



15. INSTALL CRANKSHAFT PULLEY


A094448E01

  1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.

  1. Using SST, install the pulley bolt.

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

    Torque:
    250 N*m{ 2,550 kgf*cm , 184 ft.*lbf }



16. INSTALL WATER INLET ASSEMBLY


A109711

  1. Install 2 new O-rings.

  1. Apply soapy water to the O-ring.

  1. Install the water inlet with the 4 bolts and nut.

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

  1. Install the 3 water by-pass hose.



17. INSTALL INJECTOR DRIVER


A105899

NOTICE:
  1. Be careful not to drop or strike the injector driver.
  2. The injector driver is grounded at the bolt and nut. To ensure that it is grounded, clean all oil and foreign matter from the installation areas of the injector driver and engine before installing the injector driver.

  1. Install the injector driver with the bolt and 2 nuts.

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



18. INSTALL WATER PUMP PULLEY


A094892E01

  1. Temporarily install the pulley with the 4 bolts.

  1. Using SST, hold the pulley and tighten the 4 bolts.

    SST
    09960-10010   (09962-01000, 09963-00700)

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



19. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


A111049E01

  1. Temporarily install the V-ribbed belt tensioner with the 4 bolts.

    Each bolt length is as follows:
    Mark
    		Specified Length
    A
    		70 mm (2.76 in.)
    B
    		33 mm (1.30 in.)

  1. Tighten bolt 1 shown in the illustration.

    Torque:
    43 N*m{ 439 kgf*cm , 32 ft.*lbf }

  1. Tighten the other bolts.

    Torque:
    43 N*m{ 439 kgf*cm , 32 ft.*lbf }



20. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

  1. Install the plate and idler pulley with the bolt.

    Torque:
    43 N*m{ 439 kgf*cm , 32 ft.*lbf }



21. INSTALL GENERATOR ASSEMBLY


A106509

  1. Install the generator with the 2 bolts.

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



    A106507

  1. Install the bracket with the bolt and nut.

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



    A106506E04

  1. Install the battery cable with the nut.

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

  1. Install the bracket of the wire harness to the generator with the bolt.

  1. Attach the clamp of the wire harness to the generator.

  1. Connect the cable to the generator, and then attach the rubber cap.



22. REMOVE ENGINE STAND

  1. Remove the bolts and engine from the engine stand.



23. INSTALL FRONT ENGINE MOUNTING INSULATOR

  1. Install the mounting bracket with the 4 bolts.

    Torque:
    43 N*m{ 439 kgf*cm , 32 ft.*lbf }



24. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


A094447E01

  1. Using SST, hold the crankshaft.

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

  1. Apply adhesive to 2 or 3 threads of the mounting bolts end.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent

  1. Install the front spacer, drive plate and rear spacer on the crankshaft.



    A095047E01

  1. Install and tighten the 8 mounting bolts uniformly in several steps.

    Torque:
    83 N*m{ 850 kgf*cm , 61 ft.*lbf }

    NOTICE:
    Do not start the engine for at least 1 hour after installing.



25. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY


    C110860E01

  1. Install the automatic transmission assembly to the engine with the 9 bolts.

    Torque:
    Bolts A and B:
    71 N*m{ 724 kgf*cm , 52 ft.*lbf }
    Bolt B:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

    HINT:
    Make sure that the mark is positioned as shown in the illustration.



26. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


A108863E01

  1. Install a new gasket as shown in the illustration.



    A109531E01

  1. Install the exhaust manifold with the 6 nuts.

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

    NOTICE:
    Do not damage the stud bolt when installing the exhaust manifold.

    HINT:
    First tighten either of the 2 nuts indicated by the arrows in the illustration.



27. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


A108864E01

  1. Install a new gasket as shown in the illustration.



    A109532E01

  1. Install the exhaust manifold with the 6 nuts.

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

    NOTICE:
    Do not damage the stud bolt when installing the exhaust manifold.

    HINT:
    First tighten either of the 2 nuts indicated by the arrows in the illustration.



