ENGINE ASSEMBLY (w/o DPF) INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket with the 4 bolts.

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

  2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket with the 4 bolts.

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

  3. INSTALL OIL COOLER COVER SUB-ASSEMBLY

    Click here

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


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

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

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


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

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the vacuum hose.

  6. INSTALL WATER OUTLET


    1. A01BHVXE01

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

      Tech Tips

      Make sure the claws of the gasket face the water outlet.

    2. Install the water outlet with the 2 bolts.

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

  7. INSTALL INTAKE MANIFOLD


    1. A01BDGBE01

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

    2. Tighten the 2 nuts and 4 bolts in the order shown in the illustration.

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

      Note

      Make sure that the swirl control valve actuator is not damaged by the surrounding parts.

  8. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

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

  9. INSTALL GLOW PLUG ASSEMBLY

    Click here

  10. INSTALL NO. 2 CYLINDER BLOCK INSULATOR

  11. INSTALL THERMOSTAT

    A01BHU2E02

    1. Install a new gasket onto the thermostat.

      Tech Tips

      When installing the thermostat onto 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° on either side of the prescribed position.

  12. INSTALL WATER INLET


    1. A01BGMWE01

      Install the water inlet with the 3 bolts.

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

  13. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install a new gasket and the No. 2 water by-pass pipe with the bolt and 2 nuts.

      Torque:
      for bolt
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
      for nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  14. INSTALL CRANKSHAFT PULLEY


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

    2. A01BHJJE01

      Using SST, install the pulley bolt.

      SST
      09213-58014
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  15. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

  16. INSTALL COMMON RAIL ASSEMBLY

    Click here

  17. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.

    2. Temporarily install a new gasket and the union bolt.

    3. Tighten the 3 bolts and union bolt.

      Torque:
      for bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Connect the 3 fuel hoses.

  18. INSTALL VACUUM SWITCHING VALVE BRACKET


    1. Install the vacuum switching valve bracket with the bolt.

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

    2. Connect the 2 vacuum hoses and vacuum switching valve connector.

  19. INSTALL EGR COOLER ASSEMBLY

    Click here

  20. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  21. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. A01BCLDE01

      Install a new gasket onto the intake manifold.

      Tech Tips

      Fit the gasket to the cutout of the intake manifold.

    2. A01BD19E02

      Install the throttle body assembly with the 2 bolts and 2 nuts. (A)

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    3. Connect the water by-pass hose. (B)

    4. Connect the water by-pass hose No.2. (C)

    5. Connect the throttle motor connector. (D)

  22. INSTALL CAMSHAFT POSITION SENSOR

    A01BE2P

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

    2. A01BERQ

      Install the camshaft position sensor with the bolt.

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

      Note

      Do not crack or jam the O-ring when installing the camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  23. INSTALL CRANKSHAFT POSITION SENSOR

    A01BAAT

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

    2. A01BFNV

      Install the crankshaft position sensor with the bolt.

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

      Note

      Do not crack or jam the O-ring when installing the crankshaft position sensor.

    3. Connect the 3 wire harness clamps.

    4. A01BB55

      Connect the crankshaft position sensor to the No. 1 vacuum pipe.

    5. Connect the crankshaft position sensor connector.

  24. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A01BGLUE01

      Using SST, install a new gasket and the engine coolant temperature sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  25. INSTALL TIMING BELT

    Click here

  26. INSTALL VACUUM PUMP ASSEMBLY


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

    2. Install the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

  27. INSTALL TIMING GEAR COVER INSULATOR


    1. Install the timing gear cover insulator with the bolt.

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

  28. INSTALL VANE PUMP ASSEMBLY


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

    2. A01BEQHE01

      Install the vane pump assembly with the 2 nuts.

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

      Note

      Make sure that the vane pump O-ring is not caught between other parts.

  29. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  30. REMOVE ENGINE STAND


    1. A01BAPWE01

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Tech Tips

      Part No.

      No. 1 Engine Hanger 12284-30020
      No. 2 Engine Hanger 12282-67020
      Bolt 91552-81014 and 91642-81030
      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

  31. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. A01BFU0E01

      Install the 2 front engine mounting insulators and 2 engine mounting stabilizers with the 2 nuts.

