CYLINDER HEAD > INSTALLATION

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1. INSPECT CYLINDER HEAD SET BOLT


    A078721E01

  1. Using vernier calipers, measure the tension portion diameter of the bolt.

    Standard outside diameter:
    8.95 to 9.05 mm (0.3524 to 0.3563 in.)

    Minimum outside diameter:
    8.75 mm (0.3445 in.)

    If the diameter is less than the minimum, replace the bolt.



2. INSTALL CYLINDER HEAD GASKET NO.2


    A108733E01

  1. Place a new cylinder head gasket on the cylinder block with the L mark upward.

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Be careful to install the gasket in the correct direction.
    3. Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.



3. INSTALL CYLINDER HEAD LH

NOTICE:
The cylinder head bolts are tightened in 2 successive steps.

  1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

  1. Install the plate washer to the cylinder head bolt.



    A078719E02

  1. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.

    SST
    09011-38121  

    Torque:
    54 N*m{ 550 kgf*cm , 40 ft.*lbf }



    A078730E01

  1. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.

  1. Retighten the cylinder head bolts by 90° in the same sequence as step (c).

  1. Check that each painted mark is now at 90° angle to the front.



    A078718E01

  1. Using a socket hexagon wrench 8 mm, install the hexagon bolt.

    Torque:
    19 N*m{ 189 kgf*cm , 14 ft.*lbf }



    A108141E02

  1. Using several steps, install and tighten the 2 bolts and intake air connector bracket No.2 uniformly in the sequence shown in the illustration.

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

  1. Connect the ground cable with the 2 bolts.

    Torque:
    Nut A:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }
    Nut B:
    11 N*m{ 112 kgf*cm , 97 in.*lbf }



4. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078741E01

  1. Place the No.4 camshaft at 90° angle of the timing mark (1-dot mark) on the cylinder head.

  1. Apply MP grease to a new oil seal lip.



    A078742E01

  1. Install the oil seal to the camshaft.

    NOTICE:
    1. Do not turn over the oil seal lip.
    2. Insert the oil seal until it stops.

  1. Remove any old packing material from the contact surface.



    A078737E01

  1. Apply seal packing to the No.1 bearing cap as shown in the illustration.

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Install the No.1 bearing cap within 5 minutes after applying seal packing.
    2. Do not expose the seal to engine oil within 2 hours after installing.



    A005209E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078743E01

  1. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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



5. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078744E01

  1. Align the timing marks (1-dot mark) of the camshaft drive gear with the mark on the driven gear.

  1. Place the camshaft on the cylinder head.



    A005214E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078745E01

  1. Using several steps, install and tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

  1. Remove the service bolt.



6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    A078674E01

  1. Apply seal packing to the cylinder head as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes after applying seal packing.
    3. Do not start the engine within 2 hours after installing.



    A108159

  1. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.

    Torque:
    8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



    A108125

  1. Install the 2 brackets with the 2 bolts.



    A114812

  1. Install the 2 engine wire harness clamps.

    CAUTION:
    Wear insulating gloves.



    A036719

  1. Using an E6 "torx" socket wrench, install the engine wire harness protector with the 2 bolts.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



