ENGINE ASSEMBLY (w/o DPF) INSTALLATION


  1. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH


    1. A01BC80E01

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

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

  2. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH


    1. A01BDC4E01

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

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

  3. INSTALL DIESEL ENGINE WATER TEMPERATURE SENSOR


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

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

  4. INSTALL OIL COOLER COVER SUB-ASSEMBLY

    A01BHZ8

    1. Install a new gasket and the oil cooler cover onto 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. A01BABQ

      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. A01BABSE01

      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. A01BHVX

      Set a new gasket.

    2. Install the water outlet with the 2 bolts.

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

  9. INSTALL INTAKE MANIFOLD

    A01BAG7E01

    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 in the sequence shown in the illustration.

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

  10. 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. A01BAQBE01

      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. A01BB48

      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.

  11. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    A01BFOP

    1. Install the No. 2 intake manifold insulator.

  12. INSTALL NO. 1 GLOW PLUG CONNECTOR

    A01BE1N

    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.

  13. INSTALL NO. 2 CYLINDER BLOCK INSULATOR

  14. 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.

  15. INSTALL WATER INLET


    1. A01BFN3

      Install the water inlet with the 3 bolts.

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

      Note

      Torque the 2 upper bolts first.

  16. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the gasket.

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

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

  17. 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.

  18. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01BI3F

      Temporarily install the nozzle leakage pipe with the 3 bolts.

    2. A01BG79

      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  { 133 kgf*cm, 10 ft.*lbf }

    4. Connect the 3 fuel hoses.

  19. INSTALL CRANKSHAFT PULLEY


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

    2. A01BHJJE01

      Using SST, install the pulley bolt.

      SST
      09213-58013
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  20. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


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

    2. Aligning the projecting edge of the fuel supply pump head to the key-slot of the supply pump gear, install the pump onto 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. Temporarily install the fuel supply pump with the 2 nuts.

    5. A01BHHYE01

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    6. Install the supply pump gear set nut.

      Tech Tips

      Set a new O-ring before tightening the supply pump gear set nut.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    7. A01BGD8

      Temporarily install the supply pump stay with the 2 nuts on the engine block side.

    8. Tighten the 2 nuts to the specified torque.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    9. A01BCD7

      Install the No. 2 camshaft timing pulley flange and the pump drive shaft pulley with the 4 bolts.

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

  21. INSTALL PUMP DRIVE SHAFT PULLEY

  22. INSTALL NO. 2 CAMSHAFT TIMING PULLEY FLANGE


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

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

  23. INSTALL COMMON RAIL ASSEMBLY

    A01BEK0

    1. Install the common rail with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
    2. A01BFUS

      Connect the fuel hose.

    3. Connect the 2 connectors to the common rail.

  24. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01BDF3

    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.

    • Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.


    1. Temporarily install the fuel inlet pipe.

    2. A01BC23

      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. Using SST, tighten the union nut on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective when SST is parallel to a torque wrench.

    5. Using SST, tighten the union nut on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective when SST is parallel to a torque wrench.

  25. INSTALL FUEL INJECTION PIPE

    Note


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

    • Keep the injection pipe connection clean.


    1. A01BF2K

      Install the injection pipes.


      1. Temporarily install the 4 injection pipes.

      2. A01BG01

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

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. A01BC1D

        Using SST, tighten the union nut on the fuel injector side to the specified torque.

        SST
        09023-12701
        Torque:
        32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
        35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

        Tech Tips


        • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

        • This torque value is effective when SST is parallel to a torque wrench.

      4. A01BE78

        Using SST, tighten the union nut on the common rail side to the specified torque.

        SST
        09023-12701
        Torque:
        32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
        35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

        Tech Tips


        • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

        • This torque value is effective when SST is parallel to a torque wrench.

      5. A01BALH

        Install the 3 bolts.

      6. Connect the fuel injector connector and harness clamps.

  26. INSTALL OIL LEVEL GAUGE GUIDE


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

    2. Apply a light coat of engine oil to the O-ring.

    3. Install the oil level gauge guide with the bolt.

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

    4. Install the oil level gauge.

  27. TEMPORARILY TIGHTEN MANIFOLD STAY


    1. Temporarily tighten the bolt and the manifold stay onto the cylinder block.

  28. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01BACYE03

    1. Temporarily tighten the electric EGR control valve.


      1. Install 2 new gaskets and the electric EGR control valve onto the intake air connector as shown in the illustration.

      2. A01BH7Q

        Temporarily tighten the intake air connector with electric EGR control valve to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose onto the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

  29. TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY

    A01BGO0

    1. Temporarily tighten the EGR cooler assembly.


      1. Temporarily tighten the EGR cooler assembly and new gaskets.

      2. A01BBGP

        Temporarily tighten the EGR cooler assembly stay bolt.

