ENGINE ASSEMBLY > INSTALLATION

for Preparation Click here

NOTICE:

When the manual transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

HINT:

Only perform this procedure when replacement of the transverse engine engine mounting insulator is necessary.

1. Temporarily install the transverse engine engine mounting insulator with the 5 bolts.
   

2. Fully tighten the 5 bolts in the order shown in the illustration.
   

   Torque:

   52 N*m{ 530 kgf*cm , 38 ft.*lbf }

HINT:

Only perform this procedure when replacement of the engine mounting insulator RH is necessary.

1. Temporarily install the engine mounting insulator RH with the 3 bolts.
   

2. Fully tighten the 3 bolts in the order shown in the illustration.
   

   Torque:

   52 N*m{ 530 kgf*cm , 38 ft.*lbf }

1. Apply MP grease to the lip of a new inner oil seal.
   

   NOTICE:

   Keep the lip free from foreign matter.

2. Using SST and a hammer, tap in the inner oil seal until its surface is flush with the ring gear sub-assembly.
   

   SST

   09950-70010   (09951-07150)
   09951-01600  
   

   Oil seal tap in depth:

   14.7 to 15.7 mm (0.5787 to 0.6181 in.)
   

   NOTICE:

   1. Uniformly tap in the oil seal.
      
   2. Do not tap the oil seal at an angle.
      

1. Install the ring gear sub-assembly.
   

   NOTICE:

   Do not forcefully pry the ring gear sub-assembly during installation.

2. Using a screwdriver, install a new snap ring.
   

   NOTICE:

   Confirm that the snap ring is correctly located in the groove of the crankshaft bearing.

1. Install a new one-way clutch O-ring.
   

1. Turn the one-way clutch assembly counterclockwise while installing it.
   

1. Using SST, hold the crankshaft.
   

   SST

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

2. Clean the 8 bolts and their holes.
   

3. Apply adhesive to 2 or 3 end threads of each bolt tip.
   

   Text in Illustration 

   *1

   Adhesive

   Adhesive:

   Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent
   

4. Temporarily install the front flywheel plate spacer, the flywheel and the rear flywheel plate spacer with the 8 bolts.
   

   Text in Illustration 

   *1	Front Flywheel Plate Spacer
   *2	Flywheel
   *3	Rear Flywheel Plate Spacer
   	Engine
   	Transaxle

   HINT:

   1. The front spacer is reversible.
      
   2. As the rear flywheel plate spacer and the flywheel are not reversible, be sure to install them in the direction shown in the illustration.
      

5. Fully tighten the 8 bolts in the order shown in the illustration.
   

   Torque:

   78 N*m{ 795 kgf*cm , 57 ft.*lbf }

   NOTICE:

   Do not start the engine for at least an hour after installing the flywheel.

1. Insert SST into the clutch disc assembly, and then insert them both into the flywheel sub-assembly.
   

   Text in Illustration 

   *1	Clutch disc
   *2	Flywheel

   SST

   09301-00210  
   

   NOTICE:

   Insert the clutch disc assembly in the correct direction.

1. Align the matchmark on the clutch cover assembly with that on the flywheel sub-assembly.
   

   Text in Illustration 

   *a	Temporarily
   *b	Matchmark

2. Following the procedures shown in the illustration, tighten the 6 bolts in order, starting with the bolt located near the knock pin at the top.
   

   SST

   09301-00210  
   

   Torque:

   19 N*m{ 195 kgf*cm , 14 ft.*lbf }

   HINT:

   1. Following the order in the illustration, tighten the bolts evenly one at a time.
      
   2. Move SST up and down, right and left lightly after checking that the disc is in the center, and tighten the bolts.
      

1. Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.
   

   Maximum non-alignment:

   0.5 mm (0.020 in.)
   

2. If the alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
   

   SST

   09333-00013  
   

1. Clean and degrease all installation surfaces for the clutch release with bearing cylinder assembly.
   

2. Temporarily tighten the bleeder clutch release tube onto the clutch release with bearing cylinder assembly.
   

3. Install the new clutch release with the bearing cylinder with the 3 new bolts.
   

   NOTICE:

   1. The clutch release with bearing cylinder assembly and installation bolts cannot be reused and must be replaced with new ones.
      
   2. Clean and degrease all installation surfaces and make sure the clutch release with bearing cylinder assembly fits securely with the transaxle during installation. The first bolt should be tightened by hand the clutch release with bearing cylinder assembly when installing.
      
   3. Ensure that none of the clutch disc spline grease adheres to the clutch release with bearing cylinder assembly.
      
   4. The clutch release with bearing cylinder assembly cannot be disassembled.
      

   Torque:

   23 N*m{ 229 kgf*cm , 17 ft.*lbf }

4. Install the clutch tube boot onto the transaxle.
   

5. Install the release cylinder bleeder plug onto the clutch release bleeder.
   

   Torque:

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

6. Install the release cylinder bleeder plug cap.
   

7. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.
   

   Text in Illustration 

   *1	Bleeder clutch release tube
   *2	Clutch release bleeder

8. Temporarily tighten the 2 bolts and install the clutch release bleeder.
   

9. Using a union nut wrench 10 mm, install the bleeder clutch release tube.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).

1. Separate the bleeder clutch release tube from the clutch release bleeder.
   

2. Remove the 2 bolts and the clutch release bleeder.
   

1. Using SST, apply pressure of 0.1 MPa to the clutch pipe location shown in the illustration and confirm that pressure is maintained for 15 seconds or more.
   

   SST

   09992-00242  
   

   If the pressure drops, replace the bleeder clutch release tube.
   