7. INSTALL WATER INLET PIPE


    A080823

  1. Install a new O-ring to the water inlet pipe.

  1. Apply soapy water to the O-ring.

  1. Connect the water inlet pipe to the water inlet.

  1. Install the bolt which is used to fix the water inlet pipe to the cylinder head with the bolt.

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



8. INSTALL OIL LEVEL GAUGE GUIDE

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

  1. Apply soapy water to the O-ring.

  1. Push in the oil level gauge guide end into the guide hole of the cylinder block.



    A108140

  1. Install the oil level gauge guide with the bolt.

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

  1. Install the oil level gauge.



9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2


    A108153E01

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



    A078402E02

  1. Install the exhaust manifold converter No.2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.

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

  1. Retighten nuts 1 and 2 shown in the illustration.



10. CONNECT COOLING FAN ECU

  1. Connect the 2 bolts and cooling fan ECU.

    Torque:
    2.6 N*m{ 26 kgf*cm , 23 in.*lbf }



11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2


    A108154

  1. Install the 2 bolts and exhaust manifold heat insulator No.2.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }



12. INSTALL MANIFOLD CONVERTER INSULATOR NO.3


    A108736

  1. Install the bolt, nut and manifold converter insulator No.3.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }



13. INSTALL CYLINDER HEAD GASKET


    A078324E01

  1. Place a new cylinder head gasket on the cylinder block with the R mark upward.

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Be careful to install the gasket in the correct direction.
    3. Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.



14. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE:
The cylinder head bolts are tightened in 2 successive steps.

  1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

  1. Install the plate washers to the cylinder head bolts.



    A078717E02

  1. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.

    SST
    09011-38121  

    Torque:
    54 N*m{ 550 kgf*cm , 40 ft.*lbf }



    A078730E01

  1. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.

  1. Retighten the cylinder head bolts by 90° in the same sequence as step (c).

  1. Check that each painted mark is now at 90° angle to the front.



    A078716E01

  1. Using a socket hexagon wrench 8 mm, install the hexagon bolt.

    Torque:
    19 N*m{ 189 kgf*cm , 14 ft.*lbf }

  1. Connect the engine wire harness clamp with the nut.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



15. INSTALL NO.2 CAMSHAFT

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078735E01

  1. Place the No.2 camshaft at 90° angle of the timing mark (2-dot mark) on the cylinder head.

  1. Apply MP grease to a new oil seal lip.



    A078736E01

  1. Install the oil seal to the camshaft.

    NOTICE:
    1. Do not turn over the oil seal lip.
    2. Insert the oil seal until it stops.

  1. Remove any old packing material from the contact surface.



    A078737E01

  1. Apply seal packing to the No.1 bearing cap as shown in the illustration.

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Install the No.1 bearing cap within 5 minutes after applying seal packing.
    2. Do not expose the seal to engine oil within 2 hours after installing.



    A005283E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078738E01

  1. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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



16. INSTALL CAMSHAFT

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. Apply new engine oil to the thrust portion and journal of the camshaft.



    A078739E01

  1. Align the timing marks (2-dot mark) of the camshaft drive gear with the mark on the driven gear.

  1. Place the camshaft on the cylinder head.



    A005204E01

  1. Install the 5 bearing caps in their proper locations.

  1. Apply a light coat of engine oil to the threads of the bearing cap bolts.



    A078740E01

  1. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.

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

  1. Remove the service bolt.



17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    A078673E01

  1. Apply seal packing to the cylinder head as shown in the illustration.

    Seal packing:
    Part No.08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head cover within 3 minutes after applying seal packing.
    3. Do not start the engine within 2 hours after installing.



    A108160

  1. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.

    Torque:
    8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



    A078541

  1. Install the engine wire harness with the 3 nuts and 2 clamps.

    Torque:
    8.4 N*m{ 85 kgf*cm , 74 in.*lbf }



18. INSTALL IGNITION COIL ASSEMBLY

Torque:
8.0 N*m{ 80 kgf*cm , 71 in.*lbf }



19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    A108151E01

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



    A078400E02

  1. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.

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

  1. Retighten nuts 1 and 2 shown in the illustration.



20. INSTALL MANIFOLD STAY

  1. Temporarily install the manifold stay to the exhaust manifold and transaxle.

  1. Fully tighten the 2 bolts.

    Torque:
    34 N*m{ 347 kgf*cm , 25 ft.*lbf }



21. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    A108152

  1. Install the 3 bolts and exhaust manifold heat insulator No.1.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }



22. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3


    A077857

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

    Minimum length:
    41.5 mm (1.634 in.)

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



    A078440E01

  1. Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.



