GENERATOR (w/ DPF) INSTALLATION


  1. INSTALL GENERATOR ASSEMBLY (for LHD)


    1. A01KHPRE01

      Temporarily install the generator assembly 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, 87 in.*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 engine oil level dipstick guide.

    7. Install the engine oil level dipstick guide with the bolt.

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

    8. Install the engine oil level dipstick sub-assembly.

    9. Install the engine wire harness with the 2 bolts and connect the 2 connectors.

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

  2. INSTALL GENERATOR ASSEMBLY (for RHD)


    1. A01KHPRE01

      Temporarily install the generator assembly 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, 87 in.*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 engine oil level dipstick guide.

    7. Install the engine wire harness with the 2 bolts and connect the connector.

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

  3. INSTALL FAN AND GENERATOR V BELT

    A01KEFJE02

    1. Use the pulley set bolt of the tensioner to rotate the tensioner pulley clockwise, and then install the V belt.

      Text in Illustration
      *1 Fan Pulley
      *2 Crankshaft
      *3 Tensioner
      *4 Generator
      *a Turn

      Note

      Make sure that the V belt is set properly at each pulley.

    2. A01KH7RE01

      Make sure that the indicator mark of the tensioner is within range A, as shown in the illustration.

  4. INSTALL NO. 1 AIR HOSE


    1. Connect the No. 1 air hose and tighten the hose clamp.

  5. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH (for Double Cab)


    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 }

  6. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH (for Double Cab)


    1. A01KGS6

      Install the fender side apron sub-assembly RH with the 5 bolts.

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

  7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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