ENGINE ASSEMBLY INSTALLATION


  1. INSTALL REAR END PLATE

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

  2. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A01KF0GE02

      Using SST, fix the crank shaft pulley.

      SST
      09213-58012
      09330-00021

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent
    3. A01KIF5E01

      Install the bolts, as shown in the illustration.

      Torque:
      178 N*m  { 1816 kgf*cm, 131 ft.*lbf }

      Note

      Do not start the engine within 1 hour after the installation.

  3. INSTALL CLUTCH DISC ASSEMBLY


    1. A01KGUAE01
      Text in Illustration
      *A 5L
      *B 2KD-FTV
      A01KFFI Engine side

      Insert SST in the clutch disc, then insert them in the flywheel.

      SST
      09301-00110

      Note

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

  4. INSTALL CLUTCH COVER ASSEMBLY


    1. A01KHCHE03
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the clutch cover and the flywheel.

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

      Torque:
      19.1 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Following the order in the illustration, tighten the bolts at a time evenly.

      • Move SST up and down, right and left lightly, after checking that the disc is in the center, tighten the bolts.

      SST
      09301-00110

  5. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY



  6. INSTALL STARTER ASSEMBLY



  7. INSTALL ENGINE WIRE

  8. INSTALL ENGINE W/TRANSMISSION ASSEMBLY


    1. A01KHMWE01
      Text in Illustration
      *1 Bolt A
      *2 Bolt B
      *3 Bolt C

      Using an engine lifter, install the engine assembly with transmission.

      Torque:
      Bolt A
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }
      Bolt B
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }
      Bolt C
      42 N*m  { 430 kgf*cm, 31 ft.*lbf }

  9. INSTALL FRONT SUSPENSION MEMBER ASSEMBLY


    1. Using an engine lifter, install the front suspension member assembly with the 4 bolts.

      Torque:
      150 N*m  { 1530 kgf*cm, 110 ft.*lbf }

    2. Install the front stabilizer cover RH and LH.

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

    3. Install the front shock absorber assembly RH and LH at the lower arm part.

      Torque:
      105 N*m  { 1070 kgf*cm, 77 ft.*lbf }

  10. INSTALL PRESSURE FEED TUBE ASSEMBLY

  11. INSTALL VANE PUMP ASSEMBLY

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  12. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01KGSCE02

      Install the oil reservoir with bracket and 2 bolts.

    2. Connect the pressure feed tube.

    3. Connect the return tube.

  13. 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 }

  14. INSTALL FRONT SPRING BUMPER NO.1


    1. Install the front spring bumper No. 1 RH and LH and nut.

      Torque:
      120 N*m  { 1225 kgf*cm, 88 ft.*lbf }

  15. INSTALL 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 }

  16. INSTALL TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Connect the RH side by the same procedures with the LH side.

  17. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

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  18. INSTALL PROPELLER SHAFT ASSEMBLY REAR



  19. INSTALL ENGINE WIRE

  20. INSTALL INTAKE AIR CONNECTOR


    1. A01KFK2E02

      Install the intake air connector with diesel throttle body assembly, new gasket, 2 bolts and 2 nuts.

      Torque:
      A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      B
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the connector and hose.


      1. Connect the throttle control motor connector.

      2. Connect the throttle full switch connector.

      3. Connect the Intake air temp. sensor connector.

      4. Connect the vacuum hose.

  21. INSTALL TURBOCHARGER SUB-ASSEMBLY

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  22. INSTALL EXHAUST PIPE ASSEMBLY FRONT

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  23. INSTALL AIR CLEANER HOSE NO.2

  24. INSTALL AIR CLEANER PIPE

  25. INSTALL FUEL HOSE ALL (ENGINE ROOM)

  26. INSTALL RADIATOR ASSEMBLY

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  27. INSTALL FLUID COUPLING ASSEMBLY


    1. Insert the fan shroud and the fan with coupling simultaneously

    2. Install the fan with coupling with the 4 nuts.

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

    3. Install the fan shroud with the 2 bolts.

  28. INSTALL RADIATOR HOSE OUTLET

    A01KHGVE02

  29. INSTALL RADIATOR HOSE INLET

  30. INSTALL AIR HOSE NO.3

  31. INSTALL AIR HOSE NO.1

  32. INSTALL REAR HEATER WATER INLET HOSE A (FROM ENGINE)

  33. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

  34. INSTALL FAN AND GENERATOR V BELT


    1. A01KHUCE01
      Text in Illustration
      *1 Auto Tensioner

      Set the V belt to everything except the auto tensioner, as shown in the illustration.

    2. Loosen the V belt by turning the belt tensioner clockwise.

    3. Then set the V belt to the auto tensioner.

    4. A01KEFAE01

      After a new belt has been installed, check that the mark is within the B range as shown in the illustration.

  35. INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH

  36. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH

  37. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH

  38. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH

  39. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Torque:
    11.5 N*m  { 115 kgf*cm, 8.5 ft.*lbf }

  40. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

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  41. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  42. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Install the control cable with clip and nut.

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

  43. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Install the control cable with clip and nut.

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

  44. INSTALL FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)

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  45. INSTALL FRONT SEAT ASSEMBLY RH (W/O TILT CAB CAB TYPE)

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  46. INSTALL BATTERY NEGATIVE TERMINAL

  47. REFILL ENGINE COOLANT


    1. Slowly fill the system with coolant.


      • Use of improper coolants may damage engine cooling system.


      • Use "Toyota Long Life Coolant" or equivalent and mix it with plan water according to the manufacturer's directions.


      • Using of coolant which includes more than 50 % [freezing protection down to -35°C (-31°F)] or 60 % [freezing protection down to -50°C (-58°F)] of ethylene-glycol is recommended but not more than 70 %.

      Note


      • Do not use an alcohol type coolant or plain water alone.


      • The coolant should be mixed with plain water (preferably demineralized water or distilled water).

        Capacity:

        w/ Front heater

        w/o heater

        10.1 liters (10.5 US qts, 8.7 Imp. qts)

        9.2 liters (9.51 US qts, 7.9 Imp. qts)

        w/ Front and Rear

        heater

        		 10.9 liters (11.5 US qts, 8.9 Imp. qts)

    2. Reinstall the radiator cap.

    3. Start the engine, and bleed the cooling system.

    4. Refill the radiator reservoir with coolant until it reaches the "full" line.

  48. ADD POWER STEERING FLUID

  49. BLEED INJECTION PIPE


    1. Move the priming pump of the fuel filter up and down until it becomes hard.

  50. BLEED POWER STEERING FLUID


    1. Check the fluid level.

    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 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 wheel to the left or right full lock position and keep it there for 2 - 3 seconds. Then turn the wheel to the opposite full lock position and keep it there for 2 - 3 seconds (step A).

      2. Repeat step A several times.

    7. Stop the engine.

    8. A01KEKBE17
      Text in Illustration
      *a Normal
      *b Abnormal

      Check for foaming or emulsification.

      Especially, if the system has to be bled twice because of foaming or emulsification, check for fluid leakage in the system.

    9. Check the fluid level.

  51. CHECK POWER STEERING FLUID LEAKAGE

  52. CHECK ENGINE COOLANT LEAK

  53. INSPECT FUEL LEAK

  54. CHECK EXHAUST GAS LEAK

  55. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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