1. Temporarily tighten the bleeder clutch release tube onto the clutch release bleeder.
   

   Text in Illustration 

   *1	Bleeder clutch release tube
   *2	Clutch release bleeder

2. Install the 2 bolts and clutch release bleeder.
   

   Torque:

   17 N*m{ 170 kgf*cm , 12 ft.*lbf }

3. Using a union nut wrench 10 mm, install the bleeder clutch release tube.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).

1. Install the bleeder clutch release tube with the bolt.
   

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

2. Using a union nut wrench 10 mm, install the bleeder clutch release tube.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Use the formula to calculate special torque values for situations when union nut wrench is combined with a torque wrench (Click here).

1. Hook the outer lever to the low fixture lever of the reverse restrict pin to secure it.
   

2. Make sure that the knock pins are not loose, bent, damaged or scratched and then install the transaxle onto the engine with the contact surfaces of the engine and transaxle flat against each other.
   

3. Align the input shaft with the clutch disc and install the manual transaxle onto the engine.
   

4. Install the 10 bolts.
   

   Torque:

   Bolt A:

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

   Bolt B (for Flange Bolt):

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

   Bolt B (for Bolt with Washer):

   33 N*m{ 337 kgf*cm , 24 ft.*lbf }

   Bolt C:

   39 N*m{ 398 kgf*cm , 29 ft.*lbf }

   NOTICE:

   Insert knock pins into the knock pin holes securely so that the end face of the transaxle assembly fits close against the engine assembly before tightening the bolts.

1. Using SST, hold the crankshaft.
   

   SST

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

2. Clean the 8 bolts and their holes.
   

3. Apply adhesive to 2 or 3 end threads of each bolt tip.
   

   Text in Illustration 

   *1

   Adhesive

   Adhesive:

   Toyota Genuine Adhesive 1324, Three bond 1324 or equivalent
   

4. Temporarily install the front drive plate spacer, the drive plate and the rear drive plate spacer with the 8 bolts.
   

   Text in Illustration 

   *1	Front Drive Plate Spacer
   *2	Drive Plate
   *3	Rear Drive Plate Spacer
   	Engine
   	Transaxle

   HINT:

   1. The front spacer is reversible.
      
   2. As the rear drive plate spacer and the drive plate are not reversible, be sure to install them in the direction shown in the illustration.
      

5. Fully tighten the 8 bolts in the order shown in the illustration.
   

   Torque:

   88 N*m{ 897 kgf*cm , 65 ft.*lbf }

   NOTICE:

   Do not start the engine for at least an hour after installing the drive plate.

1. Confirm that 2 knock pins are on the transaxle contact surface of the engine cylinder block before transaxle installation.
   

   Text in Illustration 

   *1	Knock Pin
   *2	Crankshaft

2. Apply clutch spline grease to the round of the crankshaft contact surface (*3) with the torque converter centerpiece.
   

   Clutch spline grease:

   Toyota Genuine Clutch Spline Grease or equivalent
   

   Maximum spread:

   Approximately 1 g (0.353 oz)
   

3. Maintain the engine and CVT in a horizontal position, align the knock pins and holes (*4), and tighten the 9 bolts shown the illustration.
   

   Torque:

   *1:

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

   *2:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

   *3:

   39 N*m{ 398 kgf*cm , 29 ft.*lbf }

   NOTICE:

   1. Confirm that there are 2 knock pins on the fitting surface of the engine block before installing the CVT.
      
   2. Do not twist or apply excessive force to the CVT.
      
   3. Check that the torque converter rotates smoothly after installation of the CVT.
      

   HINT:

   Bolt length
   1. *1: 45 mm (1.77 in.)
      
   2. *2: 45 mm (1.77 in.)
      
   3. *3: 35 mm (1.38 in.)
      

1. Clean and degrease the 6 drive plate and torque converter setting bolts.
   

2. Apply adhesive to 2 or 3 threads on the ends of the 6 torque converter set bolts.
   

   Text in Illustration 

   *1

   Adhesive

   Adhesive:

   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
   

3. Use SST to hold the crankshaft pulley in place.
   

   SST

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

4. Install the 6 torque converter set bolts.
   

   Torque:

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

   HINT:

   Tighten the black-colored bolt first, and then tighten the 5 silver-colored bolts.

1. Install the starter assembly with the 2 bolts.
   

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

2. Connect the connector.
   

3. Connect terminal 30 with the nut.
   

   Torque:

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

4. Close the terminal cap.
   

1. Insert the protruding portion into the end of the cylinder block and while pushing it along the cylinder block, fit the claw into the cylinder block.
   

   NOTICE:

   1. Make sure that the claw makes a click sound, indicating that it fits tightly.
      
   1. Replace the claw with a new one if it does not fit tightly or is deformed.
      

1. Install the drive shaft heat insulator bracket onto the engine with the 2 bolts.
   

   Torque:

   16 N*m{ 166 kgf*cm , 12 ft.*lbf }

1. Install the engine wire onto the engine assembly with transaxle.
   

2. Install the ground wire onto the transaxle with the bolt.
   

   Torque:

   13 N*m{ 130 kgf*cm , 9 ft.*lbf }

3. Install the nut to the generator.
   

   Torque:

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

4. Install the terminal cap to the generator.
   

5. Install the engine wire onto the wiring harness bracket with the bolt .
   

   Torque:

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

6. Install the nut to the starter.
   

   Torque:

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

7. Install the 2 ground wires onto the cylinder block with the 2 bolts.
   

   Torque:

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

1. Install the No. 2 radiator hose with the clip.
   

   Text in Illustration 

   *a	View A
   *b	Upper
   *c	Clip installation range

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

1. Install the water filler with the bolt.
   

   Torque:

