ENGINE ASSEMBLY (w/o DPF) INSTALLATION


  1. INSTALL NO.1 FRONT ENGINE MOUNTING BRACKET LH

    A01KI5Z

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

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

  2. INSTALL NO.1 FRONT ENGINE MOUNTING BRACKET RH

    A01KHWV

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

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

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Using a 17mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.

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

  4. INSTALL OIL COOLER COVER SUB-ASSEMBLY

    A01KES8

    1. Install a new gasket and oil cooler cover to the cylinder block.

    2. Install the No. 2 vacuum transmitting pipe and install the 13 bolts and 2 nuts.

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

    3. Connect the vinyl tube to the oil cooler cover.

    4. Connect the oil pressure switch connector.

  5. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Clean the oil filter installation surface.

    2. Apply engine oil to the oil filter gasket.

    3. Lightly screw a new oil filter to the oil cooler cover until the oil filter does not turn.

    4. Using SST, tighten the oil filter an additional 3/4 turn.

      SST
      09228-07501
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  6. INSTALL NO.2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No.2 vacuum transmitting pipe with the 2 nuts and bolt.

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

  7. INSTALL NO.1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No.1 vacuum transmitting pipe with the nut and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      13 N*m  { 129 kgf*cm, 9 ft.*lbf }

    2. Connect the vacuum hose.

  8. INSTALL WATER OUTLET


    1. Install the water outlet and a new gasket with the 2 bolts.

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

    2. Install the plug with the clamp onto the water outlet. (without Heater)

  9. INSTALL INTAKE MANIFOLD

    A01KHW9E01

    1. Install a new gasket.

    2. Temporarily install the intake manifold with the 2 nuts and the 4 bolts.

    3. Uniformly tighten the 2 nuts and the 4 bolts as shown in the illustration.

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

  10. INSTALL NO.1 INTAKE MANIFOLD INSULATOR

  11. INSTALL GLOW PLUG ASSEMBLY

    Note


    • Measure the resistance of the glow plug when reinstalling it.

      If the result is not as specified, replace it with a new one.

    • Replace the glow plug with a new one when it has been dropped or subjected to a physical impact.

    • Remove any carbon deposits from the glow plug hole when reinstalling it.


    1. A01KHCSE02
      Text in Illustration
      *a Tape

      Wrap tape around a φ 4.4 drill, 118.5 mm (4.665 in.) from its tip.

    2. Insert the drill 118.5 mm (4.665 in.) into the glow plug hole and remove the carbon deposits by manually turning the drill.

    3. Insert the φ 4 drill into the glow plug hole and remove any carbon deposits from the tip end portion of the glow plug hole by manually turning the drill.

    4. A01KIIK

      Install the 4 glow plugs.

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

      Note

      Do not use any tools, such as air tools, which are liable to cause any impact to the glow plugs, when installing them.

  12. INSTALL NO.2 INTAKE MANIFOLD INSULATOR

    A01KILK

    1. Install the No. 2 Intake manifold Insulator.

  13. INSTALL NO.1 GLOW PLUG CONNECTOR

    A01KIEP

    1. Temporarily install the No. 1 glow plug connector with the 4 nuts.

    2. Tighten the 4 nuts to the specified torque.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

    3. Install the 4 screw grommets.

    4. Connect the wire harness to the No. 1 glow plug connector and install the nut.

      Torque:
      2.6 N*m  { 27 kgf*cm, 23 in.*lbf }

    5. Install the screw grommet.

  14. INSTALL CYLINDER BLOCK INSULATOR NO.2

  15. INSTALL THERMOSTAT

    A01KHH6E04
    Text in Illustration
    *1 Gasket
    *2 Jiggle Valve
    *a CORRECT
    *b INCORRECT
    *c Upward

    1. Install a new gasket to the thermostat.

      Tech Tips

      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.

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

      Tech Tips

      The jiggle valve may be set within 30° of vertical in either direction.

  16. INSTALL WATER INLET

    A01KG1I

    1. Install the water inlet and a new gasket with the 3 bolts.

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

      Note

      Torque the 2 upper bolts first.