      3. A01BEW1

        Tighten the EGR cooler assembly with the 2 nuts and 2 bolts.

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

  30. TIGHTEN MANIFOLD STAY


    1. Tighten the bolt.

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

  31. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY

    A01BEFZ

    1. Tighten the electric EGR control valve with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01BBVC

      Connect the intake air temperature sensor connector.

    3. A01BG0F

      Connect the vacuum hose to the electric EGR control valve.

    4. Connect the electric EGR control valve connector.

    5. A01BH0B

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01BDUS

      Connect the 2 vacuum hoses to the vacuum regulating valve.

    7. Connect the vacuum regulating valve connector.

  32. TIGHTEN EGR COOLER ASSEMBLY

    A01BBGP

    1. Tighten the EGR cooler assembly stay bolt.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01BH3G

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

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

  33. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install a new gasket onto the intake air connector.

    2. A01BEHN

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A01BA8Q

      Connect the 2 throttle body connectors.

  34. 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.

  35. 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.

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


    1. A01BH1Y

      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


    1. A01BC61E03

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

      Tech Tips

      If reusing the timing belt, align the matchmarks 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 pump drive shaft pulley, camshaft timing pulley and No.1 timing belt idler in sequence.

    3. A01BAP9

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

      Note


      • Do not scratch and deform the rod end.

      • Press the tensioner rod in upward.

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

    4. Using the press, slowly apply 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force to the push rod.

      Note

      Do not apply a load of 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) or more to the push rod.

    5. Align the holes of the push rod and housing and pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    6. Temporarily 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 2 bolts when installing the tensioner

    8. Remove the 1.27 mm hexagon wrench from the tensioner.

    9. A01BB9ZE03

      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. A01BDL8

      Install the No.1 timing belt cover with the 6 bolts.

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

    2. Install the wire harness clamp.

  39. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01BFC7E01

      Temporarily install the V-ribbed belt tensioner with the 4 bolts.

      Tech Tips

      Make sure that the V-ribbed belt tensioner is in contact with the engine block at points A shown in the illustration.

    2. Tighten the V-ribbed belt tensioner with the 4 bolts.

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

  40. INSTALL VACUUM PUMP ASSEMBLY

    A01BAO8

    1. Apply a coat of engine oil to the 2 new O-rings.

    2. Install 2 new O-rings onto the vacuum pump.

    3. Install the vacuum pump with the 2 nuts.

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

      Note


      • Be careful not to drop the O-rings during installation.

      • Make sure that the vacuum pump is securely installed.

  41. INSTALL TIMING GEAR COVER INSULATOR

  42. 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.

  43. REMOVE ENGINE STAND

  44. INSTALL FRONT SUSPENSION CROSS MEMBER


    1. Install the engine assembly onto the cross member.

    2. Install the 4 bolts for the left and right sides of the front suspension cross member.

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

  45. 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.

  46. 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.

  47. INSTALL ENGINE ASSEMBLY


    1. Using an engine lifter, install the engine assembly w/ transmission onto the vehicle.

    2. A01BCFWE05

      Install the stabilizer brackets and the front suspension cross member with the 16 bolts.

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

    3. Connect the rear engine mount.

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

      Note

      Tighten the nut not the bolt when installing the mount.

    4. Remove the engine lifter slowly.

  48. 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 }

  49. INSTALL ENGINE WIRE


    1. Install the engine wire onto the engine assembly.

  50. CONNECT SHOCK ABSORBER ASSEMBLY FRONT LH

    Click here

  51. CONNECT SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  52. CONNECT FRONT SUSPENSION 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.

  53. CONNECT FRONT SUSPENSION SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  54. 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 }

  55. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  56. 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.

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

    Tech Tips

    Use the same procedures described for the LH side.

  58. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolt.

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

  59. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A01BCFSE02

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

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

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    3. Set the flywheel onto the crankshaft.