   13 N*m{ 127 kgf*cm , 9 ft.*lbf }

1. Install the No. 1 radiator hose with the 2 clips.
   

   Text in Illustration 

   *a	View A
   *b	View B
   *c	Upper
   *d	Rear of Vehicle
   *e	Front of Vehicle
   *f	Clip installation range

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

1. Install the inlet heater water hose with the clip.
   

   Text in Illustration 

   *a	View A
   *b	Upper
   *c	Front
   *d	Clip installation range

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

1. Install the water by-pass hose with the clip.
   

   Text in Illustration 

   *a	View A
   *b	Upper
   *c	Clip installation range
   *d	Paint mark of the hose
   *e	Hose clamp
   *f	Stopper

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

2. Engage the hose clamp.
   

1. Install the water by-pass hose with the 2 clips.
   

   Text in Illustration 

   *a	View A
   *b	View B
   *c	Upper
   *d	Clip installation range
   *e	Paint mark of the hose
   *f	Hose clamp
   *g	Stopper

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

2. Engage the hose clamp.
   

3. Connect the 2 water by-pass hoses to the oil cooler with the 2 clips.
   

   Text in Illustration 

   *a	View A
   *b	View B
   *c	Rear of Vehicle
   *d	Clip installation range

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

4. Install the water by-pass hose onto the CVT with the bolt.
   

   Torque:

   29 N*m{ 296 kgf*cm , 21 ft.*lbf }

5. Engage the clamp and install the breather hose to the water by-pass hose.
   

1. Set the engine assembly with transaxle on the engine lifter.
   

2. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator RH and transverse engine engine mounting insulator can be installed.
   

   CAUTION:

   Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

   NOTICE:

   1. Make sure that the engine is clear of all wiring and hoses.
      
   2. While raising the engine into the vehicle, do not allow it to contact the vehicle.
      

3. Install the transverse engine engine mounting insulator with the through bolt and nut.
   

   Torque:

   52 N*m{ 530 kgf*cm , 38 ft.*lbf }

4. Install the engine mounting insulator RH with the bolt and 2 nuts.
   

   Torque:

   52 N*m{ 530 kgf*cm , 38 ft.*lbf }

5. Secure the hole (A) shown in the illustration and the body with a piece of rope.
   

   Text in Illustration 

   *1

   Rope

   NOTICE:

   When installing the engine assembly with the transaxle, make sure that the engine assembly does not move to the vehicle front, to prevent it from contacting other parts.

6. Remove the 2 bolts and the 2 engine hangers.
   

1. Install the engine moving control rod with the bolt.
   

   Torque:

   100 N*m{ 1020 kgf*cm , 74 ft.*lbf }

1. Install the engine moving control rod cover with the 2 clips.
   

1. Using a "TORX" socket wrench (E8), install the compressor with the 2 stud bolts.
   

   Torque:

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

2. Install the compressor with the 2 bolts and the 2 nuts.
   

   Torque:

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

   HINT:

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

3. Connect the connector.
   

1. Remove the attached vinyl tape from the suction hose.
   

2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
   

   Compressor oil:

   ND-OIL 8 or equivalent
   

3. Install the O-ring onto the suction hose.
   

4. Connect the suction hose to the cooler compressor with the bolt.
   

   Torque:

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

1. Connect the discharge hose to the vehicle with the bolt.
   

   Torque:

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

2. Remove the attached vinyl tape from the discharge hose.
   

3. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
   

   Compressor oil:

   ND-OIL 8 or equivalent
   

4. Install the O-ring onto the discharge hose.
   

5. Connect the discharge hose to the cooler compressor with the bolt.
   

   Torque:

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

1. Support the front frame assembly with 4 wooden blocks and the jack.
   

2. Provisionally install the front frame assembly onto the body with the 6 bolts.
   
   

   
   
   
   

   Text in Illustration 

   *1	Datum Hole
   *2	OK
   *3	NG

   Bolt	Underhead Length (mm)
   A	38
   B	69

3. By inserting SST into the datum holes in the front frame assembly RH and LH alternately, tighten bolts A and B on both sides to the specified torque, in several steps.
   

   SST

   09670-00011  
   

   Torque:

   108 N*m{ 1101 kgf*cm , 80 ft.*lbf } for bolt A

   140 N*m{ 1428 kgf*cm , 103 ft.*lbf } for bolt B

   NOTICE:

   1. Insert SST into the datum hole in a vertical orientation.
      
   2. If SST can not be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.
      

4. Install the engine moving control rod to engine mounting control bracket with the bolt.
   

   Torque:

   120 N*m{ 1224 kgf*cm , 89 ft.*lbf }

5. Remove the strong rope from engine mounting control bracket and body.
   

1. Coat the spline of the inboard joint with gear oil.
   

2. Align the inboard joint splines and install the drive shaft with a screwdriver and hammer.
   

   NOTICE:

   1. Face the cut area of the front drive shaft hole snap ring downward.
      
   2. Do not damage the oil seal.
      
   3. Do not damage the inboard joint boot.
      

   HINT:

   Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

HINT:

Use the same procedure as for the LH side.

1. Install the drive shaft heat insulator with the 2 bolts and the 2 nuts.
   

   Torque:

   16 N*m{ 166 kgf*cm , 12 ft.*lbf }

1. Push the front axle out of the vehicle to align the splines of the drive shaft with the front axle and insert the front axle.
   

   NOTICE:

   1. Do not push the front axle further out of the vehicle than is necessary.
      
   2. Do not damage the outboard joint boot.
      
   3. Check for any foreign matter on the speed sensor rotor and insertion area.
      
   4. Do not damage the speed sensor rotor.
      

HINT:

The installation procedure for the RH side is the same as that for the LH side.