  17. INSTALL NO.2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new gasket.

    2. Install the No.2 water by-pass pipe with the 2 nuts and bolt.

      Torque:
      Nut
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  18. INSTALL NO.2 TURBO WATER HOSE


    1. Connect the turbo water hose to the water inlet.

    2. Install the hose clamp with the bolt.

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

  19. INSTALL FUEL COOLER


    1. Install the fuel cooler with the 2 bolts.

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

    2. Connect the 2 water by-pass hoses.

  20. INSTALL NO.2 NOZZLE LEAKAGE PIPE ASSEMBLY

    A01KIPX

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

    2. A01KIL6

      Install 2 new gaskets and 2 union bolts to the nozzle leakage pipe.

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

    3. Tighten the 3 bolts.

      Torque:
      13 N*m  { 129 kgf*cm, 9 ft.*lbf }

    4. Connect the 3 fuel hoses.

  21. INSTALL CRANKSHAFT PULLEY

    A01KEV4E01

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

    2. Using SST, install the pulley bolt.

      SST
      09213-58013
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 220 ft.*lbf }

  22. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring and the pulley key to the fuel supply pump.

    2. Aligning the projecting edge of the fuel supply pump head with keyslot of the supply pump gear, install the fuel supply pump to the timing gear case.

    3. While holding the fuel supply pump by hand, push the supply pump gear rearward to engage the pump gear and drive shaft.

    4. A01KIHV

      Temporarily install the fuel supply pump with the 2 nuts.

    5. A01KEAJ

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    6. Tighten the supply pump gear set nut through a new O-ring to the specified torque.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    7. A01KIHV

      Tighten the 2 nuts to the specified torque.

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

  23. INSTALL PUMP DRIVE SHAFT PULLEY

  24. INSTALL NO.2 CAMSHAFT TIMING PULLEY FLANGE

    A01KHRQE01

    1. Install the No.2 camshaft timing pulley flange with the 4 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  25. INSTALL COMMON RAIL ASSEMBLY


    1. A01KI1X

      Install the common rail with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
    2. A01KHC7

      Connect the fuel hose.

    3. Connect the 2 connectors to the common rail.

  26. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01KIQC

    Note

    When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe sub-assembly.


    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. A01KGTAE02
      Text in Illustration
      *1 No. 1 Clamp
      *2 No. 2 Clamp

      Connect the No. 1 injection pipe clamp with the bolt.

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

    3. Install the No. 2 injection pipe clamp with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01KIQCE02
      Text in Illustration
      *A Common Rail Side
      *B Supply Pump Side

      Using union nut wrench 17mm, tighten the union nut on the common rail side to the specified torque.

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

      Note

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

    5. Using union nut wrench 17 mm, tighten the union nut on the supply pump to the specified torque.

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

      Note

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

  27. INSTALL FUEL INJECTION PIPE

    A01KH8X

    Note

    When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipe sub-assemblies No. 1, No. 2, No. 3 and No. 4.


    1. Temporarily install the injection pipe sub-assembly.

    2. A01KG8U

      Install the 2 injection pipe clamp No. 2 with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A01KFL5

      Using union nut wrench 17 mm, tighten the union nut on the fuel injector side to the specified torque.

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

      Note

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

    4. A01KFP6

      Using union nut wrench 17 mm, tighten the union nut on the common rail side to the specified torque.

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

    5. A01KG0R

      Install the wire harness with the 3 bolts.

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

    6. Connect the fuel injector connector and harness clamp.

  28. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the bolt.

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

  29. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01KIO1

      Temporarily install the electric EGR control valve.


      1. Temporarily install the electric EGR control valve to the intake air connector with a new gasket.

      2. A01KHMN

        Temporarily install the electric EGR control valve and intake air connector with the bolt and 2 nuts.

      3. A01KFC3

        Temporarily install the manifold stay with the bolt.

      4. A01KGBO

        Connect the vacuum hose to the intake air connector.

  30. TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY


    1. A01KFZH

      Temporarily install the EGR cooler assembly.


      1. Temporarily install the EGR cooler assembly with 2 new gaskets with the 2 bolts and 2 nuts.

      2. A01KI8B

        Temporarily install the bolt as shown in the illustration.

      3. A01KEGC

        Tighten the 2 bolts and 2 nuts to the specified torque.

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

  31. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01KI6F

      Tighten the electric EGR control valve.


      1. Tighten the bolt and 2 nuts to the specified torque.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01KFHL

      Connect the intake air temperature sensor connector.

    3. A01KEP3

      Connect the vacuum hose to the electric EGR control valve.

