ENGINE ASSEMBLY > INSTALLATION

for Preparation Click here



1. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH


A098936E01

  1. Install the mounting bracket with the 4 bolts.

    Torque:
    68 N*m{ 694 kgf*cm , 50 ft.*lbf }



2. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH

  1. Install the mounting bracket with the 4 bolts.

    Torque:
    68 N*m{ 694 kgf*cm , 50 ft.*lbf }



3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

  1. Using a 17 mm deep socket wrench, install the sensor.

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



4. INSTALL CAMSHAFT POSITION SENSOR

  1. Apply clean engine oil to a new O-ring.

  1. Install the O-ring to the sensor.

  1. Install the sensor with the bolt.

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



5. INSTALL CRANKSHAFT POSITION SENSOR

  1. Apply clean engine oil to a new O-ring.

  1. Install the O-ring to the sensor.

  1. Install the sensor with the bolt.

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



6. INSTALL VANE PUMP ASSEMBLY


A098935E01

  1. Install a new O-ring to the vane pump.

  1. Install the vane pump with the 2 nuts.

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



7. INSTALL VACUUM PUMP ASSEMBLY


A098930E01

  1. Install a new O-ring to the vacuum pump.

  1. Install the vacuum pump with the 2 nuts.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf }



8. INSTALL OIL COOLER COVER SUB-ASSEMBLY


A038741E01

  1. Install a new gasket and the oil cooler cover with the 13 bolts and 2 nuts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

  1. Connect the oil pressure connector and install the wire harness.



9. INSTALL INTAKE MANIFOLD


A098944E02

  1. Install a new gasket and the manifold to the cylinder head with the 4 bolts and 2 nuts in the order shown in the illustration.

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



10. INSTALL OIL LEVEL GAUGE GUIDE

  1. Apply clean engine oil to a new O-ring.

  1. Install the O-ring to the level gauge.

  1. Install the level gauge with the bolt.

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



11. INSTALL FUEL SUPPLY PUMP ASSEMBLY


A070715E01

  1. Check that the supply pump gear in the timing gear case moves back and forth smoothly.

  1. Install a new O-ring to the pump.

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



    A060835E01

  1. Align the set key on the drive shaft with the groove of the injection gear.



    A098897E01

  1. Install the pump with the 2 nuts.

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

  1. Set a new O-ring before tightening the set nut.



    A070711E01

  1. Using SST, hold the crankshaft pulley and install the set nut.

    SST
    09213-58013  
    09330-00021  

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



    A071144E01

  1. Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

    Thrust clearance:
    0.15 to 0.55 mm (0.0059 to 0.0217 in.)

    If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.



    A098896E01

  1. Connect the 2 connectors.



    A098895E01

  1. Connect the 2 fuel hoses.



    A098974E01

  1. Temporarily install the fuel inlet pipe with the union nuts.

    NOTICE:
    1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
    2. Keep the fuel inlet pipe free of foreign matter.

  1. Using SST, tighten the injection pipe union nut on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nut on the supply pump side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 in.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Install the oil level gauge guide with the 2 bolts.

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



    G036615E01

  1. Install the clamp with the bolt.

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



12. INSTALL COMMON RAIL ASSEMBLY

NOTICE:
When replacing the common rail, do not remove the foreign object mixing prevention caps of the common rail until just before the fuel inlet pipe and injection pipe are connected to the common rail.



    A098899E01

  1. Install the common rail with the 2 bolts.

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

  1. Connect the fuel pressure sensor connector.



13. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


A098974E01

  1. Temporarily install the fuel inlet pipe with the union nuts.

    NOTICE:
    1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
    2. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.

  1. Using SST, tighten the inlet pipe union nut on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

  1. Using SST, tighten the inlet pipe union nut on the supply pump side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

  1. Install the oil level gauge guide with the 2 bolts.

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



    G036615E01

  1. Install the clamp with the bolt.

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



14. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


A098898E01

  1. Temporarily install the leakage pipe with the 3 bolts.

  1. Temporarily install a new gasket with the check valve.

  1. Fully tighten the 3 bolts and check valve.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf } for check valve
    13 N*m{ 133 kgf*cm , 10 ft.*lbf } for bolt

  1. Connect the 2 fuel hoses.



15. INSTALL INJECTION PIPE


G038585E02

NOTICE:
  1. When replacing the injector, also replace the injection pipe.
  2. Keep the joints of the injection pipe clean.

  1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

  1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

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

    HINT:
    If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.