1. Install the lower arm onto the steering knuckle with a new castle nut.
   

   Torque:

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

   NOTICE:

   If the holes for the clip are not aligned, tighten the nut by a further turn of up to 60°.

2. Install a new clip.
   

HINT:

The installation procedure for the RH side is the same as that for the LH side.

1. Install the stabilizer link with the nut.
   

   Torque:

   74 N*m{ 755 kgf*cm , 55 ft.*lbf }

   HINT:

   If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold the stud.

HINT:

The installation procedure for the RH side is the same as that for the LH side.

1. Install the speed sensor onto the steering knuckle with the bolt.
   

   Torque:

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

   NOTICE:

   1. Check that the speed sensor tip and installation area are free of foreign matter.
      
   2. Install the speed sensor without turning it from its original installation angle.
      

2. Install the flexible hose and speed sensor with the bolt.
   

   Torque:

   Bolt A:

   29 N*m{ 296 kgf*cm , 21 ft.*lbf }

   Bolt B:

   29 N*m{ 300 kgf*cm , 22 ft.*lbf }

   NOTICE:

   Install the flexible hose and speed sensor without twisting them.

HINT:

The installation procedure for the RH side is the same as that for the LH side.

1. Clean the threaded parts on the drive shaft and axle hub nut using a non-residue solvent.
   

   NOTICE:

   1. Be sure to perform this work for a new drive shaft.
      
   2. Keep the threaded part free of oil and foreign objects.
      

2. Using a 30 mm deep socket wrench, install a new axle hub nut.
   

   Torque:

   216 N*m{ 2203 kgf*cm , 159 ft.*lbf }

3. Using a chisel and hammer, stake the axle hub nut.
   

HINT:

The installation procedure for the RH side is the same as that for the LH side.

1. Install the union to check valve hose with the clip.
   

1. Install the a new clip.
   

2. Using a union nut wrench 10 mm, connect the No. 1 clutch hose to the clutch release cylinder to flexible hose tube.
   

   Torque:

   15 N*m{ 155 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Use the formula to calculate special torque values for situations where union nut wrench is combined with a torque wrench (Click here).

1. Install the transmission control cable to the No. 1 transmission control cable bracket, using a new clip.
   

2. Using the nut, connect the transmission control cable to the transmission control shaft lever.
   

   Torque:

   12 N*m{ 122 kgf*cm , 9 ft.*lbf }

1. Install the 2 new clips <B> onto the transmission control cable.
   

2. Connect the transmission control cable with the 2 clips <A> onto the transaxle.
   

3. Put the shift lever in the reverse position and release the fixture lever.
   

   Text in Illustration 

   *1	Reverse Restrict Pin Assembly
   *2	Outer Lever
   *a	Release

1. Connect the outlet heater water hose with the clip.
   

   Text in Illustration 

   *a	View A
   *b	Upper
   *c	RH
   *d	Clip center installation range

   NOTICE:

   Install the clip so that its claws are within the clip center installation range.

1. Connect the inlet heater water hose with the clip.
   

   Text in Illustration 

   *a	View A
   *b	Upper
   *c	RH
   *d	Clip center installation range

   NOTICE:

   Install the clip so that its claws are within the clip center installation range.

1. Line up the pipe and connector and push them together until a "click" sound is heard.
   

   NOTICE:

   1. Check that there are no scratches or foreign objects on the connecting part.
      
   2. If the pipe is difficult to push into the connector, apply a small amount of clean engine oil to the tip of the pipe and reinsert it
      
   3. After connecting, check that the pipe and connector are securely connected by pulling on them.
      

1. Install the EFI fuel pipe clamp.
   

1. Connect the No. 1 fuel vapor feed hose with the clip.
   

1. Connect the radiator hose to the radiator assembly with the hose clamp.
   

   Text in Illustration 

   *1	White Paint Mark
   *a	View A
   *b	Upper Side
   *c	Projection On Radiator

   NOTICE:

   Perform the installation with the hose clip and mark at the correct angle.

1. Install the No. 3 radiator hose with the 2 clamps.
   

   Text in Illustration 

   *a	View A
   *b	View B
   *c	Upper
   *d	LH
   *e	Front of Vehicle
   *f	Clip installation range

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

1. Connect the radiator reservoir tank hose with the clip.
   

   Text in Illustration 

   *a	View A
   *b	Upper
   *c	Front of Vehicle
   *d	Clip installation range

   NOTICE:

   Install the clip so that its claws are within the clip installation range.

2. Engage the hose clamp.
   

1. Connect the earth wire with the bolt.
   

   Torque:

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

2. Connect the 4 engine wire connectors and 2 clamps to the engine room junction block.
   

3. Install the junction block cover.
   

4. Connect the 2 connectors to the battery terminal.
   

5. Connect the engine wire connector to the ECM.
   

6. Turn the lever and connect the ECM connector.
   

1. Align the 2 hinges with the guides on the case and engage them in the grooves.
   

   Text in Illustration 

   *1	Clamp
   *2	Guide

2. Install the air cleaner and hose with the 2 clamps.
   

3. Connect the air cleaner hose with the hose clamp as shown in the illustration.
   

   Torque:

   3.0 N*m{ 31 kgf*cm , 27 in.*lbf }

   Text in Illustration 

   *1	Recession
   *2	Protrusion
   *a	View A
   *b	Upper Side

   NOTICE:

   1. The clamp should contact the air cleaner hose stopper.
      
   1. Perform the installation with the hose clip at the correct angle.
      

4. Connect the ventilation hose.
   

5. Install the mass air flow meter connector and the wire harness clamp.
   

1. Install the No. 2 battery carrier with the 3 bolts.
   

   Torque:

   17 N*m{ 75 kgf*cm , 13 ft.*lbf }

2. Engage the harness clamp.
   

1. Install the battery tray.
   

1. Install the battery onto the vehicle.
   

2. Install the battery clamp with the 2 nuts.
   

   Torque:

   3.5 N*m{ 36 kgf*cm , 35 in.*lbf }

3. Connect the cable to the battery terminal.
   

   Torque:

   5.0 N*m{ 55 kgf*cm , 43 in.*lbf }

1. Install the V-ribbed belt.
   

   Text in Illustration 

   *1	V-ribbed belt
   *a	Paint Mark

   NOTICE:

   1. There are 2 types of V-ribbed belt. The type to use depends on the type of generator, so be sure to confirm the belt type before installing.
      

