ENGINE ASSEMBLY INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. A01CHPUE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the timing chain cover within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the intake manifold with the 8 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  2. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A01CH8BE01

      Turn the drive gear and align the hole with the matchmark as shown in the illustration.

    2. Install a new O-ring onto the timer cover.

    3. A01CI5SE01

      Align the matchmarks of the timer cover and the front end plate, then install the supply pump.

    4. A01CHOV

      When the crankshaft position sensor's installation hole can be accessed directly:


      1. Check that the knock pin of the injection pump drive gear is at the center of the hole. Then, proceed to step (f).

        If not, perform steps (b) and (c) again.

    5. A01CH68E01

      When the crankshaft position sensor's installation hole can not be accessed directly:


      1. Tape the screwdriver as shown in the illustration.

      2. A01CIOU

        Remove the service plug from the timing chain or belt cover sub-assembly.

      3. A01CJEHE01

        Insert the screwdriver into the service plug hole.

      4. Check that the tape end and timing chain or belt cover sub-assembly are aligned as shown in the illustration.

        If not, perform steps (b) and (c) again.

      5. Install the service plug hole.

    6. A01CGZX

      Install the injection or supply pump with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    7. A01CIH3

      Install the holder clip with the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    8. Connect the 2 connectors.

  3. INSTALL FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CIXS

      Install a new gasket and the fuel return pipe with the union bolt.

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

    2. Install the fuel pipe clamp with the nut. Tighten the nut until the clamp's edges make contact with the engine side clamp's edges.

  4. INSTALL FUEL DELIVERY PIPE


    1. A01CICS

      Install 2 new gaskets and the fuel delivery pipe with the union bolt.

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

  5. INSTALL COMMON RAIL ASSEMBLY


    1. A01CIBY

      Install the common rail assembly and the No. 3 injection pipe bracket with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    2. Connect the fuel pressure sensor connector.

  6. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJ7V

      Temporarily install the fuel pipe with the union nuts.

    2. Using SST, tighten the union nuts.

      SST
      09023-12901
      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

      Note

      Refer to the torque above when not using SST. When using SST, calculate the torque in accordance with the lengths of SST and the torque wrench. Click here

    3. Install the pipe clamp with the nut. Tighten the nut until the clamp's edges make contact with the engine side clamp's edges.

  7. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. A01CJ4U

      Install 4 new gaskets and the No. 4 fuel pipe with the 2 union bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf, for M10 bolt }
      25 N*m  { 250 kgf*cm, 18 ft.*lbf, for M12 bolt }

  8. INSTALL VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Install the vacuum pump assembly with a new O-ring and the 2 nuts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  9. INSTALL VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

      Install the vacuum pump oil pipe sub-assembly with a new gasket and the 3 union bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  10. INSTALL VACUUM PIPE


    1. Install the vacuum pipe with 2 new gaskets, the union bolt, and the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  11. INSTALL WATER PUMP ASSEMBLY


    1. A01CH6IE01

      Apply a continuous bead of seal packing (diameter 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the water pump within 3 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    2. A01CIV9

      Install the water pump assembly with the 8 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CI1KE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the water by-pass pipe sub-assembly within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the water by-pass pipe sub-assembly with the clamp and the 4 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  13. INSTALL WATER PIPE SUB-ASSEMBLY


    1. A01CIX4

      Install the water pipe sub-assembly with a new O-ring and the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  14. INSTALL WATER OUTLET HOUSING


    1. A01CHN1

      Install the water outlet sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  15. INSTALL WATER TEMPERATURE SENDER GAUGE ASSEMBLY


    1. A01CJ4L

      Install the water temperature sender gauge assembly with a new gasket.

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

  16. INSTALL THERMOSTAT


    1. A01CIICE01

      Apply a continuous bead of seal packing (diameter 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.

      Note


      • Remove any oil from the contact surface.

      • Install the water pump within 3 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    2. A01CI6X

      Install a new gasket onto the thermostat.

    3. Align the jiggle valve to the position shown in the illustration and install the thermostat.

    4. A01CGNU

      Install the water outlet with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  17. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. A01CITH

      Install the water outlet sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  18. INSTALL CAMSHAFT POSITION SENSOR


    1. A01CHJI

      Install the camshaft position sensor with a new O-ring and the bolt.

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

  19. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Install the crankshaft position sensor with a new O-ring and the bolt.