    4. Connect the electric EGR control valve connector.

    5. A01KF00

      Install the vacuum regulating valve with bracket with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01KI27

      Connect the 2 vacuum hoses to the vacuum regulating valve.

    7. Connect the vacuum regulating valve connector.

  32. TIGHTEN EGR COOLER ASSEMBLY


    1. A01KI8B

      Tighten the EGR cooler assembly.


      1. Tighten the bolt to the specified torque.

        Torque:
        22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01KI9L

      Install the water by-pass hose No. 2 with the clamp.

    3. Install the water by-pass hose No. 4 with the clamp.

    4. Install the oil return hose with the clamp.

  33. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. A01KGJM

      Install a new gasket to intake air connector.

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

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

    3. Connect the 2 connectors.

  34. INSTALL CAMSHAFT POSITION SENSOR


    1. A01KHUYE02
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to the O-ring on the camshaft position sensor.

    2. A01KFV3

      Install the camshaft position sensor with the bolt.

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

      Note

      Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  35. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01KHTXE02
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.

    2. A01KEX7

      Install the crankshaft position sensor with the bolt.

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

      Note

      Be careful that the O-ring is not cracked or jammed when installing the crankshaft position sensor.

    3. Attach the 3 wire harness clamps.

    4. Connect the crankshaft position sensor connector.

  36. INSTALL NO.1 TIMING BELT IDLER SUB-ASSEMBLY

    A01KFZL

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

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

      Note

      Do not reuse the washer.

  37. INSTALL TIMING BELT

    A01KER0E06

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

      Text in Illustration
      *a Timing Marks

      Tech Tips

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

      Note


      • The engine should be cold.

      • When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

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

    3. A01KGUQE01

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

      Note


      • Do not scratch or deform the rod end.

      • Press in the tensioner rod upward.

      • Protect the tip of the push rod with a cloth in order to prevent damage.

    4. Using a press, slowly push in the push rod using 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) of force.

      Note

      Do not impose a load of over 9807 N (1000 kgf, 2205 lbf) to the push rod.

    5. 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.

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

    7. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the bolts in order to avoid malfunction of the timing belt tensioner.

    8. A01KI6OE01

      Remove the 1.27 mm hexagon wrench from the tensioner.

    9. A01KFPKE06
      Text in Illustration
      *a Matchmarks
      *b Timing Marks

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

  38. INSTALL NO.1 TIMING BELT COVER


    1. A01KER2E01

      Install the timing belt cover with the 6 bolts (A).

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

    2. Install the wire harness clamp.

    3. Install the water hose clamp with the bolt (B).

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

  39. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolt.

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

  40. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Temporarily install the 2 engine mount insulators with the 6 nuts and 4 bolts.

    3. A01KFLI

      Tighten the engine mounting with the 4 bolts and 4 nuts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

    4. Tighten the engine mount insulator with the 2 nuts.

      Torque:
      76 N*m  { 775 kgf*cm, 56 ft.*lbf }

  41. INSTALL FRONT SUSPENSION MEMBER ASSEMBLY

    A01KGIFE02
    Text in Illustration
    *1 Front Suspension Damper

    1. Temporarily tighten the 4 bolts and install the front suspension member assembly.

    2. Temporarily tighten the 2 nuts and 2 suspension dampers.

    3. Fully tighten the 4 bolts.

      Torque:
      150 N*m  { 1530 kgf*cm, 111 ft.*lbf }

    4. Fully tighten the 2 nuts and 2 suspension dampers.

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

  42. INSTALL ENGINE WIRE

  43. CONNECT PRESSURE FEED TUBE ASSEMBLY

    A01KGVN

    1. Connect the tube with the union bolt and a new gasket.

      Torque:
      42.1 N*m  { 430 kgf*cm, 31 ft.*lbf }

  44. CONNECT STEERING GEAR OUTLET RETURN TUBE

    A01KFQW

    1. Install the return tube.

      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }
    2. A01KEK0

      Face the claw to the vehicle is front, and install the return hose to the PS gear assembly with the clip.

    3. A01KIMS

      Install the hose with bolt (LHD steering position type only).

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

  45. INSTALL STEERING TORQUE SHAFT ASSEMBLY

    A01KEEOE01
    Text in Illustration
    *a Matchmark

    1. Align the matchmarks on the torque shaft and bevel gear.

    2. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    3. A01KFIDE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the sliding yoke and steering gear.