      Generator	Paint Mark
      80 A	Blue
      100 A	Red

   2. Before installing the V-ribbed belt, check each pulley for any liquid or chips.
      
   1. Check that the ribs of the V-ribbed belt are correctly fitted into the grooves of the pulleys.
      

2. Turn the V-ribbed belt tensioner clockwise and remove the 4 mm bi-hexagon wrench.
   

1. Temporarily install the No. 1 V-ribbed belt onto each pulley.
   

   NOTICE:

   1. Before installing the No. 1 V-ribbed belt, check each pulley for any liquid or chips.
      
   1. Check that the ribs of the No. 1 V-ribbed belt are correctly fitted into the grooves of the pulleys.
      

1. Turn the adjust bolt B to adjust the tension of No. 1 V-ribbed belt.
   

   Deflection:

   Pressing Force N ( kg, lb)	New Belt mm (in.)	Used Belt mm (in.)
   10 (10, 22)	8.0 to 10.0 (0.315 to 0.394)	10.0 to 12.0 (0.394 to 0.472)

2. Tighten bolt A.
   

   Torque:

   44 N*m{ 449 kgf*cm , 32 ft.*lbf }

1. Check the belt for wear, cracks or other signs of damage.
   If any of the following defects is found, replace the V-ribbed belt.
   

   HINT:

   1. The belt is cracked.
      
   2. The belt is worn out to the extent that the cords are exposed.
      
   3. The belt has chunks missing from the ribs.
      

2. Check that the belt fits properly in the ribbed grooves.
   

   HINT:

   Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

   Text in Illustration 

   *a	Correct
   *b	Incorrect

1. Check the belt for wear, cracks or other signs of damage.
   If any of the following defects is found, replace the No. 1 V-ribbed belt.
   

   HINT:

   1. The belt is cracked.
      
   2. The belt is worn out to the extent that the cords are exposed.
      
   3. The belt has chunks missing from the ribs.
      

2. Check that the belt fits properly in the ribbed grooves.
   

   HINT:

   Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom to the pulley. If it has slipped out, replace the No. 1 V-ribbed belt. Install a new No. 1 V-ribbed belt correctly.

   Text in Illustration 

   *a	Correct
   *b	Incorrect

3. Inspect the No. 1 V-ribbed belt deflection.
   

   Text in Illustration 

   *1	Crankshaft
   *2	A/C Compressor
   *3	Tensioner

   Deflection:

   Pressing Force N ( kg, lb)	New Belt mm (in.)	Used Belt mm (in.)
   10 (10, 22)	8.0 to 10.0 (0.315 to 0.394)	10.0 to 12.0 (0.394 to 0.472)

   HINT:

   No. 1 V-ribbed belt tension

   New Belt N (kg, lb)	Used Belt N (kg, lb)
   397 to 593 (40 to 60, 89 to 133)	300 to 398 (31 to 41, 67 to 89)

   NOTICE:

   1. Check the No. 1 V-ribbed belt deflection at the specified point.
      
   2. When installing a new belt, set its deflection value as specified.
      
   3. When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.
      
   4. When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.
      

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

   Minimum Length:

   Item	Length
   Front	41.5 mm (1.634 in.)

   HINT:

   If the length is not as specified, replace the compression spring.

2. Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the exhaust manifold.
   

   Text in Illustration 

   *1	Gasket
   *2	Wooden Block

   NOTICE:

   1. Install the gasket in the correct direction.
      
   2. Do not reuse the gasket.
      
   3. Do not damage the gasket by dropping it, etc.
      
   4. Do not damage the outer surface of the gasket.
      
   5. Do not push in the gasket with the exhaust pipe when connecting it.
      
   6. After the installation, check that the gaps between the flanges of the exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.
      

3. Install the front exhaust pipe assembly to the exhaust manifold with the 2 bolts and the 2 compression springs.
   

   Torque:

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

4. Using a vernier caliper, measure the free length of the compression springs.
   

   Minimum Length:

   Item	Length
   Rear	38.5 mm (1.594 in.)

   HINT:

   If the length is not as specified, replace the compression spring.

5. Fully push a new exhaust pipe gasket onto the front exhaust pipe assembly.
   

   NOTICE:

   1. Install the gasket in the correct direction.
      
   2. Do not reuse the gasket.
      
   3. Do not damage the gasket by dropping it, etc.
      
   4. Do not damage the outer surface of the gasket.
      
   5. Do not push in the gasket with the exhaust pipe when connecting it.
      
   6. After the installation, check that the gaps between the flanges of the exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.
      

6. Install the front exhaust pipe assembly to the tail exhaust pipe assembly with the 2 bolts and the 2 compression springs.
   

   Torque:

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

1. Install the front bumper energy absorber with the 14 screws.
   

1. Engage the 6 claws and install the front bumper cover.
   

2. Tighten the 4 screws.
   

3. Install the 5 clips.
   

4. Install the pin hold clip.
   

   NOTICE:

   Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertically.

   HINT:

   Use the same procedure for the RH and LH sides.