    A098972E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



    A098893E01

  1. Temporarily install the No. 4 injection pipe with the union nuts.

  1. Install 2 new injection pipe clamps with the 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    NOTICE:
    1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
    2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.



    A098973E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



16. INSTALL OIL FILTER SUB-ASSEMBLY

  1. Check and clean the oil filter installation surface.

  1. Apply clean engine oil to the gasket of a new oil filter.

  1. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.



    A060101E01

  1. Using SST, tighten the oil filter. Depending on the work space available, choose from the following.

    SST
    09228-07501  

    1. If enough space is available, use a torque wrench to tighten the oil filter.

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

    2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 turn by hand or with a common wrench.



17. INSTALL EGR VALVE ASSEMBLY

  1. Install a new gasket and the EGR valve.



18. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


G037199E01

  1. Install 2 new gaskets and the pipe with the 2 nuts and 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    HINT:
    The gasket's claws should be on the pipe side.



19. INSTALL INTAKE AIR CONNECTOR


A114779E01

  1. Install a new gasket and the air connector with the 2 nuts and bolt.

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



20. INSTALL DIESEL THROTTLE BODY BRACKET


A114779E02

  1. Install the bracket with the 3 bolts.

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



21. INSTALL DIESEL THROTTLE BODY ASSEMBLY


A098878E02

  1. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.

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



    A098877E01

  1. Connect the 2 connectors.



22. INSTALL VACUUM SWITCHING VALVE BRACKET


A099619E01

  1. Install the bracket with the 2 bolts.

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

  1. Connect the vacuum hose at the 3 points as shown in the illustration.

  1. Connect the 2 connectors.



23. INSTALL MANIFOLD STAY


A099932E01

  1. Install the stay with the 2 bolts.

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

    HINT:
    The stay's indented area (labeled A) must face the manifold.



24. INSTALL GLOW PLUG ASSEMBLY


25. INSTALL WATER OUTLET


A098977E01

  1. Install a new gasket to the cylinder head, as shown in the illustration.



    A098933E01

  1. Install the water outlet with the 2 bolts.

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



26. INSTALL THERMOSTAT


    A110388E01

  1. Install a new gasket to the thermostat.

    HINT:
    When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

  1. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

    HINT:
    The jiggle valve may be set within 30°of either side of the prescribed position.



27. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

  1. Install the bracket with the 4 bolts.

    Torque:
    47 N*m{ 479 kgf*cm , 35 ft.*lbf }



28. INSTALL NO. 1 CHARGE AIR COOLER SUPPORT BRACKET

  1. Install the bracket with the 2 bolts.

    Torque:
    36 N*m{ 367 kgf*cm , 27 ft.*lbf }



29. INSTALL NO. 2 CHARGE AIR COOLER SUPPORT BRACKET

  1. Install the bracket with the 2 bolts.

    Torque:
    36 N*m{ 367 kgf*cm , 27 ft.*lbf }



30. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


A097638E01

  1. Install the tensioner with the 4 bolts.

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

    HINT:
    Firmly press and hold the tensioner against the cylinder block to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.



31. INSTALL GENERATOR ASSEMBLY


A111821E01

  1. Install the generator and adjusting bar with the 2 bolts.

    Torque:
    62 N*m{ 630 kgf*cm , 46 ft.*lbf } for bolt A
    25 N*m{ 254 kgf*cm , 19 ft.*lbf } for bolt B

  1. Install the generator wire with the nut.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

  1. Connect the generator connector.



32. INSTALL GENERATOR BRACKET


33. INSTALL EXHAUST MANIFOLD


A098946E01

  1. Install a new gasket, manifold, 4 new collars and 8 spacers to the cylinder head with 8 new nuts.

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

    NOTICE:
    1. Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
    2. Install the collars to the positions labeled A.



34. INSTALL TURBOCHARGER STAY


A098818E01

  1. Temporarily install a new gasket and the turbocharger with 3 new nuts.

    HINT:
    When installing the turbo oil pipe, loosely tighten the 3 nuts so that the turbocharger and cylinder head can be aligned easily.



  1. Temporarily install the turbo oil pipe.

    HINT:
    Before installing the oil pipe, clean it.


    1. Install a new gasket and the oil pipe with the 2 nuts, but only loosely install the nuts.

      NOTICE:
      The notch (narrow part) of the gasket must face the engine.