      Torque:
      for Nut Type A
      76 N*m  { 775 kgf*cm, 56 ft.*lbf }
      for Nut Type B
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  32. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  33. CONNECT PRESSURE FEED TUBE ASSEMBLY


    1. Install a new gasket to the pressure feed tube assembly.

    2. A01BBC6E01

      Connect the pressure feed tube assembly to the vane pump assembly with the union bolt.

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

      Tech Tips

      Make sure the stopper of the pressure feed tube assembly contacts the vane pump assembly as shown in the illustration.

  34. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE


    1. A01BF46E01

      Connect the No.1 oil reservoir to pump hose to the vane pump assembly with the clip.

  35. INSTALL ENGINE ASSEMBLY


    1. Set an engine lifter in place.

    2. Operate the engine lifter and install the engine to the vehicle.

    3. A01BCFWE05

      Install the engine with crossmember with the 16 bolts.

      Torque:
      for bolt A
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
      for bolt B
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
      for bolt C
      150 N*m  { 1530 kgf*cm, 111 ft.*lbf }

  36. CONNECT STEERING TORQUE SHAFT ASSEMBLY


    1. A01BG7RE01

      Align the matchmarks on the steering torque shaft assembly and the power steering link assembly.

    2. A01BH0EE01

      Install bolt (B) and tighten the 2 bolts.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  37. CONNECT SHOCK ABSORBER ASSEMBLY FRONT LH

    Click here

  38. CONNECT SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  39. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER LH


    1. A01BCZVE02

      Connect the front suspension upper arm to the steering knuckle with the nut.

      Torque:
      113 N*m  { 1,150 kgf*cm, 83 ft.*lbf }

    2. Install a new cotter pin.

      Note


      • If the holes for the cotter pin are not aligned, tighten the nut up to 60°.

      • Do not damage the ball joint dust cover.

  40. CONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  41. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A01BB1EE01

      Install the brake caliper assembly to the steering knuckle with the 2 bolts.

      Torque:
      123 N*m  { 1,250 kgf*cm, 91 ft.*lbf }

  42. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  43. INSTALL SPEED SENSOR FRONT LH (w/ ABS)


    1. A01BFZEE01

      Install the speed sensor to the steering knuckle with the 2 bolts.

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

      Note


      • Prevent foreign matter from adhering to the speed sensor.

      • Be careful not to damage the speed sensor.

      • Do not twist the sensor wire when installing the speed sensor.

  44. INSTALL SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  45. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolt.

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

  46. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. for Manual Transmission:

      Apply adhesive to 2 or 3 threads of each of the 8 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    2. A01BHJJE01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    3. for Manual Transmission


      1. A01BCISE01

        Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.

        Torque:
        178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

    4. for Automatic Transmission.


      1. A01BFMDE01

        Install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

        Note

        Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer with the knock pin of the flywheel and ring gear, and then install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

        Tech Tips

        As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in the direction shown in the illustration.

      2. A01BGYSE01

        Install and uniformly tighten the 8 bolts in several steps in the sequence shown in the illustration.

        Torque:
        178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

  47. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)


    1. A01BHPFE01

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

      SST
      09301-00110

      Note

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

  48. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A01BG9GE02

      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.

      SST
      09301-00110
      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 the SST up and down, left and right.

  49. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A01BCZQ

      Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

      Maximum non-alignment
      1.3 mm (0.051 in.)
    2. A01BEOPE01

      If alignment is not as specified, adjust the diaphragm spring tip alignment using SST.

      SST
      09333-00013

  50. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Click here

  51. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  52. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


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

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

  53. CONNECT ENGINE ROOM MAIN WIRE


    1. Install the nut and close the cover.

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

    2. Connect the 5 connectors.

    3. Attach the clamp and connect the engine room main wire.

  54. CONNECT ENGINE WIRE


    1. Connect the connectors to the ECM.

    2. Install the wire harness support to the ECM.

    3. Install the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Connect the 3 connectors and engine wire.

  55. CONNECT VACUUM HOSE


    1. Connect the vacuum hose to the vacuum pump.

  56. CONNECT NO. 1 FUEL HOSE


    1. Connect the No. 1 fuel hose to the fuel supply pump.

  57. CONNECT NO. 2 FUEL HOSE


    1. Connect the No. 2 fuel hose to the No. 2 nozzle leakage pipe.

  58. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose to the No. 2 water by-pass pipe.

