ENGINE ASSEMBLY > INSTALLATION

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1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


A108860

  1. Using a 19 mm deep socket wrench, install the temperature sensor.

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



2. INSTALL OIL PRESSURE SWITCH ASSEMBLY


A110658

  1. Using a 24 mm deep socket wrench, install the oil pressure switch.

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }

    NOTICE:
    Do not start the engine within 1 hour after installation.



3. INSTALL ENGINE OIL LEVEL SENSOR

  1. Install the engine oil level sensor and a new gasket with the 4 bolts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



4. INSTALL IGNITION COIL ASSEMBLY

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

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



5. INSTALL OIL FILLER CAP SUB-ASSEMBLY


6. INSTALL ENGINE MOUNTING BRACKET RH

  1. Install the mounting bracket with the 4 bolts.

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



7. INSTALL ENGINE MOUNTING BRACKET LH

  1. Install the mounting bracket with the 4 bolts.

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



8. INSTALL KNOCK SENSOR


A103957E01

  1. Install the 2 knock sensors so that they are horizontal as shown in the illustration. Then install the 2 bolts.

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

    HINT:
    It is acceptable for the sensor to be tilted +10° to -5°.



9. INSTALL FUEL INJECTOR ASSEMBLY


  1. Install a new O-ring, new backup rings (No. 1, No. 2, No. 3) and new E-ring to the fuel injector as shown in the illustration.


    A103999E01

    NOTICE:
    1. Check that there is no foreign matter or damaged areas in the injector's O-ring groove.
    2. Check that the installation direction of the No. 1 and No. 2 backup ring 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.

  1. Install the injector nozzle holder clamp.



    A104000

  1. Apply gasoline to the O-ring. Install the nozzle holder clamp by aligning the protruding part of the clamp to the notch of the delivery pipe.

    NOTICE:
    1. Make sure there is no gap between the delivery pipe and clamp.
    2. Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
    3. Insert the injector straight into the delivery pipe without tilting it.



10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

  1. Install a new injector vibration insulator to the cylinder head.

  1. Apply lubricant to the installation hole of the injector.



    A105909

  1. Insert the stud bolt into the fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

    NOTICE:
    1. If an injector is dropped, replace it with a new one.
    2. Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
    3. Be extremely careful not to touch or strike the tips of the injectors.
    4. When inserting the fuel delivery pipe, push it in evenly without tilting it.



    A103985E01

  1. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

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

  1. Connect the 3 connectors and 2 clamps.



11. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

  1. Install a new injector vibration insulator to the cylinder head.

  1. Apply lubricant to the installation hole of the injector.



    A105910

  1. Insert the stud bolt into the No. 2 fuel delivery pipe until the screw threads protrude enough so that a nut can be attached.

    NOTICE:
    1. If an injector is dropped, replace it with a new one.
    2. Check that there is no foreign matter or damage in the injector insertion hole of the delivery pipe.
    3. Be extremely careful not to touch or strike the tips of the injectors.
    4. When inserting the fuel delivery pipe, push it in evenly without tilting it.



    A103983E01

  1. Install the fuel delivery pipe by uniformly tightening the 2 bolts and 2 nuts in several passes in the order shown in the illustration.

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

  1. Connect the 3 connectors and 3 clamps.



12. 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.



13. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY


A104006

  1. Install the fuel pipe to the delivery pipe with the 2 bolts.

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



14. 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.



15. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY


A108642

  1. Install 2 new gaskets, the fuel main tube and pulsation damper to the fuel pump.

    Torque:
    40 N*m{ 408 kgf*cm , 28 ft.*lbf }



16. INSTALL INTAKE MANIFOLD


A103979E04

  1. Install a new gasket and the intake manifold with the 4 bolts and 2 nuts.

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



17. INSTALL INTAKE AIR SURGE TANK SUB-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 }



18. INSTALL NO. 4 WATER BY-PASS PIPE

  1. Install the water by-pass pipe with the bolt.

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



19. INSTALL NO. 3 WATER BY-PASS PIPE

  1. Install the water by-pass pipe with the bolt.

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



20. INSTALL REAR ENGINE COVER SUB-ASSEMBLY


A109616

  1. Install the engine cover with the 3 clips.



21. CONNECT NO. 2 WATER BY-PASS HOSE


22. CONNECT NO. 1 WATER BY-PASS HOSE


23. INSTALL INJECTOR DRIVER


A105899

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

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



24. 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 }



25. 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 }



26. 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 }



27. 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.



28. 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.



29. 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.



30. INSTALL OIL DIPSTICK GUIDE 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.



31. INSTALL ENGINE WIRE

  1. Install the engine wire to the engine assembly.



32. REMOVE ENGINE ASSEMBLY

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



33. INSTALL FRONT ENGINE MOUNTING INSULATOR


A108858E02

  1. Install the front suspension crossmember sub-assembly with the 2 bolts.

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



34. 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.