    2. Install a new gasket and the oil pipe with the 2 bolts, but only loosely install the bolts.

      NOTICE:
      The claws of the gasket must face the pipe.



    3. Install a new gasket and the oil pipe with the union bolt, but only loosely install the union bolt.


      A110343E01



      4. A099944E03

    4. Temporarily install the turbocharger stay with the 3 bolts.

  1. Tighten the 3 nuts of the turbocharger.

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

  1. Tighten the 2 nuts and 2 bolts of the oil pipe, and the union bolt.

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf } for bolts

    Torque:
    13 N*m{ 133 kgf*cm , 9 ft.*lbf } for nuts

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

  1. Tighten the 3 bolts of the turbocharger stay.

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



35. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


36. INSTALL TURBINE OUTLET ELBOW


    A098816E01

  1. Install a new gasket and the outlet elbow with the 3 nuts.

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



37. INSTALL NO. 1 TURBO WATER HOSE


A098815E01

  1. Connect the 2 hoses to the 2 tubes.

  1. Move the 2 clamps to the locations where the hoses and tubes are connected.



38. INSTALL NO. 1 TURBO INSULATOR


A110342

  1. Temporarily install the turbo insulator with the bolt.



39. INSTALL VENTILATION PIPE


40. CONNECT VENTILATION HOSE


41. INSTALL CAMSHAFT TIMING PULLEY


A060182E01

  1. Install the camshaft timing pulley.

  1. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

    Torque:
    98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }



42. INSTALL CRANKSHAFT PULLEY


A072417E02

  1. Align the pulley set key with the key groove of the pulley.

  1. Using SST, install the pulley bolt.

    SST
    09213-58013  

    Torque:
    365 N*m{ 3,722 kgf*cm , 270 ft.*lbf }



43. INSTALL TIMING BELT


A070691E02

  1. Check that the timing marks are aligned as shown in the illustration.

    HINT:
    If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

    NOTICE:
    1. The engine should be cold.
    2. When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

  1. Using a 10 mm hexagon wrench, install the washer and timing belt idler pulley with the bolt.

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

  1. Check that the idler pulley moves smoothly.
    If it does not move smoothly, check the idler sub-assembly and washer.

  1. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.



    A070548E01

  1. Place the tensioner upright. Then set the press to the top of the tensioner.

    NOTICE:
    1. Do not scratch or deform the rod end.
    2. Press in the tensioner rod upward.
    3. Protect the tip of the push rod with a cloth in order to prevent damage.

  1. Using a press, slowly push in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force.

    NOTICE:
    Do not impose a load of over 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) to the push rod.

  1. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

  1. Tighten the 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    NOTICE:
    Uniformly tighten the 2 bolts and install the tensioner.



    A059983E01

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



    A070549E02

  1. Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.



44. INSTALL NO. 1 TIMING BELT COVER

  1. Install the timing belt cover with the 6 bolts.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

  1. Install the wire harness clamp.

  1. Install the water hose clamp with the bolt.

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



45. INSTALL ENGINE WIRE

  1. Connect the engine wire to the engine.



46. REMOVE ENGINE STAND


47. INSTALL ENGINE ASSEMBLY


A098988E01

  1. Attach the chain block and engine sling device to the engine hangers.

  1. Slowly lower the engine into the engine compartment.

  1. Install the engine mounting bracket with the 4 bolts and 4 nuts.

    Torque:
    38 N*m{ 388 kgf*cm , 28 ft.*lbf }

  1. Remove the 2 engine hangers.



48. INSTALL REAR END PLATE

  1. Install the end plate with the bolt.

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



49. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


A054047E01

  1. Clean the bolt and its hole.

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

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



    A072424E02

  1. Using SST, hold the crankshaft.

    SST
    09213-58013  
    09330-00021  

    Torque:
    365 N*m{ 3,722 kgf*cm , 270 ft.*lbf }

  1. Install the flywheel on the crankshaft.



    A114803E01

  1. Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

    Torque:
    178 N*m{ 1,815 kgf*cm , 132 ft.*lbf }

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



50. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


A054047E01

  1. Clean the bolt and its hole.

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

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



    A072424E02

  1. Using SST, hold the crankshaft.

    SST
    09213-58013  
    09330-00021  

    Torque:
    365 N*m{ 3,722 kgf*cm , 270 ft.*lbf }

  1. Install the flywheel, drive plate and drive plate spacer on the crankshaft.



    A114804E01

  1. Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

    Torque:
    178 N*m{ 1,815 kgf*cm , 132 ft.*lbf }

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



51. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)


    C112690E01

  1. Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.