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

  20. INSTALL OIL COOLER ASSEMBLY


    1. A01CH3V

      Install the oil cooler assembly and 2 new gaskets to the oil filter bracket sub-assembly with the 4 nuts.

      Torque:
      12 N*m  { 125 kgf*cm, 9.0 ft.*lbf }
    2. A01CJ4BE01

      Apply a continuous bead of seal packing (diameter 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent.

      Note


      • Remove any oil from the contact surface.

      • Install the oil cooler within 3 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    3. A01CGSY

      Install the oil cooler assembly with oil filter bracket with the 15 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  21. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01CHFVE02

      Install the oil pressure switch.


      1. Install the oil pressure switch with a new O-ring by hand, then further tighten it by 20 to 30° as shown in the illustration.

    2. Connect the oil pressure switch connector.

  22. INSTALL EXHAUST MANIFOLD


    1. A01CIBDE01

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

    2. A01CJCEE01

      Install the manifold with the 8 bolts. Uniformly, tighten the 8 nuts in the order shown in the illustration.

      Torque:
      60 N*m  { 610 kgf*cm, 44 ft.*lbf }

    3. Retighten the bolts in the same order as step (b).

      Torque:
      60 N*m  { 610 kgf*cm, 44 ft.*lbf }
    4. A01CHWE

      Install the exhaust manifold heat insulator sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  23. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Tech Tips

    Click here

  24. INSTALL RADIATOR PIPE


    1. A01CIP1

      Install the radiator pipe with a new gasket and the 2 bolts.

      Torque:
      18 N*m  { 180 kgf*cm, 21 ft.*lbf }

  25. INSTALL GENERATOR BRACKET SUB-ASSEMBLY


    1. A01CHR0

      Install the generator bracket with the 3 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  26. INSTALL GENERATOR BELT ADJUSTING BAR


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

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

  27. INSTALL VANE PUMP ASSEMBLY


    1. Coat a new O-ring with power steering fluid and install it to the vane pump.

    2. A01CHBB

      Install the vane pump assembly with the 2 bolts.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  28. INSTALL INJECTOR ASSEMBLY

    Note

    Register the injector compensation code of a new fuel injector in the ECM when replacing the fuel injector. Register the injector compensation code in advance so that it can be installed in the correct position. Click here


    1. A01CJFWE03

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a light amount of clean engine oil to 4 new O-rings.

    3. A01CI6EE01

      Install an O-ring to each injector as shown in the illustration.

    4. Install a new No. 2 cylinder head cover gasket to each injector.

    5. Insert the 4 injectors into the cylinder head.

      Note


      • Check that the insertion part of the fuel injector has no foreign matter attached.

      • When reusing a fuel injector, install the same fuel injector that was removed. Otherwise, it could cause the engine to malfunction.

      • Carefully insert the fuel injector so that the O-ring is not caught between the cylinder head and the injector.

    6. A01CGOO

      Temporarily install the 4 nozzle holder clamps with the 4 clamp bolts.

      Note

      Be sure to install the holder clamps and bolts in their original positions.

    7. A01CIVME01

      Install the 4 holder seals.

      Note

      Securely insert the tip of the holder seal into the fuel injector.

    8. A01CGPT

      Temporarily install the nozzle leakage pipe assembly through 5 new gaskets by hand with the union bolt and the 4 hollow screws.

    9. A01CGMW

      Temporarily tighten the union nuts of injection pipes No. 1, No. 2, No. 3 and No. 4 by hand.

    10. A01CIA6

      Tighten the 4 nozzle holder clamp bolts.

      Torque:
      25 N*m  { 225 kgf*cm, 18 ft.*lbf }

      Note

      After tightening the nozzle holder clamp bolts, check that the fuel injector and the nozzle holder clamp do not interfere with the valve spring.

    11. A01CHSY

      Tighten the 4 hollow screws and union bolt.

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

  29. INSTALL OIL LEVEL GAUGE GUIDE


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

  30. INSTALL INJECTION PIPE CLAMP


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

    2. A01CHFZ

      Temporarily install the 2 injection pipe clamps and oil level dipstick guide with the 2 nuts.

    3. Tighten the nut until the clamp's edges make contact with the engine side clamp's edges.

  31. INSTALL VENTURI ASSEMBLY


    1. A01CI8SE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the intake pipe with EGR valve within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the venturi assembly with the 4 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  32. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ5RE01

      Install the water by-pass pipe sub-assembly with the 3 bolts and 2 union bolts.