35. 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.



36. INSTALL ENGINE AND TRANSMISSION ASSEMBLY


A108856

  1. Remove the No. 1 and No. 2 engine hangers.

  1. Set the engine lifter.

  1. Operate the engine lifter, then install the engine to the vehicle.



    A109620E02

  1. Install the engine and transmission assembly with crossmember with the 12 bolts.

    Torque:
    167 N*m{ 1,700 kgf*cm , 123 ft.*lbf } for bolt A
    204 N*m{ 2,080 kgf*cm , 150 ft.*lbf } for bolt B
    50 N*m{ 510 kgf*cm , 37 ft.*lbf } for bolt C
    49 N*m{ 500 kgf*cm , 36 ft.*lbf } for bolt D



    C104745

  1. Install the engine rear mounting member with the 4 bolts.

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



37. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY


    C104743

  1. Temporarily tighten the floor shift gear shifting rod sub-assembly with the nut.



38. INSTALL POWER STEERING LINK WIRE HARNESS


    C105532

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

    Torque:
    118 N*m{ 1,200 kgf*cm , 87 ft.*lbf }



    C105531E01

  1. Install the power steering earth wire to the power steering link assembly with bolt (B).

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Connect wire harness connector (E) to the power steering link assembly and securely lock the connector.

  1. Connect 2 wire harness connectors (C) and (D) to the power steering link assembly.

  1. Install the 2 wire harness clamps to the power steering link assembly.

  1. Connect the earth wire to the bracket with bolt (A).

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



39. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    C105528E01

  1. Align the matchmarks on the intermediate shaft assembly No.2 and the power steering link assembly.



    C105527E03

  1. Install bolt (A) and tighten the 2 bolts.

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



40. INSTALL FRONT LOWER BALL JOINT BOLT RH


41. INSTALL FRONT LOWER BALL JOINT BOLT LH


42. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH


    C105333E01

  1. Install the front shock absorber with front coil spring on the vehicle by tightening the 3 nuts on the suspension support side.

    Torque:
    67 N*m{ 683 kgf*cm , 49 ft.*lbf }



    C110619E01

  1. Insert the bolt from the rear of the vehicle, and install the front shock absorber lower side on the front suspension lower arm.

  1. Temporarily tighten the nut while holding the bolt.



    C105332E01

  1. Tighten a lock nut.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



43. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH


    C105333E01

  1. Install the front shock absorber with front coil spring on the vehicle by tightening the 3 nuts on the suspension support side.

    Torque:
    67 N*m{ 683 kgf*cm , 49 ft.*lbf }



    C110619E01

  1. Insert the bolt from the rear of the vehicle, and install the front shock absorber lower side on the front suspension lower arm.

  1. Temporarily tighten the nut while holding the bolt.



    C105332E01

  1. Tighten a lock nut.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }



44. INSTALL TIE ROD ASSEMBLY RH

HINT:
Perform the same procedure as for the LH side.



45. INSTALL TIE ROD ASSEMBLY LH

  1. Connect the tie rod end LH to the steering knuckle with the nut.

    Torque:
    65 N*m{ 663 kgf*cm , 50 ft.*lbf }

  1. Install a new clip.

    NOTICE:
    If the holes for the clip are not aligned, tighten the nut up to 60° further.



46. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER

  1. Install the protector with the 4 bolts.

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



47. CONNECT HEIGHT CONTROL SENSOR LINK

  1. Connect the height control sensor link and install it with the nut.

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



48. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY


A109604

  1. Using an E8 "torx" socket, install the compressor with the stud bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 89 ft.*lbf }



    A109520

  1. Install the compressor with the 3 bolts and nut.

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



49. INSTALL V-RIBBED BELT


    A109593

  1. Install the V-ribbed belt.

  1. While turning the belt tensioner counterclockwise, remove the bar.

    NOTICE:
    1. Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley.
    2. Check that the V-ribbed belt is properly set to each pulley.



    A107548E02

  1. If it is difficult to install the V-ribbed belt, perform the following procedure.

    1. Put the V-ribbed belt on everything except the tensioner pulley as shown in the illustration.

    2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the tensioner pulley.

      NOTICE:
      1. Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley.
      2. Check that the V-ribbed belt is properly set to each pulley.



50. CONNECT ENGINE WIRE

  1. Connect the ground cable and install it with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 89 ft.*lbf }



    A108748

  1. Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Install the engine room No. 1 relay block cover.

  1. Connect the battery positive (+) cable and install it with the nut.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Connect the ECM connectors.