    A109431

  1. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.

    Torque:
    Bolt:
    48 N*m{ 490 kgf*cm , 35 ft.*lbf }
    Nut:
    56 N*m{ 571 kgf*cm , 41 ft.*lbf }

  1. Connect the heated oxygen sensor connector.



23. INSTALL EXHAUST PIPE ASSEMBLY FRONT


    A109430

  1. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.

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

  1. Connect the heated oxygen sensor connector.



24. INSTALL TIMING BELT NO.3 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.

    HINT:
    If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.



    A078748E01

  1. If the timing belt cover gasket is needed to repair, follow the procedure below.

    1. Repair the cracks and breaks by applying the seal packing to the damaged area.

      Seal packing:
      Part No.08826-00080 or equivalent

      NOTICE:
      When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.



  1. If the timing belt cover gasket is needed to replace, follow the procedure below.

    1. Using a screwdriver and gasket scraper, remove the remaining gasket.

      NOTICE:
      Do not damage the timing belt cover.



      2. A078749E01

    2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

      NOTICE:
      1. Affix the gasket in the center of the groove.
      2. At the corners, try to keep the gasket thickness uniform.

      HINT:
      Gasket length
      Gasket
      		D
      		E
      		F
      		G
      Length
      		335 mm
      (13.19 in.)
      		180 mm
      (7.09 in.)
      		133 mm
      (5.24 in.)
      		72 mm
      (2.83 in.)

    3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.

      Seal packing:
      Part No.08826-00080 or equivalent

      NOTICE:
      When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.



    A108157E01

  1. Install the timing belt cover No.3 with the 6 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 76 in.*lbf }



25. INSTALL CAMSHAFT TIMING PULLEY


    A078750E01

  1. Paying attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.

    HINT:
    1. Face the belt guide of the RH timing pulley toward front of the engine.
    2. Face the belt guide of the LH timing pulley toward rear of the engine.



    A108162E01

  1. Using SST, tighten the RH pulley bolt.

    SST
    09960-10010   (09962-01000, 09963-01000)
    09249-63010  

    Torque:
    125 N*m{ 1,275 kgf*cm , 92 ft.*lbf }

    NOTICE:
    The torque indicated above is for using SST without any extension tool. If extension tools are used, find the reading of the torque wrench by the formula (Click here).

    Extended length:
    SST (09249-63010) 150 mm (5.91 in.)



    A108164E01

  1. Using SST, tighten the LH pulley bolt.

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

    Torque:
    125 N*m{ 1,275 kgf*cm , 92 ft.*lbf }



26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2

  1. Install the timing belt idler sub-assembly No.2.

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



27. INSPECT TIMING BELT

NOTICE:
  1. Do not bend, twist or turn the timing belt inside out.
  2. Do not allow the timing belt to come into contact with oil, water or steam.
  3. Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects as shown in the illustration. Also, check the points below.


    EM03336E02

  1. If there is premature parting:

    1. Check for proper installation.
    2. Check the timing cover gasket for damage and proper installation.

  1. If the belt teeth are cracked or damaged, check if either camshaft is locked.

  1. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.

  1. If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.

  1. If there is noticeable wear on the belt teeth:

    1. Check the timing cover for damage.
    2. Check that the gasket has been installed correctly.
    3. Check for foreign object on the pulley teeth.
    If there is any trouble in the belt condition, replace the timing belt.



28. INSTALL TIMING BELT

  1. Remove any oil or water on the pulleys, and keep them clean.

    NOTICE:
    1. If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
    2. Wipe only the pulleys; do not use any cleaning agent.

  1. Inspect the idler pulleys.

    1. Check that the idler pulley turns smoothly.

    2. Visually check the seal portion of the idler pulley for oil leakage.

  1. Inspect the water pump.

    1. Turn the pulley, and check that the water pump bearing moves smoothly and does not make any noise.

    2. Visually check the drain hole for coolant leakage.

  1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.