  59. CONNECT NO. 4 RADIATOR HOSE


    1. Connect the No. 4 radiator hose to the water inlet.

  60. CONNECT RADIATOR HOSE INLET


    1. Connect the radiator hose inlet to the water outlet.

  61. INSTALL NO. 4 AIR HOSE


    1. Install the No. 4 air hose to the diesel throttle body.

  62. CONNECT OIL RETURN HOSE


    1. Connect the oil return hose to the intake manifold.

  63. INSTALL EXHAUST MANIFOLD


    1. Set a new gasket on the cylinder head.

    2. Install the exhaust manifold, 8 washers, 8 collars with 8 new nuts.

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

      Note

      Install the collars so that the side with the smaller external diameter faces the exhaust manifold.

  64. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  65. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01BFC7E01

      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.

  66. INSTALL GENERATOR ASSEMBLY

    Click here

  67. INSTALL NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Install the spacer, No. 2 idle pulley and pulley plate with the bolt.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  68. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01BFLCE02

      Temporarily install the No. 1 compressor mounting bracket with the 4 bolts.

      Tech Tips

      Make sure that the No. 1 compressor mounting bracket is in contact with the cylinder block.

    2. Tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  69. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BFP8E01

      Install the compressor outlet elbow with the 2 hose clamps and bolt.

      Torque:
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for hose clamp A
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      for hose clamp B
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  70. INSTALL AIR TUBE ASSEMBLY


    1. A01BGL8E01

      Install the air tube with the 2 hose clamps and 2 bolts.

      Torque:
      for bolt A
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }
      for bolt B
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for hose clamp
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

  71. INSTALL NO. 1 AIR CLEANER HOSE


    1. Install the air cleaner hose to the compressor inlet elbow.

      Note

      Pull the hose to make sure that it is locked and securely connected.

  72. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  73. TEMPORARILY INSTALL FAN PULLEY


    1. Temporarily install the fan pulley with the 4 nuts.

  74. INSTALL FAN AND GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  75. TIGHTEN FAN PULLEY


    1. Tighten the 4 nuts and install the fan pulley.

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

  76. INSTALL FRONT WHEELS

    Torque:
    100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

  77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  78. ADD ENGINE OIL


    1. Add new engine oil.

      Engine Oil
      Oil Grade Oil Viscosity (SAE)
      G-DLD-1, API CF-4 or CF, ACEA B1

      5W-30

      10W-30

      15W-40

      20W-50
      Capacity
      Item Fill Amount
      Drain and refill without oil filter change 6.8 liters (7.2 US qts, 6.0 Imp. qts)
      Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Dry fill 7.7 liters (8.1 US qts, 6.8 Imp. qts)

    2. Install the oil filler cap.

  79. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.6 liters (14.4 US qts, 12.0 Imp. qts)
      w/ Front Heater 14.6 liters (15.4 US qts, 12.8 Imp. qts)
      w/ Front and Rear Heaters 16.6 liters (17.5 US qts, 14.6 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01BGFB

      Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.

    6. 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.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  80. ADD POWER STEERING FLUID

  81. ADD MANUAL TRANSMISSION OIL (for Manual Transmission)


    1. A01BD8XE01

      Park the vehicle in a level place.

    2. Remove the transmission filler plug and gasket.

    3. Check that the oil surface is within 5 mm (0.20 in.) below the lowest point of the transmission filler plug opening.

      Oil grade
      GL-4
      Viscosity
      SAE 75W-90
      Capacity
      2.6 liters (2.7 US qts, 2.3 lmp.qts)

      Note


      • Problems may occur when the oil level is too high or too low.

      • After replacing the oil, drive the vehicle and check the oil level again.