28. INSTALL OIL DIPSTICK SUB-ASSEMBLY


A110659

  1. Install a new O-ring to the oil dipstick guide.

  1. Apply a light coat of engine oil to the O-ring.

  1. Push in the oil dipstick guide end into the guide hole.

  1. Install the No. 1 oil dipstick guide with the bolt.

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

  1. Install the No. 2 oil dipstick guide with the bolt.

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

  1. Install the oil dipstick.



29. INSTALL ENGINE WIRE

  1. Install the engine wire to the engine assembly.



30. INSTALL ENGINE AND TRANSMISSION

  1. Install the engine and transmission to the vehicle body (Click here).



31. ADD ENGINE OIL

  1. Add new oil.

    Oil capacity:
    Condition
    		Capacity
    Drain and refill with oil filter change
    		6.3 liters (6.7 US qts, 5.5 imp. qts)
    Drain and refill without oil filter change
    		5.9 liters (6.2 US qts, 5.2 imp. qts)
    Dry fill
    		7.2 liters (7.6 US qts, 6.3 imp. qts)

  1. Install the oil filter cap.



32. ADD AUTOMATIC TRANSMISSION FLUID


  1. Add the automatic transmission fluid following the flow chart below.


    C104890E03



  1. When adding the maximum amount of fluid: [*1]

    1. Lift up the vehicle.



      2. C106915

    2. Remove the 2 bolts and transmission case cover.



      3. C112102E01

    3. Remove the refill plug and overflow plug.



      4. C112103E01

    4. Add ATF through the refill hole until it drains out from the overflow hole.

      NOTICE:
      Be sure to use ATF WS.



      5. C112104E01

    5. Install a new gasket and the overflow plug.

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

    6. Add proper amount of ATF through the refill hole.

      NOTICE:
      Refill amount differs depending on the related procedures indicated below.
      Related procedures
      		Refill amount
      Removal and installation of oil pan
      (Including the oil drain)
      		1.1 liters (1.2 US qts, 1.0 lmp.qts)
      Removal of transmission valve body assembly
      		2.5 liters (2.6 US qts, 2.2 lmp.qts)
      Removal of torque converter assembly
      		4.2 liters (4.4 US qts, 3.7 lmp.qts)



      7. C112678E01

    7. Install a new O-ring and the refill plug.

      Torque:
      39 N*m{ 400 kgf*cm , 53 ft.*lbf }

    8. Lower the vehicle.



      9. C101492E01

    9. Using SST, create a short-circuit between terminals TC and CG of the DLC3.

      SST
      09843-18040  

    10. Start the engine.

      NOTICE:
      1. Be sure to place the key inside the cabin in order to start the engine.
      2. Turn the A/C off.

    11. Slowly move the shift lever from the P to the S position, shift the gear from 1st to 6th and then return the shift lever to the P position.

    12. Switch to the fluid temperature detection mode.

      1. Move the shift lever from the N to the D position, or from D to N, within 1.5 seconds.
      2. Continue this procedure for 6 seconds or more.

      Standard:
      Meter indicator light "D" comes on for 2 seconds and then goes off.

    13. Return the shift lever to the P position and disconnect terminal TC after confirming the above condition.

    14. Idle the engine to raise fluid temperature.



      15. G031805E06

    15. Lift up the vehicle immediately after meter indicator light "D" comes on.

      NOTICE:
      1. Add fluid only when the meter indicator light is on.
      2. Perform this procedure while the engine is idling.



      16. C112104E01

    16. Remove the overflow plug. If ATF overflows, proceed to [*2].
      If ATF does not overflow, proceed to [*3].

      HINT:
      "Overflow" indicates the condition under which ATF drains out from the overflow tube.



    C112105E01

  1. When fluid overflows: [*2]

    NOTICE:
    Capacity of the overflow tube is approximately 3 cc.


    1. Install a new gasket and the overflow plug when the draining ATF has become a trickle.

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

      NOTICE:
      Be careful when handling the drained ATF as it will be hot.

    2. Install a new O-ring and tighten the refill plug.

      Torque:
      39 N*m{ 400 kgf*cm , 29 ft.*lbf }



      3. C106915

    3. Install the transmission case cover with the 2 bolts.

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

    4. Lower the vehicle.

    5. Turn the engine switch off and remove the SST.



    C112678E01

  1. When fluid does not overflow:[*3]

    1. Remove the refill plug.



      2. C112103E01

    2. Add ATF through the refill hole until it drains out from the overflow hole.



      3. C112105E01

    3. Install a new gasket and the overflow plug when the draining ATF has become a trickle.

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

    4. Install a new O-ring and tighten the refill plug.

      Torque:
      39 N*m{ 400 kgf*cm , 29 ft.*lbf }



      5. C106915

    5. Install the transmission case cover with the 2 bolts.

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

    6. Lower the vehicle.

    7. Turn the engine switch off and remove the SST.



    C101492E01

  1. When adding a minimum amount of fluid: [*4]

    1. Using SST, create a short-circuit between terminals TC and CG of the DLC3.

      SST
      09843-18040  

    2. Start the engine.

      NOTICE:
      1. Be sure to place the key inside the cabin in order to start the engine.
      2. Turn the A/C off.