    SST
    09301-00110  

    NOTICE:
    Take care not to insert the clutch disc facing the wrong direction.



52. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)


    D029623E01

  1. Align the matchmarks on the clutch cover and flywheel.

  1. Tighten the 6 bolts as described below.

    1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.

    2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.

      Torque:
      19 N*m{ 195 kgf*cm , 14 in.*lbf }

  1. Lightly move SST up and down, and right and left.

    SST
    09301-00110  

  1. Check that the disc is in the center, and then tighten the bolts.



53. INSTALL COOLER COMPRESSOR ASSEMBLY

  1. Install the compressor with the 4 bolts.

    Torque:
    50 N*m{ 510 kgf*cm , 37 ft.*lbf }



54. CONNECT HOSES AND CONNECTORS


G034367E01

  1. Using SST, install the pressure feed tube.

    SST
    09023-12701  

    Torque:
    51 N*m{ 520 kgf*cm , 38 ft.*lbf }



    G035298E01

  1. Connect the 2 fuel hoses.

  1. Connect the vacuum pump hose.

  1. Connect the oil reservoir to pump hose.



    G035297E03

  1. Connect the 4WD control ECU connector.

  1. Connect the turbo motor driver connector.

  1. Connect the 3 TCM connectors.

  1. Connect the 4 ECM connectors.



    G035296E01

  1. Connect the 2 injector driver connectors.



    G035294E01

  1. Install the ground cable with the bolt.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }

  1. Connect the 2 engine room junction block connectors.

  1. Install the engine room J/B wire with the nut.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

  1. Install the engine room relay block cover (side).

  1. Install the engine room relay block cover (upper).



55. INSTALL TRANSMISSION ASSEMBLY (for Manual Transmission)

  1. Install the transmission assembly (Click here).



56. INSTALL TRANSMISSION ASSEMBLY (for Automatic Transmission)

  1. Install the transmission assembly (Click here).



57. INSTALL PROPELLER SHAFT ASSEMBLY

  1. Front Side:
    Install the propeller shaft assembly (Click here).

  1. Rear Side:
    Install the propeller shaft assembly (Click here).



58. INSTALL FRONT EXHAUST PIPE


    A111834

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

    Minimum length:
    40 mm (1.57 in.)
    If the free length is less than the minimum, replace the compression spring.

  1. Install the front pipe to the pipe support.



    A111803E01

  1. Install a new gasket to the outlet pipe.

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

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

  1. Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

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

    CAUTION:
    Do not reuse the gasket.



59. INSTALL STARTER ASSEMBLY


    A111844E01

  1. A/T:
    Install the starter and ground cable with the 2 nuts and bolt.

  1. M/T:
    Install the starter and ground cable with the nut and bolt.

    Torque:
    68 N*m{ 693 kgf*cm , 50 ft.*lbf }

  1. Install the starter wire to terminal 30 with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

  1. Connect the starter connector.

  1. A/T:
    Install the A/T oil dipstick with the 2 bolts.

  1. M/T:
    Install the clutch release cylinder.



60. INSTALL CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    A112150

  1. Install a new gasket and the intake air connector with the 4 bolts.

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



    A112149

  1. Using a 22 mm deep socket wrench, install a new gasket and the IAT sensor.

    Torque:
    29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }



    A110367E01

  1. Install the CAC with the 4 bolts.

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for bolt A

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf } for bolt B

  1. Tighten the 4 hose clamps of the No. 1 and No. 2 air hose.

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

  1. Connect the diesel turbo IAT sensor connector.



61. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


A098873E01

  1. Install the engine cover with the 3 bolts and 2 nuts.

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



62. INSTALL RADIATOR ASSEMBLY

  1. Install the radiator assembly (Click here).



63. INSTALL AIR CLEANER ASSEMBLY

  1. Install the cleaner with the 2 bolts.

    Torque:
    14 N*m{ 143 kgf*cm , 10 ft.*lbf }

  1. Connect the connector to the MAF meter.

  1. Connect the hose clamp.



64. INSTALL BATTERY AND BATTERY TRAY


65. INSTALL BATTERY BRACKET


66. ADD TRANSMISSION OIL (for Manual Transmission)


D025304E13

  1. Stop the vehicle on a level surface.

  1. Remove the filer plug and gasket.

  1. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.
    If the result is not as specified, add transmission oil.