    4. A01BGK5E02

      For manual transmission


      1. Install the flywheel with the 8 bolts.

        Torque:
        178 N*m  { 1,815 kgf*cm, 131 ft.*lbf }

    5. For automatic transmission.


      1. Install the flywheel, drive plate and drive plate spacer rear with the 8 bolts.

        Torque:
        178 N*m  { 1,815 kgf*cm, 131 ft.*lbf }

  60. 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.

  61. 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.

  62. 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

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

    Refer to the procedures under "INSTALL MANUAL TRANSMISSION ASSEMBLY" Click here.

  64. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Refer to the procedures under "INSTALL AUTOMATIC TRANSMISSION ASSEMBLY" Click here.

  65. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

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

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

  66. CONNECT ENGINE WIRE


    1. Connect the +B terminal and connector of the starter.

      Torque:
      M8 nut
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      M10 nut
      21 N*m  { 215 kgf*cm, 16 ft.*lbf }
    2. A01BFD1E03

      Install the 4 connectors and nut as shown in the illustration.

    3. Connect the clamps of the engine wire and earth cable.

    4. Connect the connectors to the ECM.

    5. Install the wire harness support onto the ECM.

  67. CONNECT VACUUM HOSE


    1. A01BASG

      Connect the vacuum hose to the vacuum pump assembly.

      Tech Tips

      Connect the vacuum hose with its white mark facing up.

  68. CONNECT NO. 1 FUEL HOSE


    1. Connect the No. 1 fuel hose with the clamp to the supply pump assembly.

  69. CONNECT NO. 2 FUEL HOSE


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

  70. CONNECT NO. 3 WATER BY-PASS HOSE


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

  71. CONNECT NO. 4 RADIATOR HOSE


    1. Connect the No. 4 radiator hose to the water outlet with the clamp.

  72. CONNECT RADIATOR HOSE INLET


    1. Connect the radiator inlet hose to the water inlet with the clamp.

  73. CONNECT NO. 4 AIR HOSE


    1. Connect the No. 4 air hose to the diesel throttle body with the clamp.

  74. CONNECT OIL RETURN HOSE


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

  75. INSTALL EXHAUST MANIFOLD

    A01BFQG

    1. Install a new gasket onto the cylinder head.

    2. Install the exhaust manifold with 8 new 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.

  76. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BEFGE01

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

      Note

      Install the gasket in the correct direction.

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

  77. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. A01BCUS

      Temporarily install the turbocharger stay with the 2 bolts and new nut.

  78. FULLY TIGHTEN TURBOCHARGER STAY


    1. A01BCUS

      Tighten the 2 bolts and nut to the specified torque to install the turbocharger stay.

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

  79. FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01BAAME01

      Tighten the 2 bolts, 2 nuts and union nut to install the turbo oil inlet pipe 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 }

  80. INSTALL TURBINE OUTLET ELBOW


    1. A01BE8V

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

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

  81. CONNECT NO. 1 TURBO WATER HOSE


    1. A01BC20

      Connect the 2 turbo water hoses with the 2 clips.

  82. INSTALL EXHAUST MANIFOLD HEAT INSULATOR


    1. A01BG6A

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

  83. INSTALL NO. 1 TURBO INSULATOR


    1. A01BEFA

      Temporarily install the turbo insulator with the 2bolts.

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

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

  84. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. A01BHQ5

      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 the ventilation pipe sub-assembly.

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

  85. INSTALL TURBOCHARGER STROKE SENSOR CONNECTOR


    1. A01BETM

      Connect the turbocharger stroke sensor connector.

  86. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BFYF

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

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

  87. CONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01BBX8

      Connect the turbocharger motor connector.

  88. INSTALL GENERATOR ASSEMBLY


    1. A01BCVDE01

      Install the generator with the bolt.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Install the generator wire to terminal B with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7.2 ft.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  89. INSTALL GENERATOR BRACKET


    1. A01BCXBJ01

      Install the generator bracket with the 2 bolts.

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

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


    1. Install the idler pulley and washers with the bolt.

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

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


    1. A01BFLCE02

      Temporarily install the compressor bracket with the 4 bolts.

      Tech Tips

      Make sure that the compressor bracket is in contact with the engine block.

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

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

  92. INSTALL W/ PULLEY COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A01BFJ0E01

      Install the compressor and magnetic clutch with the 4 bolts.