    4. Tighten the bolt.

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

  46. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH


    1. Support the front suspension lower arm No. 1 LH with a jack, connect the front suspension lower arm No. 1 LH to the steering knuckle.

    2. Install new castle nut to the steering knuckle.

      Torque:
      140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

    3. Install new cotter pin.

  47. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Connect the RH side using the same procedures as the LH side.

  48. CONNECT FRONT STABILIZER BAR

    A01KHO7

    1. Install the 4 bolts and connect the stabilizer bar.

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

  49. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH

    A01KF92

    1. Install the front shock absorber assembly LH and bolt, temporarily tighten the nut.

  50. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Temporarily tighten the RH side using the same procedures as the LH side.

  51. CONNECT TIE ROD END SUB-ASSEMBLY LH


    1. Connect the tie rod end to the knuckle arm.

    2. Install the nuts and new cotter pin.

      Torque:
      91 N*m  { 928 kgf*cm, 67 ft.*lbf }

  52. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Connect the RH side using the same procedures as the LH side.

  53. INSTALL EXHAUST MANIFOLD

    A01KG97

    1. Install the new gasket onto the cylinder head.

    2. Install the exhaust manifold with the 8 nuts, spacers and collars.

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

      Note

      Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

  54. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KG5FE04
      Text in Illustration
      *1 Claw
      *a Wide
      *b Narrow
      *c Outside

      Install a new gasket to the turbo oil inlet pipe sub-assembly.

      Note

      Insert the gasket with its claws facing the turbo oil inlet pipe sub-assembly.

    2. Temporarily tighten the turbo oil inlet pipe sub-assembly with the 2 bolts, 2 nuts and union bolt.

  55. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

      Temporarily tighten the turbocharger stay with the 2 bolts and a new nut.

  56. FULLY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

      Tighten the 2 bolts and nut to the specified torque.

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

  57. FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KHCKE04
      Text in Illustration
      *1 Union Bolt

      Tighten the 2 bolts, 2 nuts and union bolt to the specified torque and install the turbo oil inlet sub-assembly.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf, for bolt }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for nut }
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for union bolt }

  58. INSTALL TURBINE OUTLET ELBOW


    1. A01KEND

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

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  59. CONNECT NO.1 TURBO WATER HOSE


    1. A01KHWT

      Connect the No. 1 turbo water hose with the 2 clips.

  60. INSTALL NO.1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01KG7W

      Temporarily install the No. 1 exhaust manifold heat insulator with the 2 bolts.

  61. INSTALL NO.1 TURBO INSULATOR


    1. A01KGR2

      Temporarily install the No. 1 turbo insulator with the 2 bolts.

    2. Tighten the 4 bolts to the specified torque and install the No. 2 turbo insulator and No. 1 exhaust manifold heat insulator.

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

  62. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. A01KGB4

      Install a new O-ring to the ventilation pipe sub-assembly.

    2. Apply a small amount of engine oil to the O-ring and install it to the ventilation pipe sub-assembly with the bolt.

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

  63. INSTALL ENGINE WIRE HARNESS (for LHD)


    1. A01KG9Q

      Install the engine wire harness with bracket with the 2 bolts.

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

  64. INSTALL ENGINE WIRE HARNESS (for RHD)


    1. A01KIQT

      Install the engine wire harness with bracket with the 2 bolts.

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

  65. CONNECT TURBOCHARGER STROKE SENSOR


    1. A01KEZH

      Connect the turbocharger stroke sensor connector to the turbocharger.

  66. INSTALL NO.2 AIR CLEANER HOSE


    1. A01KF86

      Connect the No. 2 air hose and tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  67. CONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01KHOK

      Connect the turbocharger motor connector to the turbocharger.

  68. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01KEB4

      Install the compressor outlet elbow with No. 2 air hose with the hose clamp and bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf, for bolt }
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf, for hose clamp }

  69. INSTALL OIL LEVEL GAUGE GUIDE


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

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

    3. Install the level gauge with the bolt.

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

  70. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A01KI8ME07
    Text in Illustration
    *1 Cylinder Block
    *2 Tensioner

    1. Install the V-ribbed belt tensioner with the 4 bolts.

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

      Tech Tips

      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.

  71. INSTALL GENERATOR ASSEMBLY


    1. A01KHPRE01

      Temporarily install the generator and generator bracket with the 3 bolts.