      Torque:
      Union bolt
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      Bolt
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  33. INSTALL EGR VALVE BRACKET


    1. A01CIJH

      Install the EGR valve bracket with 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  34. INSTALL OIL SEPARATOR ASSEMBLY


    1. A01CGOXE01

      Install the oil separator bracket with the 4 bolts onto the oil separator.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    2. A01CH8V

      Connect the 3 hoses.

    3. Install the oil separator assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CHCD

      Install the harness bracket with the 2 bolts onto the oil separator.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  35. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. Install the ventilation pipe sub-assembly with the 2 bolts.

    2. Connect the 3 hoses.

  36. CONNECT WIRE HARNESS AND CONNECTORS


    1. A01CH2B

      Connect the 3 connectors.

  37. INSTALL DIESEL THROTTLE BODY


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

    2. A01CJBFE01

      Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.

      Tech Tips


      • Remove any oil from the contact surface.

      • Apply seal packing to the inner side of the bolt holes.

      • Install the diesel throttle body assembly within 3 minutes of applying the seal packing.

      • Do not run the engine for at least 2 hours after installing.

    3. A01CH6X

      Install the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CIXR

      Connect the 2 diesel throttle body connectors.

  38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install a new cylinder head cover gasket onto the cylinder head cover.

    2. A01CGZM

      Install the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    3. Install the cylinder head cover cushion rubber.

    4. Connect the ventilation hose.

  39. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CJGU

      Install the No. 2 cylinder head cover sub-assembly with a new gasket and the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  40. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A01CJFY

      Install the oil filler cap sub-assembly.

  41. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Install the EGR cooler with a new gasket and the 2 bolts.

      Torque:
      Flange
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }
      Engine
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Connect the water by-pass hose.

  42. INSTALL NO. 1 AIR HOSE


    1. A01CITQE01

      Install the No. 1 air hose with the 2 hose bands.

  43. INSTALL ENGINE ASSEMBLY


    1. A01CISZ

      Install the engine hanger with the 2 bolts.

      Torque:
      108 N*m  { 1100 kgf*cm, 80 ft.*lbf }
    2. A01CGMU

      Install the engine to the engine mounting brackets with the 2 nuts.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

    3. Remove the engine hanger.

  44. INSTALL CLUTCH DISC ASSEMBLY


    1. A01CH3DE01

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

      SST
      09301-00120

      Note

      Take care not to insert the clutch disc assembly in the wrong direction.

  45. INSTALL CLUTCH COVER ASSEMBLY


    1. A01CIYVE01

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

    2. In the order shown in the illustration, tighten the 10 bolts starting from the bolt located near the knock pin on the top.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

      Tech Tips


      • Evenly tighten the bolts by following the order shown in the illustration.

      • Tighten the bolts after checking that the disc is in the center by lightly moving SST up and down, left and right.

      SST
      09301-00120

  46. INSTALL MANUAL TRANSMISSION ASSEMBLY


    1. A01CHNG

      Support the manual transmission with a transmission jack.

    2. Install the transmission.

      Note

      Do not apply excessive force to the transmission assembly as this will cause the input shaft to break.

    3. Install the 12 bolts.

      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

    4. Install the connector and clamp.

  47. INSTALL NO. 1 ENGINE MOUNTING BRACKET


    1. A01CI3C

      Install the No. 1 engine mounting bracket with the 3 bolts and 3 washers.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }
    2. A01CH1X

      Install the nut.

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

  48. INSTALL NO. 3 ENGINE MOUNTING BRACKET


    1. A01CI1C

      Install the No. 3 engine mounting bracket with the 3 bolts and 3 washers.

      Torque:
      103 N*m  { 1050 kgf*cm, 76 ft.*lbf }
    2. A01CH6D

      Install the nut.

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

  49. INSTALL PARKING BRAKE PLATE SUB-ASSEMBLY


    1. A01CI7A

      Install the parking brake plate sub-assembly with the 4 nuts.

      Torque:
      127 N*m  { 1290 kgf*cm, 93 ft.*lbf }

  50. INSTALL PARKING BRAKE DRUM SUB-ASSEMBLY


    1. Install the companion flange.

    2. A01CID4

      Install the parking brake dust cover to the parking drum sub-assembly with the bolt.