  1. Connect the connector holder.



51. INSTALL ECM COVER


A105290

  1. Install the ECM cover with the 3 bolts.

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



52. CONNECT 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.



53. CONNECT HEATER WATER OUTLET HOSE A


A107679

  1. Connect the outlet hose.



54. CONNECT HEATER WATER INLET HOSE A


A107676

  1. Connect the inlet hose.



55. CONNECT UNION TO CHECK VALVE HOSE


A107674

  1. Connect the hose to the surge tank.



56. CONNECT RADIATOR RESERVE TANK HOSE


57. CONNECT RADIATOR HOSE INLET

  1. Connect the hose to the water inlet with thermostat and radiator tank upper.



58. CONNECT RADIATOR HOSE OUTLET

  1. Connect the hose to the water inlet and radiator tank lower.



59. INSTALL AIR CLEANER ASSEMBLY WITH HOSE

  1. Tighten the hose clamp.

  1. Install the air cleaner cap together with the 3 bolts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



    A103949

  1. Install the VSV (for EVAP) to the air cleaner hose.



    A103948

  1. Connect the MAF meter connector and clamp to the air cleaner.



    A103947

  1. Connect the ventilation hose to the cylinder head cover with the clamp.



60. INSTALL NO. 1 AIR CLEANER INLET


A107673

  1. Install the air cleaner inlet with the bolt.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



61. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    C109590E01

  1. Remove the SST from the transmission.

    SST
    09325-40010  

  1. Insert the yoke of the intermediate shaft into the transmission.

    HINT:
    Be careful not to damage the oil seal.



    F048233

  1. Install the 2 center support bearing washers and center support bearing, and temporarily tighten the 2 bolts.



    C104521E01

  1. Align the matchmarks on the propeller shaft flange and differential companion flange, and connect the shaft with the 4 bolts, washers and nuts.

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



    C109187E01

  1. Adjust the dimension between the edge surface of the center support bearing and the edge surface of the cushion to 11.5 to 13.5 mm (0.4528 to 0.5315 in.) respectively as shown in illustration.



    C109375E01

  1. Check that the center line of the bracket is at right angles to the shaft axial direction.



    F048233

  1. Tighten the 2 bolts.

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



62. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    A077857

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

    Minimum length:
    38.5 mm (1.516 in.)

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



    A109513E01

  1. Install a new gasket to the rear side of the front exhaust pipe.

    HINT:
    Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and front exhaust pipe are properly fit.

    NOTICE:
    1. Be careful with the installation direction of the gasket.
    1. Do not reuse the gasket.
    1. To ensure a proper seal, do not use the tailpipe to force the gasket onto the front exhaust pipe.



    A106753

  1. Install 2 new gaskets and the exhaust pipe front ends to the exhaust manifold with the 4 bolts and 2 nuts.

    Torque:
    62 N*m{ 632 kgf*cm , 46 ft.*lbf }

    NOTICE:
    Do not reuse the gaskets.

  1. Install the front exhaust pipe to the tailpipe with the 2 compression springs and 2 bolts.

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



63. INSTALL NO. 2 ENGINE UNDER COVER

  1. Install the under cover with the 4 screws, 2 grommets and 2 spacers.



64. INSTALL ENGINE UNDER COVER


B107493

  1. Install the under cover with the 3 clips and 10 screws.



65. INSTALL V-BANK COVER SUB-ASSEMBLY


A103946

  1. Install the V-bank cover with the 2 nuts.

    Torque:
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }



66. INSTALL ENGINE ROOM COVER SIDE RH


A105933E01

  1. Install the side cover with the 2 clips and nut.



67. INSTALL ENGINE ROOM SIDE COVER LH


A105934E01

  1. Install the side cover with the 3 clips.



68. INSTALL COOL AIR INTAKE DUCT SEAL


A105932E01

  1. Install the intake duct seal with the 7 clips.



69. INSTALL FRONT WHEEL


70. 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.



71. 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.



72. 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.



73. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


74. 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.



75. 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.



76. CHECK AND ADJUST FRONT WHEEL ALIGNMENT


    C107735E01

  1. Bounce the vehicle at the corners up and down to stabilize the suspension and inspect vehicle height.

    Toe-in:
    Toe-in
    (total)
    		A - B: 1+- 2 mm (0.04 +- 0.08 in.)

    HINT:
    If toe-in is not within the specified range, adjust it at the rack ends.



77. 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.



78. 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.



79. 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



80. CHECK FOR ENGINE OIL LEAKS


81. CHECK FOR ENGINE COOLANT LEAKS


82. CHECK FOR FUEL LEAKS


83. CHECK ENGINE OIL LEVEL


84. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL


85. CHECK ENGINE COOLANT LEVEL