    2. Tighten the 3 bolts to the specified torque.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf, for bolt A }
      36 N*m  { 367 kgf*cm, 27 ft.*lbf, for bolt B }

    3. Install the wire harness with the nut to terminal B.

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

    4. Install the terminal cap.

    5. Connect the generator connector.

    6. Apply a small amount of engine oil to a new O-ring and install it to the oil level gage guide.

    7. Install the oil level gage guide with the bolt (for LHD).

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

    8. Install the oil level gage sub-assembly (for LHD).

    9. Install the engine wire harness with the 2 bolts and connect the connector (for LHD).

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

    10. Install the engine wire harness with the 2 bolts and connect the connector (for RHD).

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

  72. INSTALL VACUUM PUMP ASSEMBLY

    A01KG5Q

    1. Install 2 new O-rings to the vacuum pump.

    2. Install the vacuum pump with the 2 nuts.

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

  73. INSTALL TIMING GEAR COVER INSULATOR


    1. A01KFI0

      Install the timing gear cover insulator with the bolt.

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

  74. CONNECT VACUUM HOSE

    A01KIG6

    1. Connect the vacuum hose to the vacuum pump as shown in the illustration.

  75. INSTALL VANE PUMP ASSEMBLY


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

    2. Install the vane pump with the 2 nuts.

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

  76. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. Install the vane pump oil reservoir with the 2 bolts.

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

  77. INSTALL NO.3 AIR HOSE

  78. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Clean the bolt and its hole.

    2. A01KEUDE05
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A01KEV4E01

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    4. Install the flywheel on the crankshaft.

    5. A01KFUTE01

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

      Torque:
      178 N*m  { 1815 kgf*cm, 132 ft.*lbf }

      Note

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

  79. INSTALL CLUTCH DISC ASSEMBLY


    1. A01KFHCE02

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

      Text in Illustration
      A01KFFI Flywheel Side
      SST
      09301-00110

      Note

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

  80. INSTALL CLUTCH COVER ASSEMBLY


    1. A01KHCHE04
      Text in Illustration
      *a Matchmark
      *b Temporarily

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

    2. Following the procedures shown in the illustration, tighten the 6 bolts starting from the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 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
      09301-00110

  81. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

    Refer to the procedures up to "INSTALL MANUAL TRANSMISSION UNIT" Click here.

  82. INSTALL RADIATOR ASSEMBLY

    A01KEL5

    1. Install the radiator with the 2 cushions, 2 radiator support cushions and 2 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
    2. A01KGZJ

      Install the radiator support with the 2 bolts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
    3. A01KFKO

      Install the wire harness with the bolt and nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. A01KFG9

      Install the inlet heater water pipe with the bolt (w/ Heater).

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    5. A01KIMH

      Install the outlet heater water pipe with the 2 bolts (w/ Heater).

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  83. INSTALL RADIATOR RESERVE TANK HOSE

    A01KF93

    1. Connect the reserve tank hose to the radiator with the clip.

  84. CONNECT OUTLET RADIATOR HOSE

    A01KHWZE02
    Text in Illustration
    *a Front
    *b Left

    1. Connect the outlet radiator hose, as shown in the illustration, with the hose clamp.

  85. INSTALL FAN PULLEY


    1. Install the fan pulley onto the water pump.

  86. INSTALL FAN SHROUD


    1. Temporarily install the fan shroud together with the fan with fluid coupling.

    2. A01KEBHE02

      Install the fan shroud with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    3. A01KF3H

      Connect the outlet radiator hose onto the fan shroud.

    4. A01KH8R

      Connect the reserve tank hose onto the fan shroud.

  87. INSTALL FLUID COUPLING ASSEMBLY

    A01KEB0

    1. Temporarily tighten the fluid coupling with the 4 nuts.

    2. Install the fan and generator V belt Click here.

    3. Fully tighten the 4 nuts.

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

  88. INSTALL INLET RADIATOR HOSE

    A01KGXWE02
    Text in Illustration
    *a Upper
    *b Left

    1. Install the inlet radiator hose, as shown in the illustration, with the 2 hose clamps.

  89. CONNECT HEATER WATER HOSE INLET A (w/ Heater)

    A01KEGP

    1. Connect the heater water inlet hose.

  90. CONNECT HEATER WATER HOSE OUTLET B (w/ Heater)

    A01KGVL

    1. Connect the heater water outlet hose.

  91. INSTALL INTERCOOLER ASSEMBLY

    Refer to the procedures up to "INSTALL INTERCOOLER ASSEMBLY" Click here.