    Oil grade:
    GL-4 or GL-5

    Viscosity:
    SAE 75W-90

    Capacity:
    2.6 liters (2.7 US qts, 2.3 lmp.qts)

    NOTICE:
    1. Too much or too little oil will lead to transmission problems.
    2. After adjusting the oil level, drive the vehicle and check the oil level again.

  1. Check for oil leakage when the oil level is low.
    If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.

  1. Install a new gasket and the filler plug.

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



67. ADD TRANSMISSION FLUID

HINT:
Drive the vehicle so that the engine and transmission are at normal operating temperature.

ATF temperature:
70 to 80° C (158 to 176° F)



    G036408E01

  1. Park the vehicle on a level surface and set the parking brake.

  1. With the engine idling and the brake pedal depressed, move the shift lever into all positions from P to L. Then return it to P.

  1. Pull out the dipstick and wipe it clean.

  1. Push it back fully into the pipe.

  1. Pull it out and check that the fluid level is in the HOT range.
    If there are leaks, it is necessary to repair or replace O-rings, FIPG, oil seals, plugs or other parts.



68. ADD ENGINE COOLANT

  1. Tighten the radiator drain cock plug by hand.

  1. Tighten the cylinder block drain cock plug.

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



    A098989E01

  1. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

    Standard capacity:
    Item
    		Specified Condition
    A/T
    		11.1 liters (11.7 US qts, 9.8 lmp. qts)
    M/T
    		9.8 liters (10.4 US qts, 8.6 lmp. qts)

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

    NOTICE:
    Never use water as a substitute for engine coolant.

  1. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

  1. Install the radiator reservoir cap.



    A099591E01

  1. Using a wrench, install the vent plug.

    Torque:
    2.0 N*m{ 20 kgf*cm , 18 in.*lbf }

  1. Bleed air from the cooling system.

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

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

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

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

    4. Stop the engine and wait until the coolant cools down to ambient temperature.

      CAUTION:
      Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.



    G036768E01

  1. After the coolant cools down, check that the coolant level is at the F line.
    If the coolant level is below the F line, add TOYOTA SLLC to the F line.



69. ADD FUEL


70. TIGHTEN FUEL TANK CAP ASSEMBLY


71. ADD ENGINE OIL

  1. Wipe the oil pan and drain plug before installing the plug.

  1. Install a new gasket and the drain plug.

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

  1. Add new oil.

    Oil capacity:

    Item
    		Capacity
    Drain and refill with oil filter change
    		6.9 liters (7.3 US qts, 6.1 Imp. qts)
    Drain and refill without oil filter change
    		6.6 liters (7.0 US qts, 5.8 Imp. qts)
    Dry fill
    		7.4 liters (7.8 US qts, 6.5 Imp. qts)

  1. Install the oil filler cap.



72. INSTALL HOOD SUB-ASSEMBLY

  1. Install the hood with the 4 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

  1. Connect the washer nozzle hose.

  1. Adjust the hood.



73. BLEED AIR FROM FUEL SYSTEM


A098962E01

  1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.



74. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


75. PERFORM INITIALIZATION
Click here

  1. Perform initialization (see page ).

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



76. CHECK FOR ENGINE OIL LEAKS


77. CHECK FOR ENGINE COOLANT LEAKS


78. CHECK FOR EXHAUST GAS LEAKS


79. CHECK FOR FUEL LEAKS


80. CHECK ENGINE IDLE SPEED AND MAXIMUM SPEED

HINT:
  1. For more information about the intelligent tester, refer to its operator's manual.
  2. If an intelligent tester is not available, use a tachometer's tester probe as a substitute.



    A098433E01

  1. Connect the intelligent tester to the DLC3.



    A082779E58

  1. If a tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

    SST
    09843-18030  

  1. Inspect the idle speed.

    HINT:
    1. The engine is warmed up.
    2. The A/C switch is OFF.


    1. Start the engine and measure the idle speed.

      Idle speed:
      700 to 800 rpm

      If the idle speed is not as specified, perform the troubleshooting procedures in the Diagnostics section.

  1. Inspect the maximum speed.

    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Measure the maximum speed.

      Maximum speed:
      4,450 to 4,750 rpm

      If the maximum speed is not as specified, perform the troubleshooting in the Diagnostics section.

  1. If the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe with SST from terminal 9 of the DLC3.

  1. Disconnect the intelligent tester from the DLC3.



81. CHECK OIL LEVEL


82. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 2 bolts.

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



83. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 2 bolts.

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