    A082349E01

  1. Turn the crankshaft counterclockwise by approximately 60°.

    NOTICE:
    To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.



    A078751E01

  1. Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No.3 timing belt cover.

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

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.



    A005062E01

  1. Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.



    A052840E01

  1. Face the front mark on the timing belt forward.

  1. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.

  1. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.



    A078702E02

  1. Install the timing belt in the following order.
    1st
    		Crankshaft timing pulley
    2nd
    		Water pump pulley
    3rd
    		LH camshaft timing pulley
    4th
    		No.2 idler pulley
    5th
    		RH camshaft timing pulley
    6th
    		No.1 idler pulley

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.



29. INSTALL CHAIN TENSIONER ASSEMBLY NO.1

  1. Set the timing belt tensioner upright on the press.



    A036238E01

  1. Slowly press in the push rod.

    NOTICE:
    Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.

  1. Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Release the press.

  1. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.

    Torque:
    27 N*m{ 280 kgf*cm , 20 ft.*lbf }

    NOTICE:
    Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause improper operation.

  1. Remove the 1.5 mm hexagon wrench from the tensioner.



    A078326E01

  1. Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body.

    NOTICE:
    Always turn the crankshaft clockwise.



    A005052E01

  1. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No.3 timing belt cover as shown in the illustration.
    If the marks do not align, remove the timing belt and reinstall it.

  1. Remove the crankshaft pulley bolt.



30. INSTALL TIMING BELT GUIDE NO.2


    A036239E01

  1. Install the timing belt guide with the cup side facing toward the engine front.



31. INSTALL ENGINE MOUNTING BRACKET RH


    A108728

  1. Install the engine mounting bracket RH with the 2 bolts and 2 nuts.

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



32. INSTALL TIMING BELT NO.2 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.



    A108158E01

  1. Install the timing belt cover with the 5 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Connect the 2 clamps.



33. INSTALL TIMING BELT NO.1 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.

  1. Install the timing belt cover.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Install the engine wire protector cover to the timing belt No.3 cover.



34. INSTALL CRANKSHAFT PULLEY


    A108137E01

  1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.

  1. Using SST, install the pulley bolt.

    SST
    09213-54015   (91651-60855)
    09330-00021  

    Torque:
    220 N*m{ 2,250 kgf*cm , 162 ft.*lbf }



35. INSTALL ENGINE MOUNTING STAY NO.2 RH


    A108727

  1. Install the engine mounting stay No.2 and the engine mounting bracket No.2 with the bolt.

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



36. INSTALL ENGINE MOVING CONTROL ROD


    A108130E01

  1. Temporarily tighten bolts B and C.

  1. First tighten bolt A, bolt B, then bolt C in this order.

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

  1. Tighten bolt D.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }



37. INSTALL AIR CLEANER BRACKET


    A108129

  1. Install the 2 bolts and air cleaner bracket.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }



38. INSTALL RESERVOIR BRACKET


    A108127

  1. Install the 2 bolts, nut and reservoir bracket.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the clamp.



39. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY


    A108126

  1. Install the 2 bolts and brake master cylinder reservoir to the bracket.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

  1. Connect the connector.



40. INSTALL WATER OUTLET

  1. Install 2 new gaskets to the 2 cylinder heads.

  1. Install the water outlet together with water by-pass hose No.1 and unlock the hose clamp.

  1. Tighten the 2 bolts, 2 nuts and 2 washers.

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

  1. Install the clamp.

  1. Connect the engine coolant temperature sensor connector.

  1. Connect the radiator hose inlet.



41. CONNECT RADIATOR HOSE INLET


42. INSTALL INTAKE MANIFOLD


    A108291E01

  1. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

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

  1. Retighten the water outlet mounting bolts and nuts.

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

  1. Install the ground cable with the nut.

    Torque:
    8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

  1. Connect the heater inlet water hose.



43. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1


    A081133

  1. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel tube sub-assembly to the fuel delivery pipe.