  92. INSTALL TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)

    A01KIQM

    1. Install the transmission service hole cover with the 12 bolts.

  93. INSTALL NO.4 MAT SET PLATE (for Double Cab)

    A01KGPT

    1. Install the mat set plate with the 6 screws.

  94. INSTALL REAR FLOOR MAT (for Double Cab)

  95. INSTALL REAR DOOR SCUFF PLATE LH (for Double Cab)

    A01KINS

    1. Install the rear door scuff plate with the 3 screws.

  96. INSTALL REAR DOOR SCUFF PLATE RH (for Double Cab)

    A01KF1Z

    1. Install the rear door scuff plate with the 3 screws.

  97. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)

    A01KEH0

    1. Install the engine service hole sub cover with the 7 bolts.

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

  98. INSTALL PARKING BRAKE LEVER ASSEMBLY (for Double Cab)

    A01KH1U

    1. Install the parking brake lever with the 4 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Connect the connector.

  99. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)

    A01KGMH

    1. Install the transmission floor shift with the 4 bolts.

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

  100. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (for Double Cab)


    1. A01KHBQ

      Install the floor shift cable transmission control select with clip and washer.

    2. Install a new clip.

  101. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (for Double Cab)


    1. A01KEIB

      Install the floor shift cable transmission control shift with the nut and washer.

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

    2. Install a new clip.

  102. INSTALL NO. 1 FRONT FLOOR MAT REAR (for Double Cab)

  103. INSTALL FRONT FLOOR PANEL BRACE (for Double Cab)

    A01KFZF

    1. Install the front floor panel brace with the 3 clips.

  104. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Double Cab)

  105. INSTALL PARKING BRAKE HOLE COVER (for Double Cab)

    A01KHZT

    1. Install the parking brake hole cover with the screw.

  106. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)

    A01KG08

    1. Install the front door scuff plate LH with the 4 screws.

  107. INSTALL FRONT SEAT ASSEMBLY LH (for Double Cab)


    1. Install the front seat LH with the 4 bolts.

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

    2. Connect the connector.

  108. INSTALL FRONT WHEEL

    Torque:
    For Full Just Low
    365 N*m  { 3722 kgf*cm, 270 ft.*lbf }
    For except Full Just Low
    135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

  109. FULLY TIGHTEN STEERING SLIDING YOKE SUB-ASSEMBLY

    A01KEYSE01
    Text in Illustration
    *a Matchmark

    1. Fully tighten the bolt.

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

    2. Install the steering link protector UPR and steering link protector LWR with the 3 bolts.

  110. STABILIZE SUSPENSION


    1. Install the front wheel and jack down the vehicle.

      Torque:
      Full just low
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }
      Except full just low
      135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

    2. Bounce the vehicle up and down several times to stabilize the suspension.

  111. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH

    A01KF92

    1. Fully tighten the nut.

      Torque:
      105 N*m  { 1071 kgf*cm, 77 ft.*lbf }

  112. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Fully tighten the RH side using the same procedures as the LH side.

  113. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.4 N*m  { 65 kgf*cm, 56 in.*lbf }

  114. ADD POWER STEERING FLUID

  115. BLEED POWER STEERING FLUID

  116. ADD ENGINE OIL


    1. Add fresh oil and install the oil filler cap.

      Engine oil
      Oil Grade Oil Viscosity (SAE)

      • API CF-4 or CF, G-DLD-1, ACEA B1

      • 20W-50


      • 15W-40


      • 10W-30


      • 5W-30 Preferred
      Capacity
      Item Fill Amount
      Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 lmp. qts)
      Drain and refill without oil filter change 6.8 liters (7.2 US qts, 6.0 lmp. qts)
      Dry fill 7.7 liters (8.1 US qts, 6.8 lmp. qts)

  117. ADD ENGINE COOLANT


    1. Pour coolant into the radiator until it overflows.

      Capacity
      Specification Capacity
      w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts)
      w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand.

      If the coolant level goes down, add coolant.

    3. Install the radiator cap securely.

    4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

    5. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    6. Maintain the engine speed at 2000 to 2500 rpm.