1. Tighten the radiator drain cock plug.
   

2. Loosen the air bleed valve.
   

   Text in Illustration 

   *1	Air Bleed Valve

3. Remove the water filler cap sub-assembly.
   

4. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC) from the water filler (Coolant level should be within 20 mm (0.787 in.) from the filler tube end).
   

   Text in Illustration 

   *a	Filler Tube End
   *b	Coolant Level

   Standard Capacity:

   Item	Capacity
   M/T	4.7 liters (5.0 US qts, 4.1 Imp. qts)
   CVT	4.9 liters (5.2 US qts, 4.3 Imp. qts)

   NOTICE:

   Never use water as a substitute for engine coolant.

   HINT:

   TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

5. Remove the reserve tank cap.
   If the coolant level is low, add coolant.
   

6. Fill the radiator reserve tank with coolant to the FULL line.
   

   Text in Illustration 

   *a

   FULL Line

7. Tighten the air bleed valve.
   

   Text in Illustration 

   *1	Air Bleed Valve

8. Install the water filler cap sub-assembly and reserve tank cap.
   

9. Start the engine and warm it up.
   

10. Bleed air from the cooling system.
    

    HINT:

    1. Before starting the engine, turn the A/C switch off.
       
    2. Adjust the air conditioning temperature setting to MAX (HOT).
       
    3. Adjust the air conditioning blower setting to LO.
       
    
    

    1. Run the engine intermittently for 7 minutes or more (5 seconds running at 3000 rpm and 45 seconds idling, repeat several times).
       

11. Stop the engine, and wait until the engine coolant cools down.
    

12. After the engine is cooled down, check that the coolant level is between the FULL and LOW lines.
    

    Text in Illustration 

    *a	FULL Line
    *b	LOW Line

    If the coolant level is low, add coolant to the reservoir tank FULL line.
    

1. Add new engine oil.
   
   

   Standard Oil Grade:

   
   

   Oil Grade	Oil Viscosity (SAE)
   API grade SL "Energy-Conserving". SM "Energy-Conserving" or ILSAC multigrade engine oil	0W-20 5W-20 5W-30 10W-30
   API grade SL or SM multigrade engine oil	15W-40 20W-50

   
   

   Standard Capacity:

   
   

   Item	Specified Condition
   Drain and refill with oil filter change	3.7 liters (3.9 US qts, 3.3 Imp. qts)
   Drain and refill without oil filter change	3.5 liters (3.7 US qts, 3.1 Imp. qts)
   Dry fill	4.2 liters (4.4 US qts, 3.7 Imp. qts)

2. Install the oil filler cap.
   

HINT:

Charge refrigerant in accordance with the equipment manual.

1. Perform vacuum purging using a vacuum pump.
   

2. Charge refrigerant HFC-134a (R134a).
   

   SST

   09985-20010   (09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150)
   

   Standard:

   330 to 390 g (11.6 to 13.8 oz.)
   

   NOTICE:

   1. Do not start the engine before charging it with refrigerant as the cooler compressor does not work properly without sufficient refrigerant. This could cause the compressor to overheat.
      
   2. Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear.
      The volume of refrigerant should be measured, not checked with the sight glass.
      

   HINT:

   
   
   1. The relationship between the refrigerant charge amount and the pressure is as follows.
      
      
      
      
      
      
   2. High Charge Range:
      If the refrigerant is overcharged, the pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.
      
   3. Low Charge Range:
      A shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens the compressor life. Operation with insufficient coolant raises the refrigerant temperature and causes heat deterioration of the rubber seals and hoses. Cracking and subsequent refrigerant leakage may occur.
      
   
   

   1. Install the caps onto the service valves on the refrigerant line.
      

1. Install a new gasket and the manual transmission drain plug.
   

   Torque:

   45 N*m{ 459 kgf*cm , 33 ft.*lbf }

2. Add manual transaxle oil.
   

   Text in Illustration 

   *1	0 to 5 mm (0 to 0.20 in.)

HINT:

Refer to the following diagram when adding fluid.

1. When adding fluid (large fill volume) *1
   
   

   
   
   

   1. Be sure that the vehicle remains level and lift the vehicle.
      

   2. Use a socket hexagon wrench (6 mm) to remove the drain plug and gasket.
      

   
   
   

   3. Use a socket hexagon wrench (6 mm) to check that the No. 1 transmission oil filler tube is tightened to the specified torque.
      

      Text in Illustration 

      *1	No. 1 Transmission Oil Filler Tube

      Torque:

      0.8 N*m{ 8.2 kgf*cm , 7 in.*lbf }

      NOTICE:

      If the No. 1 transmission oil filler tube is not tightened to the specified torque, then the fluid level cannot be adjusted correctly.

   
   
   

   4. Remove the refill plug and gasket.
      

   
   
   

   5. Add fluid into the refill hole until it flows out from the overflow hole.
      

      NOTICE:

      This transmission requires Toyota Genuine CVT Fluid TC.

   
   
   

   6. Wait until the steady flow slows to a trickle, install a gasket, and temporarily tighten the drain plug with a socket hexagon wrench (6 mm).
      

      HINT:

      Because the drain plug will be removed again, the gasket can be reused at this time.

      
      
      
      
      
      

   7. Fill the specified volume of transmission fluid into the refill hole.
      

      NOTICE:

      The fill amount varies depending on the procedures being completed.