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

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

  93. INSTALL AIR TUBE ASSEMBLY


    1. A01BAB5E01

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

      Torque:
      18 N*m  { 180 kgf*cm, 13 ft.*lbf, for bolt A }
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf, for bolt B }

  94. INSTALL NO. 1 AIR CLEANER HOSE


    1. A01BHN9

      Install the air cleaner hose to the compressor inlet elbow.

      Note

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

  95. INSTALL FENDER APRON MUDGUARD SEAL


    1. Install the fender apron mudguard seal with the 3 clips.

  96. TEMPORARILY TIGHTEN FAN PULLEY


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

  97. INSTALL FAN & 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.

  98. FULLY TIGHTEN FAN PULLEY


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

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

  99. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    A01BD2W

    1. Inspect the compression spring.


      1. Using vernier calipers, measure the free length of the compression spring.

        Minimum length
        40.5 mm (1.594 in.)

        If the free length is less than the minimum, replace the compression spring.

    2. A01BDL4E01

      Install a new gasket.


      1. Using a wooden block and plastic-faced hammer, tap in a new gasket until its surface is flush with the front exhaust pipe end.

        Note


        • Install the gasket in the correct direction.

        • Do not damage the outer surface of the gasket.

        • Do not reuse the removed gasket.

        • Do not push in the gasket with the front exhaust pipe when connecting it.

    3. A01BH7S

      Install the hanger and the front exhaust pipe.

    4. Install the 2 bolts and the 2 compression springs.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  100. INSTALL TAIL EXHAUST PIPE ASSEMBLY (for Long Wheelbase)


    1. A01BHA3

      Install a new gasket.

    2. A01BI3O

      Install the tail exhaust pipe with the 2 bolts and 2 new nuts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  101. INSTALL CENTER EXHAUST PIPE ASSEMBLY (for Super Long Wheelbase)


    1. A01BHA3

      Install a new gasket.

    2. A01BB6L

      Install the center exhaust pipe with the 2 bolts and 2 new nuts.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  102. INSTALL FRONT WHEELS

    Torque:
    100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

  103. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  104. ADD ENGINE OIL


    1. Add fresh engine oil and install the oil 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)

  105. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with coolant to the top of the inlet.

      Coolant capacity
      Condition Capacity
      w/ rear heater 18.2 liters (19.2 US qts, 16.0 lmp. qts)
      w/o rear heater 16.2 liters (17.0 US qts, 14.0 lmp. 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 install the bleeder plug.

    5. A01BGFB

      Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator 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.

  106. ADD POWER STEERING FLUID

  107. BLEED FUEL LINE


    1. A01BEO7E01

      Using a hand pump, bleed air from the fuel system until pumping becomes difficult.

  108. 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.

  109. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch 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 Pressurizes common rail internal fuel pressure, and checks 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

  110. INSPECT FOR ENGINE OIL LEAK

  111. INSPECT FOR ENGINE 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.

  112. INSPECT FOR POWER STEERING FLUID LEAK

  113. 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.

  114. INSPECT POWER STEERING FLUID LEVEL

  115. INSPECT FOR EXHAUST GAS LEAK

  116. INSTALL NO. 2 ENGINE SERVICE HOLE COVER

    A01BD0S

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A01BFN9

      Return the carpet.

  117. INSTALL ENGINE SERVICE HOLE SUB COVER ASSEMBLY


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

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

  118. INSTALL FRONT DOOR SCUFF PLATE

  119. 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 }

  120. 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.

  121. INSPECT COMPRESSION


    1. Warm up and stop the engine.

    2. Disconnect the cable from the negative battery terminal.

    3. 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.

    4. Disconnect all connectors from the 4 injectors.

    5. Connect the cable to negative battery terminal.

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

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

    7. A01BDOZE01

      Install SST into the glow plug hole.

      SST
      09992-00025   ( 09992-00121 )
      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    8. A01BGCYE01

      Connect a compression gauge to SST.

      SST
      09992-00025   ( 09992-00211, 09992-00121 )

    9. 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.

    10. Remove the compression gauge and SST.

    11. Disconnect the cable from the negative battery terminal.

    12. Connect all connectors to the 4 injectors.

    13. Install the 4 glow plugs Click here.

  122. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  123. INSPECT ABS SENSOR SIGNAL

    Click here