  1. Install the EFI fuel pipe clamp.



44. INSTALL INTAKE AIR SURGE TANK

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



    A109274E02

  1. Using a socket hexagon wrench 8 mm, install the intake manifold with the 4 bolts and 2 nuts . Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

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

  1. Connect the ground cable connector.



    A109273E02

  1. Install the surge tank stay No. 2 (A) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the surge tank stay No. 1 (B) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the engine hunger No. 1 (C) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }



    A109268

  1. Connect the ventilation hose.



    A106879E02

  1. Connect the fuel vapor feed hose (A).

  1. Connect the water by-pass hose No.3 (B).

  1. Connect the water by-pass hose No.2 (C).

  1. Connect the throttle motor connector (D).



45. INSTALL EMISSION CONTROL VALVE SET


    A109272E02

  1. Install the emission control valve set with the 2 nuts (A).

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

  1. Connect the fuel vapor feed hose No.2 (B).

  1. Connect the fuel vapor feed hose No.1 (C).

  1. Connect the wire harness clamp (D).

  1. Connect the VSV connector (E).



46. INSTALL W/ CONVERTER INVERTER ASSEMBLY
(Click here)


47. INSTALL AIR CLEANER CASE W/ RESONATOR


    A109267

  1. Install the air cleaner hose No.1 to the throttle body assembly with the hose clamp.



    A106878

  1. Install the air cleaner case w/ resonator with the 5 bolts.

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



    A109270

  1. Connect the MAF meter connector.

  1. Connect the 2 wire harness clamps to the air cleaner.



    A109893

  1. Connect the ventilation hose No.2.



48. INSTALL AIR CLEANER CAP W/ INLET

  1. Install the air cleaner filter element to the air cleaner case.



    A108124

  1. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

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



49. INSTALL COOL AIR INTAKE DUCT SEAL

  1. Install the 4 clips and cool air intake duct seal.



50. INSTALL BATTERY CARRIER SUB-ASSEMBLY


    A108128

  1. Install the 5 bolts and battery carrier.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



51. INSTALL BATTERY

  1. Install the battery clamp and battery.

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



52. INSTALL SERVICE PLUG GRIP

NOTICE:
Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.



    A115547

  1. Wear insulation gloves, then insert the service plug.

  1. Push down on the grip to lock.

  1. Close the battery service hole cover.

    NOTICE:
    Check that the 2 battery service hole cover clips are securely connected to the battery carrier bracket (click sound).



53. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. Remove the 4 shock absorber nuts.



    A112528E01

  1. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

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

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).



54. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY


    E110471

  1. Install the windshield wiper motor and link assembly with the 5 bolts.

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

  1. Connect the connector.



55. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


56. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH


    B108016E03

  1. Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069045E01

  1. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.



57. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH


    B108016E03

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069046E01

  1. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.



58. INSTALL ENGINE UNDER COVER NO.2

  1. Install the 2 bolts and engine under cover No.2.



59. INSTALL FRONT FENDER APRON SEAL RH


    A108724

  1. Install the 2 bolts, clip and fender apron seal RH.



60. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    A109416

  1. Install the fender splash shield with the screw.



61. INSTALL ENGINE UNDER COVER NO.1


    A108722

  1. Install the 6 bolts, 2 screws, 2 clips and engine under cover.



62. INSTALL FRONT WHEEL RH


63. ADD ENGINE OIL


64. CHECK FOR FUEL LEAKS

  1. Connect the intelligent tester to the DLC3.

  1. Turn the ignition switch to the ON position and turn the intelligent tester on.

    NOTICE:
    Do not start the engine.

  1. Select the Active Test mode on the intelligent tester to operate the fuel pump.

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

  1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.



65. ADD COOLANT (Hybrid side)


    C109302

  1. Loosen the bleeder plug shown in the illustration and connect a hose.

    NOTICE:
    Insert one end of the hose into the reserve tank.