    4. Check for oil leakage if the oil level is low.

    5. Install the transmission filler plug and a new gasket.

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

  82. ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

  83. CHARGE REFRIGERANT (w/ Air Conditioning System)


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A01BFDKE01
      Standard
      Single A/C
      520 to 580g (18.3 to 20.5 oz.)
      Dual A/C
      670 to 730g (23.0 to 25.7 oz.)
      SST
      07110-58060   ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

      Tech Tips

      Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

  84. BLEED AIR FROM FUEL SYSTEM


    1. A01BBOIE01

      Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01BERAE03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01BCPLE05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  85. 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 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 there 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.

      2. Repeat several times.

    7. Stop the engine.

    8. A01BAB7E03

      Check for foaming or emulsification.

      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.

  86. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the intelligent tester on.

      4. Select the following menu items: Powertrain / ECD / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Increases common rail internal fuel pressure and checks for fuel leaks Stop/Start

        • Fuel pressure inside common rail increased to specified value and engine speed increased to 2000 rpm when Active Test is performed

        • Above conditions preserved while Active Test is being performed

  87. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  88. INSPECT FOR COOLANT LEAK

    CAUTION:

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


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

    2. Warm up the engine.

    3. 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.

      Tech Tips

      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.

  89. INSPECT FOR POWER STEERING FLUID LEAK

  90. CHECK ENGINE OIL LEVEL


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

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

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

  91. INSPECT POWER STEERING FLUID LEVEL

  92. INSPECT AUTOMATIC TRANSMISSION FLUID LEVEL (for Automatic Transmission)

    Tech Tips

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

    Fluid temperature
    70 to 80 °C (158 to 176 °F)

    1. A01BFA1E01

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

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

    3. Take out the dipstick and wipe it clean.

    4. Put it back all the way.

    5. Take it out again and check that the fluid level is within the HOT range.

      If the fluid level is below the HOT range, add new fluid and recheck the fluid level. If the fluid level exceeds the HOT range, drain the fluid once, add the proper amount of new fluid and recheck the fluid level.

  93. INSPECT SHIFT LEVER POSITION (for Automatic Transmission)


    1. When shifting from P position only with ignition switch ON and depress the break pedal.

    2. Make sure that the shifting lever moves smoothly and can be moderately operated.

    3. When starting engine, make sure that the vehicle moves forward when shifting from N to D position and moves reward when shifting R position.

  94. ADJUST SHIFT LEVER POSITION (for Automatic Transmission)


    1. A01BDE0E02

      Remove a clip, nut, and disconnect between the control shaft lever to transmission control cable assembly from the control shaft lever and transmission control cable bracket No.1.

    2. A01BBPPE05

      Turn the control shaft lever until stop to a clockwise direction, return the control shaft lever 2 notches to N position.

    3. A01BEYV

      Set the shift lever to N position while holding the shift lever lightly toward the R position side and install it.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }

      Note

      Tighten the nut with it closing up cranky.

    4. Inspect the operation condition and work.

  95. INSPECT FOR EXHAUST GAS LEAK

  96. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)


    1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Stop the engine.

      • Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A01BC1LE02

      Using a gas leak detector, check for leakage of the refrigerant line.

    4. A01BCXGE01

      Bring the gas leak detector close to the drain hose with the detector's power off.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

  97. INSTALL NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Install the No. 2 engine under cover with the 6 bolts.

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

  98. INSTALL NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Install the No. 1 engine under cover with the 4 bolts.

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

  99. INSTALL NO. 2 ENGINE SERVICE HOLE COVER (for Standard Body)


    1. Install the No. 2 engine service hole cover with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Attach the clips and return the carpet to its original position.

  100. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

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

  101. INSTALL FRONT DOOR SCUFF PLATE RH

  102. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

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

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

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

  103. CHECK ENGINE IDLING SPEED AND MAXIMUM SPEED

    Note

    Turn all electrical systems OFF.


    1. Warm up and stop the engine.

    2. A01BD31E01

      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 / 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. A01BFMIE58

      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.

  104. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  105. INSPECT ABS SENSOR SIGNAL

    Click here