      
      

      Reference Capacity:

      
      

      Related Procedure	Fill Volume
      Transaxle replacement (with a new torque converter)	1.4 liters (1.48 US qts, 1.23 Imp. qts)
      Transaxle replacement (when reusing the torque converter)	0.4 liters (0.42 US qts, 0.35 Imp. qts)
      Torque converter replacement	1.6 liters (1.69 US qts, 1.41 Imp. qts)
      Torque converter removal/installation	0.4 liters (0.42 US qts, 0.35 Imp. qts)
      Oil pan removal/installation (when oil drained)	0.4 liters (0.42 US qts, 0.35 Imp. qts)
      Drive shaft removal/installation	0.4 liters (0.42 US qts, 0.35 Imp. qts)

   8. Install the gasket and temporarily tighten the refill plug.
      

      HINT:

      Because the refill plug will be removed again, the gasket can be reused at this time.

   9. Lower the vehicle.
      

2. When refilling (small fill volume) *2
   
   

   
   
   

   1. Be sure that the vehicle remains level and lift the vehicle.
      

   2. Remove the refill plug and gasket.
      

   
   
   

   3. Fill the specified volume of transmission fluid into the refill hole.
      
      

      Reference Capacity:

      
      

      Related Procedure	Fill Volume
      Oil cooler removal/installation or replacement	0.4 liters (0.42 US qts, 0.35 Imp. qts)
      Repair of oil seeping or oozing	0.4 liters (0.42 US qts, 0.35 Imp. qts)

   4. Install the gasket and temporarily tighten the refill plug.
      

      HINT:

      Because the refill plug will be removed again, the gasket can be reused at this time.

   5. Lower the vehicle.
      

1. Fill the reservoir with brake fluid.
   

   Text in Illustration 

   *1	MAX Line
   *2	MIN Line

   Brake Fluid:

   SAE J1703 or FMVSS No. 116 DOT 3
   

   NOTICE:

   Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

HINT:

In case of clutch fluid replacement, make sure that the old fluid is replaced in the clutch line between the reservoir and the bleeder before bleeding.

1. Remove the bleeder plug cap.
   

2. Connect a vinyl tube to the bleeder plug.
   

3. Depress the clutch pedal 5 times, and then loosen the bleeder plug while the pedal is depressed.
   

4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.
   

5. Repeat both of the previous 2 steps 6 times.
   

6. Tighten the bleeder plug.
   

   Torque:

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

7. Depress the clutch pedal 10 times or more and confirm its operation.
   

   NOTICE:

   This must be performed before the engine is started.

8. Install the bleeder plug cap.
   

9. Check that all the air has been bled from the clutch line.
   

1. Check the brake fluid level.
   If brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.
   

   Brake Fluid:

   SAE J1703 or FMVSS No. 116 DOT 3
   

NOTICE:

The fluid temperature can be confirmed by checking the indicator light in the meter or by using the intelligent tester. When using the intelligent tester, it is necessary to change to temperature detection mode in order to idle the vehicle appropriately.

1. When using the intelligent tester
   
   

   1. Turn the ignition switch off.
      

   2. Connect the intelligent tester to the DLC3.
      

   3. Turn the ignition switch to ON.
      

   4. Turn the tester on.
      

   5. Enter the following menus: Powertrain / Engine and ECT / Data Test / A/T Oil Temperature 1.
      

   6. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1.
      

2. When not using the intelligent tester
   
   

   
   
   

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

      SST

      09843-18040  
      

3. Start the engine.
   

   NOTICE:

   Check that electrical systems such as the air conditioning system, audio system and lighting system are off.

   HINT:

   Indicator lights of the meter blink to output DTCs when terminals TC and CG are connected.

4. Slowly move the shift lever from P to B (from P to D for multi-mode automatic transmission) and back to P again.
   

   HINT:

   Hold the shift lever in each position for about 3 seconds.

5. Move the shift lever to D, and then continuously move the shift lever back and forth between N and D at a rate of 1 shift/1.5 seconds or faster for 6 seconds or more. This will activate the fluid temperature detection mode.
   

   Standard condition:

   The indicator light (D) remains illuminated for 2 seconds and then turns off.
   

6. Return the shift lever to P.
   

7. The indicator light (D) remains off, illuminates, or blinks depending on the fluid temperature.
   
   

   Indicator Light (D):

   
   

   Remains OFF	Illuminates	Blinks
   Below 35 °C (95°F)	35 °C (95 °F) to 45 °C (113 °F)	45 °C (113 °F) or higher
   Below proper temperature	Proper temperature range	Above proper temperature

8. If the indicator remains off or illuminates, disconnect the TC terminal and perform the "Fluid Level Check".
   

   NOTICE:

   1. If the TC terminal is not OFF (open), accurate fluid level adjustment is not possible, so be sure to disconnect this terminal.
      
   2. If the TC terminal is not OFF (open), in some cases, the fluid temperature reading will immediately exceed the proper temperature for adjustment.
      
   3. If the light is blinking, stop the engine, wait for the fluid temperature to decrease, and repeat the procedure from "Fluid Temperature Check".
      

1. Idle the engine to warm it up, and ensure that the fluid temperature is correct.
   

2. Lift the vehicle immediately after the indicator light (D) illuminates.
   

   NOTICE:

   Adjust the fluid level while the indicator light (D) is illuminated.

3. Use a socket hexagon wrench (6 mm) to remove the drain plug and gasket, and then check the fluid condition.
   

   HINT:

   1. Check that the fluid flows out from the overflow tube.
      
   2. If the volume of fluid that flows out is small, it is possible that fluid was remaining in the tube (about 5 cc (0.30512 cu in.)), so assume that there was no overflow.
      

4. If the fluid overflows
   
   

   1. Wait until the steady flow slows to a trickle, and then use a socket hexagon wrench (6 mm) to install a new gasket and tighten the drain plug.
      

      Torque:

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

   2. Replace the refill plug with a new gasket and tighten the refill plug.
      

      Torque:

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

5. If the fluid does not overflow
   
   

   1. Remove the refill plug and gasket.
      

   2. Add fluid into the refill hole until it flows out from the overflow hole.
      

      NOTICE:

      This transmission requires Toyota Genuine CVT Fluid TC.