    3. Slowly move the shift lever from the P to the S position, shift the gear from 1st to 6th and then return the shift lever to the P position.

    4. Switch to the fluid temperature detection mode.

      1. Move the shift lever from the N to the D position, or from D to N, within 1.5 seconds.
      2. Continue this procedure for 6 seconds or more.

      Standard:
      Meter indicator light "D" comes on for 2 seconds and then goes off.

    5. Return the shift lever to the P position and disconnect terminal TC after confirming the above condition.

    6. Idle the engine to raise fluid temperature.



      7. G031805E06

    7. Lift up the vehicle immediately after meter indicator light "D" comes on.

      NOTICE:
      1. Add fluid only when the meter indicator light is on.
      2. Perform the procedure while the engine is idling.



      8. C112104E01

    8. Remove the overflow plug. If ATF overflows, proceed to [*5]. If ATF does not overflow, proceed to [*6].

      HINT:
      "Overflow" indicates the condition under which ATF drains out from the overflow tube.



    C112105E01

  1. When fluid overflows: [*5]

    1. Install a new gasket and the overflow plug when the draining ATF has become a trickle.

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

      NOTICE:
      Be careful when handling the drained ATF as it will be hot.



      2. C106915

    2. Install the transmission case cover with the 2 bolts.

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

    3. Lower the vehicle.

    4. Turn the engine switch off and remove the SST.



    C112678E01

  1. When fluid does not overflow: [*6]

    1. Remove the refill plug.



      2. C112103E01

    2. Add ATF through the refill hole until it drains out from the overflow hole.



      3. C112105E01

    3. Install a new gasket and the overflow plug when the draining ATF has become a trickle.

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

    4. Install a new O-ring and tighten the refill plug.

      Torque:
      39 N*m{ 400 kgf*cm , 29 ft.*lbf }



      5. C106915

    5. Install the transmission case cover with the 2 bolts.

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

    6. Lower the vehicle.

    7. Turn the engine switch off and remove the SST.



33. ADD ENGINE COOLANT

NOTICE:
Before adding engine coolant, turn the A/C switch OFF.

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

    Torque:
    12.7 N*m{ 130 kgf*cm , 9 ft.*lbf } for cylinder block drain cock plug

  1. Add engine coolant.

    Specified capacity:
    9.1 liters (9.6 US qts, 8.0 lmp. qts)

    NOTICE:
    When pressing the radiator hose:
    1. Wear protective gloves.
    1. Be careful as the radiator hose is hot.
    1. Keep your hands away from the radiator fan.

    HINT:
    1. 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 consists of a combination of low phosphates and organic acids).
    1. Please contact your TOYOTA dealer for further details.
    1. The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

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

  1. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.

  1. Install the radiator cap and reservoir cap.

  1. Bleed air from the cooling system.

    NOTICE:
    Before starting the engine to warm up the engine, turn the A/C switch OFF.


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

      HINT:
      The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

      NOTICE:
      When pressing the radiator hoses:
      1. Wear protective gloves.
      1. Be careful as the radiator hoses are hot.
      1. Keep your hands away from the radiator fan.

    2. Maintain the engine speed at 2,000 to 2,500 rpm.

    3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

      NOTICE:
      When pressing the radiator hoses:
      1. Wear protective gloves.
      1. Be careful as the radiator hoses are hot.
      1. Keep your hands away from the radiator fan.

  1. 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.



    A106564E01

  1. Check the coolant level in the radiator reservoir.
    If the coolant level is low, add SLLC to the radiator reservoir FULL line.



34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


35. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

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



36. CHECK SHIFT LEVER POSITION

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

  1. Start the engine and make sure that the vehicle moves forward when shifting from the N to the D position and moves rearward when shifting to the R position.
    If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition.



37. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

  1. Measure the thread lengths of the right and left rack ends.

    Standard:
    Difference in thread lengths is 1.5 mm (0.059 in.) or less

  1. Remove the rack boot set clips.

  1. Loosen the tie rod end lock nuts.

  1. Adjust the rack ends if the difference in thread length between the right and left rack ends is not within the specified range.

    1. Extend the shorter rack end if the measured toe-in deviates toward the outer-side.

    2. Shorten the longer rack end if the measured toe-in deviates toward the inner-side.

  1. Turn the right and left rack ends by an equal amount to adjust toe-in.

    HINT:
    Try to adjust toe-in to the center of the specified range.



    C113082

  1. Make sure that the lengths of the right and left rack ends are the same.

  1. Tighten the tie rod end lock nuts.

    Torque:
    56 N*m{ 571 kgf*cm , 41 ft.*lbf }

    NOTICE:
    Temporarily tighten the lock nut while holding the hexagonal part of the steering rack end so that the lock nut and the steering rack end do not turn together. Hold the width across flat of the tie rod end and tighten the lock nut.