      Torque:
      8.2 N*m  { 84 kgf*cm, 73 in.*lbf }

    3. Install the parking drum sub-assembly.

  51. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT


    1. Apply engine oil to a new O-ring, and install it to the companion flange.

    2. Pull the parking brake lever fully, and shift into the 1st position.

    3. A01CHRW

      Using a 36 mm socket wrench, install a new transmission output shaft rear set nut.

      Torque:
      289 N*m  { 2947 kgf*cm, 213 ft.*lbf }
    4. A01CH0V

      Using a chisel and hammer, stake the transmission output shaft rear set nut.

  52. INSTALL WIRE HARNESS


    1. Install the wire harness.

  53. CONNECT FUEL HOSE


    1. A01CIXU

      Connect the 2 fuel hoses.

  54. CONNECT PRESSURE FEED HOSE


    1. Install the pressure feed hose with a new gasket.

    2. A01CH96

      Using SST, install the pressure feed hose.

      SST
      09023-12901
      Torque:
      44 N*m  { 450 kgf*cm, 32 ft.*lbf }

  55. CONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE


    1. A01CHED

      Connect the No. 2 oil reservoir to pump hose.

  56. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. A01CIE5E01

      Install the control shift cable to the shift lever with the nut.

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

  57. CONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. A01CHK5E01

      Install the control select cable to the select lever with the nut.

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

  58. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01CHMO

      Install the clutch release cylinder assembly with the 2 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  59. INSTALL PROPELLER SHAFT ASSEMBLY

  60. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01CI20E01

      Install a new gasket and front exhaust pipe assembly, and temporarily tighten the 3 nuts.

    2. A01CHG1E01

      Temporarily tighten the bolt.

    3. Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

      Tighten the 3 nuts.

    4. Tighten the bolt.

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

  61. INSTALL EXHAUST RETARDER ASSEMBLY


    1. A01CHNOE01

      Install 2 new gaskets and exhaust retarder assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    2. A01CIBFE01

      Connect the vacuum hose.

  62. CONNECT HEATER HOSE

  63. INSTALL STARTER ASSEMBLY


    1. A01CGQR

      Install the starter assembly with the bolt and nut.

      Torque:
      154 N*m  { 1570 kgf*cm, 114 ft.*lbf }
    2. A01CICI

      Install the starter wire to terminal C with the bolt, and install the terminal cap.

      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

    3. Install the starter wire to terminal B with the nut, and install the terminal cap.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    4. Install the wire harness clamp bracket with the bolt.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  64. INSTALL GENERATOR ASSEMBLY


    1. A01CJ2NE01

      Temporarily install the generator assembly with bolt A.

    2. Temporarily install the generator bracket to the generator assembly with bolt B.

    3. Install the generator bracket with 2 bolts C.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

    4. Connect the 3 wire harness clamps.

    5. Connect the connector to the generator.

    6. Install the wire harness to terminal B with the nut, and install the terminal cap.

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

  65. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly with fan shroud.

  66. INSTALL NO. 3 RADIATOR BRACKET


    1. A01CIT5

      Install the No. 3 radiator bracket with the 3 bolts.

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

    2. Install the No. 1 radiator support with the bolt.

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

  67. INSTALL NO. 4 RADIATOR BRACKET


    1. A01CJBO

      Install the No. 4 radiator bracket with the 3 bolts.

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

    2. Install the radiator support No. 2 with the bolt.

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

  68. INSTALL HEATER HOSE


    1. A01CJFI

      Install the heater hose with the 5 bolts.

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

  69. CONNECT RADIATOR HOSE OUTLET


    1. Install the radiator hose outlet.

  70. CONNECT RADIATOR HOSE INLET


    1. Install the radiator hose inlet.

  71. INSTALL FAN PULLEY


    1. A01CI13

      Install the fan pulley.

  72. INSTALL FAN


    1. Install the fan pulley and fan temporarily with the 4 nuts.

    2. Install the fan and generator V belt.

    3. Holding the V belt, tighten the 4 nuts completely to install the fan pulley and fan properly.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  73. INSPECT DRIVE BELT


    1. A01CHS3E01

      Check the V belt deflection.

      Tech Tips

      The specified deflection values per belt are shown in the following table.

      Deflection
      Item Specified Condition
      New belt 10.5 to 12.5 mm (0.41 to 0.49 in )
      Used belt 12.5 to 16.0 mm (0.49 to 0.63 in )

      Note


      • Check the V belt deflection at the specified point.