    7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

      CAUTION:


        When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

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

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

    10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

    11. Check the coolant level inside the radiator reservoir tank again.

      If it is below the full level, add coolant.

  118. INSPECT FOR ENGINE OIL LEAK


    1. Warm up the engine and inspect for oil leak.

  119. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

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

    2. A01KH30E02
      Text in Illustration
      *1 Radiator Cap Tester

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

    3. Warm up the engine.

    4. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.

    5. Reinstall the radiator cap.

  120. INSPECT FOR FUEL LEAK

  121. INSPECT FOR EXHAUST GAS LEAK

  122. CHECK ENGINE OIL LEVEL


    1. Warm up the engine, stop the engine and wait 5 minutes.

    2. Check that the oil level is between the upper level and lower level of the oil level gauge.

      If the oil level is low, check for leakage and add oil up to the upper level of the oil level gauge.

  123. CHECK POWER STEERING FLUID LEVEL

  124. INSPECT FOR POWER STEERING FLUID LEAK

  125. CHECK ENGINE IDLING SPEED AND MAXIMUM SPEED

    Note

    Turn all the electrical systems OFF.


    1. Warm up and stop the engine.

    2. A01KI6BE08
      Text in Illustration
      *1 Intelligent Tester

      When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Select the following menu items:

        Powertrain / Engine and ECT / Data List / Engine Speed.

        Tech Tips

        Refer to the intelligent tester operator's manual for further information regarding the selection of Data List.

      4. Inspect the engine idling speed.

        Idling speed
        700 to 800 rpm

      5. Fully depress the accelerator pedal.

      6. Check the maximum speed.

        Maximum speed
        4300 to 4600 rpm

      7. Turn the ignition switch to OFF.

      8. Disconnect the intelligent tester from the DLC3.

    3. A01KFZPE58

      When not using the intelligent tester:


      1. Install SST to terminal 9 (TAC) of DLC3, then connect a tachometer.

        SST
        09843-18040

        Note

        Examine the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      2. Turn the ignition switch to ON.

      3. Inspect the engine idling speed.

        Idling speed
        700 to 800 rpm

      4. Fully depress the accelerator pedal.

      5. Check the maximum speed.

        Maximum speed
        4300 to 4600 rpm

      6. Turn the ignition switch to OFF.

      7. disconnect the tachometer.

      8. Remove SST from terminal 9.

  126. INSPECT COMPRESSION


    1. Warm up and stop the engine.

    2. Remove the 4 glow plugs Click here.

      Note

      In order to avoid shorting the circuit of the wire harness connected to the glow plug No. 1 connector, wrap vinyl tape around the wire harness terminal portion.

    3. Disconnect all the connectors from the 4 injector.

    4. Connect the cable to negative battery terminal.

      Torque:
      6.4 N*m  { 65 kgf*cm, 56 in.*lbf }

    5. Crank the engine to remove foreign objects before measuring the compression.

    6. A01KFC1E01

      Install SST into the glow plug hole.

      SST
      09992-00026   ( 09992-00121 )
      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    7. A01KH72E01

      Connect a compression gauge to SST.

      SST
      09992-00026   ( 09992-00211 )

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

      Standard pressure
      2000 kPa (20.1 kgf/cm2, 290 psi)
      Minimum pressure
      1630 kPa (16.6 kgf/cm2, 236 psi)
      Difference between each cylinder
      500 kPa (5.0 kgf/cm2, 71 psi) or less

      Note


      • Use a fully-charged battery so that the engine speed can be increased to 250 rpm or more.


      • Inspect the other cylinders in the same way.


      • Measure the compression pressure in as short a time as possible.

      If the cylinder compression is low, pour a light coat of engine oil into the cylinder through the glow plug hole, then inspect it again.

      Tech Tips


      • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.


      • If the pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket.

    9. Remove the compression gauge and SST.

    10. Disconnect the cable from the negative battery terminal.

    11. Connect all the connectors to the 4 injectors.

    12. Install the 4 glow plugs Click here.

  127. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  128. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH


    1. for Double Cab:

      Install the engine side cover LH with the 4 bolts.

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

    2. for Single Cab:

      Install the engine side cover LH with the 3 bolts.

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

  129. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH


    1. for Double Cab:

      Install the engine side cover RH with the 4 bolts.

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

    2. for Single Cab:

      Install the engine side cover RH with the 3 bolts.

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