  1. Add coolant from the reserve tank.



    C109303E01

  1. Add coolant until the level of coolant in the hose attached to the bleeder plug reaches the same level as the FULL line of the reserve tank.

    Coolant quantity:
    3.4 L (3.6 US qts, 3.0 Imp. qts.)



  1. When using the intelligent tester:



      E109221E03

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to the ON position.

    3. Select the inspection mode (Click here).

    4. On the tester, enter the following menus: Powertrain / Hybrid Control / Active test / Water Pump.

    5. Keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds.

      Standard:
      Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

      HINT:
      Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

  1. When not using the intelligent tester:

    1. Put the vehicle into the READY-on state. [*1]

    2. Turn the ignition switch off and add coolant to the FULL level because the coolant level drops as the air bleeds. [*2]

      NOTICE:
      1. Be sure to turn the ignition switch off before adding LLC.
      2. Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.

    3. Repeat steps [*1] and [*2] until air bleeding from the coolant system is completed.

      Standard:
      Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

      HINT:
      Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

  1. When the air is completely bled from the coolant system, tighten the plug.



    C109304

  1. Add coolant to the FULL mark of the reserve tank.



66. ADD COOLANT (Engine side)

  1. Tighten the lower drain plug of the radiator.

  1. Loosen the upper drain plug of the radiator.



    A080492E01

  1. Install a vinyl tube to the vent plug located on the upper drain plug.

  1. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

  1. Tighten the upper drain plug.

    CAUTION:
    1. Do not use an alcohol type coolant or plain water alone.
    2. The coolant must be mixed with plain water (preferably de-mineralized water).

      Capacity:
      9.7 liters (10.3 US qts, 8.5 lmp.qts)

    HINT:
    1. Improper coolants may damage engine cooling system.
    2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
    3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
    4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.

  1. Install the radiator cap securely.

  1. Fill the radiator reservoir tank with coolant.

  1. Warm up the engine.

    HINT:
    Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

  1. Stop the engine and wait until the coolant cools down.

  1. Remove the radiator cap and check the coolant level inside the radiator.

  1. If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

  1. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.



67. CHECK FOR ENGINE OIL LEAKS


68. CHECK FOR ENGINE COOLANT LEAKS (Hybrid side)


69. CHECK FOR ENGINE COOLANT LEAKS (Engine side)


A078989

CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Fill the radiator with coolant and attach a radiator cap tester.

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.



70. CHECK FOR EXHAUST GAS LEAKS


71. INSPECT IGNITION TIMING

  1. Set the vehicle to inspection mode (Click here).

  1. Warm up the engine.

  1. When using the intelligent tester:

    1. Connect the intelligent tester (with CAN VIM) to the DLC3.

    2. Enter DATA LIST MODE on the intelligent tester.

      Ignition timing:
      8 to 12° BTDC

      NOTICE:
      1. Turn all the electrical systems off.
      2. Inspect the engine idle speed with the cooling fan off.

      HINT:
      Refer to the intelligent tester operator's manual if you need help to select DATA LIST.

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



    A051075E02

  1. When not using the intelligent tester:

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

      SST
      09843-18040  

      NOTICE:
      1. Make sure of the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
      2. Turn off all electrical systems before connecting the terminals.
      3. Perform this inspection after the cooling fan motor is turned off.



      2. A108139

    2. Pull out the red-colored wire harness as shown in the illustration.

    3. Connect the tester terminal of the timing light to the engine.

      NOTICE:
      Use a timing light which detects the first signal.

    4. Inspect ignition timing at idle.

      Ignition timing:
      8 to 12° BTDC

      NOTICE:
      When checking the ignition timing, the transmission is in neutral.

      HINT:
      Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that the engine rpm returns to idle speed.