   3. Wait until the steady flow slows to a trickle, and then install a new gasket and tighten the drain plug.
      

      Torque:

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

   4. Install a new gasket and fully tighten the refill plug.
      

      Torque:

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

6. Lower the vehicle.
   

7. Turn the ignition switch off and disconnect the intelligent tester.
   

CAUTION:

To avoid the danger of being burned, do not remove the water filler cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

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

   Text in Illustration 

   *1	Radiator Cap Tester

2. Pump the tester to 118 kPa (1.2 kgf/cm², 17.1 psi), and then check that the pressure does not drop.
   If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.
   

1. The engine coolant should be between the LOW and FULL lines when the engine is cold.
   

   Text in Illustration 

   *1	Full Line
   *2	Low Line

   HINT:

   If it is below the LOW line, check for leaks and add Toyota Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line.

1. Check that the oil surface is within 5 mm (0.20 in.) of the bottom of the manual transmission filler plug opening.
   

   NOTICE:

   Excessively large or small amounts of oil may cause problems.

   Text in Illustration 

   *1	0 to 5 mm (0 to 0.20 in.)

2. Check for oil leakage when the oil level is low.
   

3. Install the manual transmission filler plug and a new gasket.
   

   Torque:

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

1. Clean the area and check for fluid leaks.
   

1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
   

2. Perform the operation as follows:
   

   1. Stop the engine.
      
   2. Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
      
   3. Repeat the test 2 or 3 times.
      
   4. Make sure that some refrigerant remains in the refrigeration system.
      When the compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)
      

   HINT:

   It is impossible for the above pressure to be maintained if there is leakage.

3. Using the halogen leak detector, check the refrigerant line, especially at the connection points, for leakage.
   

4. Bring the halogen leak detector close to the drain hose before performing the test.
   

   Text in illustration 

   *1	Drain hose
   *2	Halogen leak detector

   HINT:

   1. After the blower motor has stopped, leave the cooling unit for at least 15 minutes.
      
   2. Place the halogen leak detector sensor under the drain hose.
      
   3. When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to other volatile gases.
      
   If such a reaction is unavoidable, the vehicle must be lifted up.
   

5. If no gas leakage is detected from the drain hose, remove the blower motor from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.
   

6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.
   

NOTICE:

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

1. Warm up and stop the engine.
   

2. When using the intelligent tester: Check the ignition timing.
   
   

   1. Connect the intelligent tester to the DLC3.
      

   2. Start the engine and run it at idle.
      

   3. Turn the tester on.
      

   4. Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance.
      

      Standard ignition timing:

      Transaxle	Ignition Timing
      Manual Transaxle	0 to 10 degrees BTDC
      CVT	-5 to 5 degrees BTDC

      HINT:

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

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

   6. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON.
      

   7. Monitor IGN Advance of the Data List.
      

      Standard ignition timing:

      Transaxle	Ignition Timing
      Manual Transaxle	8 to 12 degrees BTDC
      CVT

      NOTICE:

      When checking the ignition timing, the transaxle should be in neutral or park.

      HINT:

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

   8. Enter the following menus: Connect the TC and TE1 / OFF.
      

   9. Turn the ignition switch off.
      

   10. Disconnect the intelligent tester from the DLC3.
       

3. When not using the intelligent tester:
   
   

   
   
   

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

      SST

      09843-18040  
      

      NOTICE:

      1. Be sure to connect the terminals correctly. Failure to do this can damage the engine.
         

   
   
   

   2. Connect the clip of the timing light to the wire harness.
      

      NOTICE:

      Use a timing light that detects the primary signal.

   3. Inspect the ignition timing at idle.
      

      Standard ignition timing:

      Transaxle	Ignition Timing
      Manual Transaxle	8 to 12 degrees BTDC
      CVT

      NOTICE:

      When checking the ignition timing, the transaxle should be in neutral or park.

      HINT:

      After running the engine at 1000 to 1300 rpm for 5 seconds, check that it returns to idle speed.

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

   5. Inspect the ignition timing at idle.
      

      Standard ignition timing:

      Transaxle	Ignition Timing
      Manual Transaxle	0 to 10 degrees BTDC
      CVT	-5 to 5 degrees BTDC

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

   7. Remove the timing light.
      

NOTICE:

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

1. Warm up and stop the engine.
   

2. Connect the intelligent tester to the DLC3.
   

3. Start the engine and run it at idle.
   

4. Turn the tester on.
   

5. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.
   

   HINT:

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

6. Inspect the engine idle speed.
   

   Standard Idle Speed:

   Transaxle	Idling Speed
   Manual Transaxle	550 to 650 rpm
   CVT	600 to 700 rpm

7. Turn the ignition switch off.
   

8. Disconnect the intelligent tester from the DLC3.
   

HINT:

This check determines whether or not the idle CO/HC complies with local regulations.

1. Start the engine.
   

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

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

4. Check the CO/HC concentration during idle and when the engine is running at 2500 rpm.
   

   HINT:

   When doing the 2 mode (with the engine idling/ running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.

   If the CO/HC concentration does not comply with local 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 causes, and then inspect the applicable parts and repair them if necessary.
      
      

      CO	HC	Problem	Possible Cause
      Normal	High	Rough idle	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leakage from intake and exhaust valves Leakage from cylinders
      Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
      High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element Plugged PCV valve Faulty EFI system: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Throttle body

1. Inspect and adjust front wheel alignment (Click here).
   

1. Install the No. 3 engine under cover with the 3 clips.
   

Torque:

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

1. Install the windshield wiper motor and link (Click here).