      • When inspecting a belt which has been used for over 5 minutes, apply the used belt specifications.

  74. INSTALL INTERCOOLER ASSEMBLY


    1. A01CIBUE01

      Install the intercooler assembly with the 4 bolts.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

  75. INSTALL NO. 2 AIR HOSE


    1. A01CITQE01

      Install the No. 1 air hose with the 2 hose bands.

  76. INSTALL NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE


    1. A01CILLE01

      Install the No. 1 intake air pipe with No. 4 air hose with the hose band.

    2. A01CHYE

      Install the bolt, and connect the intake air temperature sensor connector.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
    3. A01CHLBE01

      Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
    4. A01CGQKE01

      Install the bracket with the 2 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
    5. A01CIMYE01

      Install the hose band.

  77. INSTALL NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY


    1. A01CIY0

      Install the No. 3 cab mounting bracket with the 8 bolts.

      Torque:
      120 N*m  { 1250 kgf*cm, 89 ft.*lbf }
    2. A01CIIG

      Install the No. 1 air hose assembly with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    3. A01CJGK

      Install the air cleaner case with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A01CH0N

      Connect the connector. (with Cab tilt warning)

  78. INSTALL NO. 2 INTAKE PIPE


    1. A01CHUN

      Install the No. 2 intake pipe with the 3 bolts and 2 bands.

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

  79. INSTALL SPILL VALVE CONTROL DRIVER ASSEMBLY


    1. A01CHZZE01

      Install the injector driver assembly with the 2 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }
    2. A01CHRZ

      Connect the 2 injector driver connectors.

  80. INSTALL VACUUM RESERVOIR SUB-ASSEMBLY

  81. INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH

  82. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH

  83. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. A01CGLT

      Install the radiator reserve tank assembly with the bolt and 3 nuts.

      Torque:
      12 N*m  { 120 kgf*cm, 10 ft.*lbf }

  84. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH

  85. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH

  86. CONNECT BATTERY NEGATIVE TERMINAL

  87. ADD ENGINE OIL

  88. ADD ENGINE COOLANT


    1. Add fresh oil and install the oil filler cap sub-assembly.

      Engine oil
      Oil Grade Oil Viscosity (SAE)

      • API CD, CE, CF, CH-4, or CI-4 (You may also use API CE, or CD.)

      • 10W-30

      • 20W-20

      • 15W-40

      • 30

      • 40
      Capacity
      Item Fill amount
      Drain and refill with oil filter change 7.2 liters (7.6 US qts, 6.3 Imp. qts)
      Drain and refill without oil filter change 6.2 liters (6.6 US qts, 5.5 Imp. qts)
      Dry fill 8.9 liters ( 9.4 US qts, 7.8 Imp. qts)

  89. ADD POWER STEERING FLUID

  90. BLEED BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    Click here.

  91. INSPECT FOR ENGINE OIL LEAK

  92. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

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

    2. A01CIGLE01

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

    3. Warm up the engine.

    4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 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.

    5. Install the radiator cap.

  93. BLEED POWER STEERING SYSTEM


    1. Check the fluid level Click here.

    2. Jack up the front of the vehicle and support it with stands.

    3. Turn the steering wheel.


      1. With the engine stopped, turn the steering wheel slowly from lock to lock several times.

    4. Lower the vehicle.

    5. Start the engine.


      1. Run the engine at idle for a few minutes.

    6. Turn the steering wheel.


      1. With the engine idling, turn the steering wheel left or right to the full lock position and keep it in that position for 2 to 3 seconds, then turn the steering wheel to the opposite full lock position and keep it there for 2 to 3 seconds (*1).

      2. Repeat this procedure (*1) several times.

    7. Stop the engine.

    8. A01CGMDE01

      Check for foaming or emulsification.

      Tech Tips

      If the system has to be bled twice because of forming or emulsification, be sure to check for fluid leaks in the system.

    9. Check the fluid level Click here.

  94. INSPECT FOR POWER STEERING FLUID LEAK

  95. INSPECT FOR EXHAUST GAS LEAK

  96. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      2. Connect the intelligent tester to the DLC3.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Select the following menu items: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizing common rail internal fuel pressure, and checking for fuel leaks Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected

        • Above conditions preserved while test is ON

  97. INSTALL ENGINE UNDER COVER