    5. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

    6. Inspect ignition timing at idle.

      Ignition timing:
      7 to 24° BTDC

    7. Confirm that the ignition timing advances when the engine rpm is increased.

    8. Remove the timing light.



72. INSPECT ENGINE IDLE SPEED

  1. Set the vehicle to inspection mode (Click here).

  1. Warm up the engine.

  1. Connect the intelligent tester (with CAN VIM) to the DLC3.

  1. Enter DATA LIST MODE on the intelligent tester.

    Idle speed:
    850 to 950 rpm.

    NOTICE:
    1. When checking the idle speed, the transmission is in neutral.
    2. Check the idle speed with the cooling fan off.
    3. Switch off all accessories and air conditioning before connecting the intelligent tester.

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



73. INSPECT COMPRESSION

  1. Set the vehicle to inspection mode (Click here).

  1. Warm up and stop the engine.

  1. Remove the intake air surge tank (Click here).

    NOTICE:
    If the throttle body connector is disconnected because the DTC is detected in inspection, always reconnect it.

  1. Disconnect the injector connectors.

  1. Remove the ignition coils.

    NOTICE:
    If the ignition coil assembly connector is disconnected because the DTC is detected in inspection, always reconnect it.

  1. Remove the spark plugs.



  1. Inspect cylinder compression pressure.



      P019471E01

    1. Insert a compression gauge into the spark plug hole.

    2. Connect the intelligent tester (with CAN VIM) to the DLC3.

      NOTICE:
      Check the fully charged battery to indicate HV battery voltage in ECU data monitor.

    3. Enter ACTIVE TEST MODE on the intelligent tester.

    4. While cranking the engine, measure the compression pressure.

      Compression pressure:
      0.98 MPa (10 kgf/cm2, 142 psi)

      Minimum pressure:
      0.74 MPa (7.5 kgf/cm2, 107 psi)

      Difference between each cylinder:
      100 kPa (1.0 kgf/cm2, 15 psi)

      NOTICE:
      1. Check other cylinder's compression pressure in the same way.
      2. This measurement must be done as quickly as possible.
      3. After performing all the procedures, be sure to clear DTCs stored in the the memory. Then, check that the normal system code is output.

    5. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again.

      HINT:
      1. If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.
      2. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage past the gasket.



74. INSPECT CO/HC

  1. Set the vehicle to inspection mode (Click here).

  1. Start the engine.

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



    A109836

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

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

    HINT:
    When doing the 2 mode (with the engine is in the idle and 2,500 rpm) test, the measuring procedures are prescribed by the applicable local regulations.

    If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.

    1. Check heated oxygen sensor operation (Click here).

    2. Check heated air fuel ratio sensor operation (Click here).

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

      CO
      		HC
      		Problems
      		Causes
      Normal
      		High
      		Rough idle
      1. Faulty ignitions:
        1. Incorrect timing
        2. Fouled, shorted or improperly gapped plugs
      2. Incorrect valve clearance
      3. Leaks in intake and exhaust valves
      4. Leaks in cylinders
      Low
      		High
      		Rough idle
      (Fluctuating HC reading)
      1. Vacuum leaks:
        1. PCV hoses
        2. Intake manifold
        3. Throttle body
        4. Brake booster line
      2. Lean mixture causing misfire
      High
      		High
      		Rough idle
      (Black smoke from exhaust)
      1. Restricted air filter
      2. Plugged PCV valve
      3. Faulty EFI systems:
        1. Faulty pressure regulator
        2. Defective water temperature sensor
        3. Defective mass air-flow meter
        4. Faulty ECM
        5. Faulty injectors
        6. Faulty throttle position sensor



75. PERFORM INITIALIZATION

  1. Some system need initialization when reconnecting the battery cable. (Click here)



76. INSTALL ENGINE ROOM COVER SIDE


    A109835

  1. Install the 5 clips and engine room cover side



77. INSTALL ENGINE ROOM SIDE LH COVER


    A108719

  1. Fit the clips and install the engine room side LH cover.