  1. Place the boots on the seats and install the clips.

    NOTICE:
    Perform VGRS calibration after adjusting toe-in.

    HINT:
    Make sure that the boots are not twisted.



38. CHECK IGNITION TIMING

  1. Warm up the engine and stop the engine.

    NOTICE:
    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.



    A103811E09

  1. When using the intelligent tester:

    1. Connect the intelligent tester to the DLC3.

    2. Start the engine and idle it.

    3. Push the intelligent tester main switch ON.

    4. Enter the following items: Powertrain / Engine and ECT / Data list / IGN Advance.

      Ignition timing:
      5 to 15° BTDC @ idle

      HINT:
      Please refer to the intelligent tester operator's manual for further detail.



  1. When not using the intelligent tester:

    1. Remove the V-bank cover.



      2. A109590

    2. Connect the tester probe of a timing light to the wire of the ignition connector for the No. 1 cylinder.

      HINT:
      Use a timing light that detects the first signal.



      3. A082779E23

    3. Using SST, connect the terminals TC and CG of the DLC3.

      SST
      09843-18040  

      NOTICE:
      1. Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
      2. When checking the ignition timing, the transmission should be in the neutral.



      4. A107549

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

      Ignition timing:
      8 to 12° BTDC @ idle

    5. Remove the SST from the DLC3.

    6. Check the ignition timing.

      Ignition timing:
      5 to 15° BTDC @ idle

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

    8. Disconnect the timing light from the engine.

    9. Install the V-bank cover.



39. CHECK IDLE SPEED

  1. Warm up and stop the engine.

    NOTICE:
    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 rpm should be stabilized.



    A103811E09

  1. When using the intelligent tester:

    1. Connect the intelligent tester to the DLC3.

      NOTICE:
      Switch off all accessories and A/C before connecting the intelligent tester.

    2. Race the engine speed at 2,500 rpm for approximately 90 seconds.

    3. Push the intelligent tester main switch ON.

    4. Enter the following items: Powertrain / Engine and ECT / Data list / Engine SPD.

      Idle speed:
      600 to 700 rpm

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

      HINT:
      Please refer to the intelligent tester operator's manual for further details.

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

    5. Disconnect the intelligent tester from the DLC3.



    A082779E24

  1. When not using the intelligent tester:

    1. Using SST, connect the tachometer probe to terminal TAC of the DLC3.

      SST
      09843-18040  

      NOTICE:
      Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

    2. Race the engine speed at 2,500 rpm for approximately 90 seconds.

    3. Check the idle speed.

      Idle speed:
      600 to 700 rpm (Transmission neutral position)

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

    4. Disconnect the tachometer from the DLC3.



40. CHECK CO/HC

HINT:
This check for determining whether or not the idle CO / HC complies with regulations.

  1. Start the engine.

  1. Keep the engine speed at 2,500 rpm for approximately 180 seconds.



    A105823

  1. Insert CO / HC meter testing probe at least 40 cm (1.3 ft.) into tailpipe during idling.

  1. Immediately check CO / HC concentration at idle and / or 2,500 rpm.

    HINT:
    1. When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations.
    2. If the CO / HC concentration does not comply with regulations, troubleshoot in the order given below.


    1. Check the A/F sensor and heated oxygen sensor operation.

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

      CO
      		HC
      		Symptom
      		Causes
      Normal
      		High
      		Rough idle
      1. 1. Faulty ignitions
      1. Incorrect timing
      1. Fouled, shorted or improperly gapped plugs
      1. 2. Leaky intake and exhaust valves
      1. 3. Leaky cylinder
      Low
      		High
      		Rough idle
      (Fluctuating HC reading)
      1. 1. Vacuum leaks
      1. PCV hose
      1. Intake manifold
      1. Throttle body
      1. 2. Lean mixture causing misfire
      High
      		High
      		Rough idle
      (Black smoke from exhaust)
      1. 1. Restricted air filter
      1. 2. Faulty fuel SFI system
      1. Faulty pressure
      1. Defective ECT sensor
      1. Faulty ECM
      1. Faulty injector
      1. Faulty throttle position sensor
      1. Faulty MAF sensor



41. CHECK FOR ENGINE OIL LEAKS


42. CHECK FOR ENGINE COOLANT LEAKS


43. CHECK FOR FUEL LEAKS


44. CHECK ENGINE OIL LEVEL


45. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL


46. CHECK ENGINE COOLANT LEVEL