ENGINE ASSEMBLY INSTALLATION


  1. INSTALL ENGINE OIL LEVEL SENSOR


    1. Set a new gasket, and then install the engine oil level sensor with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 52 in.*lbf }

  2. INSTALL CRANKSHAFT POSITION SENSOR


    1. A003ADQ

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

    2. A003FZL

      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. Connect the 3 wire harness clamps.

    4. A003DF5

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

    5. Connect the crankshaft position sensor connector.

  3. INSTALL CAMSHAFT POSITION SENSOR


    1. A003HA2

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

    2. A003HO8

      Install the camshaft 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 camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  4. INSTALL DIESEL ENGINE WATER TEMPERATURE SENSOR


    1. Using a deep-socket wrench (17 mm), install the water temperature sensor.

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

  5. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  6. INSTALL CRANKSHAFT PULLEY


    1. A003FFME01

      Tighten the bolt holding the crankshaft pulley with SST.

      SST
      09213-58013
      09330-00021
      Torque:
      365 N*m  { 3,722 kgf*cm, 270 ft.*lbf }

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


    1. A003H5P

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

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

      Note

      Do not reuse the washer.

  8. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH


    1. A003ENOE01

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

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

  9. INSTALL EXHAUST MANIFOLD


    1. Install a new gasket and the exhaust manifold with the 2 bolts and 6 nuts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  10. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  11. INSTALL TURBINE OUTLET ELBOW


    1. Install a new gasket to the turbocharger.

    2. A003EY9

      Install the turbine outlet elbow with 4 new bolts.

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

  12. INSTALL TURBO WATER PIPE SUB-ASSEMBLY NO.2 (for Water Cooled Turbocharger)


    1. Install a new gasket onto the turbocharger.

    2. A003BBO

      Install the turbo water pipe No.2 with the bolt and 2 nuts to the turbocharger.

      Torque:
      Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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


    1. Water cooled turbocharger (w/ heater)


      1. Install a new gasket onto the cylinder block.

      2. A003F8R

        Install the water by-pass pipe No.2 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 }

      3. Connect the 2 water hoses with the 2 clips.

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

      5. Connect the heater water inlet hose with the clip.

    2. Water cooled turbocharger (w/o heater)


      1. Install a new gasket onto the cylinder block.

      2. A003EU5

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

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

      3. Install the turbo water pipe No.2 with the 2 bolts.

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

      4. Connect the 2 water hoses with the 2 clips.

      5. Connect the water by-pass hose No.3 with the clip.

    3. Air cooled turbocharger (w/o heater)


      1. Install a new gasket onto the cylinder block.

      2. A003EI6

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

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

  14. INSTALL COMPRESSOR ELBOW STAY


    1. A003D3R

      Install the compressor elbow stay with the bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 23 ft.*lbf }

  15. INSTALL VENTILATION HOSE HEAT INSULATOR


    1. Install the ventilation hose insulator heat with the 2 bolts.

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

  16. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

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

  17. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A003FQXE01

      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, 15 ft.*lbf }

  18. INSTALL GENERATOR ASSEMBLY


    1. A003CGHE01

      Install the generator assembly 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, 87 in.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  19. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolt.

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

      Note

      Fully tighten the generator bracket after installing the generator assembly.

  20. INSTALL IDLER 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 }

  21. INSTALL COMPRESSOR BRACKET (w/ Air Conditioning System)


    1. A003FEFE02

      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. Install the compressor bracket by tightening the 4 bolts as shown in the illustration.

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

  22. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A003B0FE01

      Install the thermostat with the jiggle valve facing up.

      Tech Tips

      The jiggle valve may be set within 15° on either side of the prescribed position.

  23. INSTALL WATER INLET


    1. A003G6NE01

      Install the water inlet with the 3 bolts.

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

  24. INSTALL GLOW PLUG


    1. Using a deep socket wrench (12 mm), install the 4 glow plugs.

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

  25. INSTALL GLOW PLUG NO.1 CONNECTOR


    1. Install the glow plug No.1 connectors with the 4 nuts.

      Torque:
      2.2 N*m  { 22 kgf*cm, 16 in.*lbf }

    2. Install the 4 grommets.

  26. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH


    1. A003DU1E01

      Install the engine mounting bracket front No.1 LH with the 4 bolt.

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

  27. INSTALL WATER OUTLET


    1. A003AUE

      Set a new gasket.

    2. A003F8UE01

      Install the water outlet with the 2 bolts.

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

  28. INSTALL OIL COOLER COVER SUB-ASSEMBLY (w/o EGR Valve)


    1. A003BZX

      Install a new gasket and oil cooler cover with the 2 nuts and 13 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A003CCI

      Install the oil drain hoses.

    3. Connect the oil pressure switch connector.

  29. INSTALL OIL COOLER COVER SUB-ASSEMBLY (w/ EGR Valve)


    1. A003AOV

      Install a new gasket and oil cooler cover with the 13 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A003DB9

      Install the vacuum transmitting pipe No.2 with the 2 nuts.

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

    3. Install the oil drain hoses.

    4. Connect the oil pressure switch connector.

  30. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A003ICG

      Confirm that the supply pump gear in the timing gear case moves back and forth smoothly.

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

    3. Aligning the projecting edge of the supply pump head to the key-slot of the supply pump gear, install the pump to the timing gear case.

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

    5. Temporarily install the supply pump with the 2 nuts.

    6. A003CTS

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    7. 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 }
    8. A003CSO

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

    9. Tighten the 2 nuts for the injection pump.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    10. A003GEB

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

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

  31. CHECK PUMP DRIVE SHAFT THRUST CLEARANCE


    1. A003C2L

      Push the pump drive shaft pulley back and forth to check a thrust clearance of the injection pump drive shaft.

      Thrust clearance
      0.15 to 0.55 mm (0.0059 to 0.0217 in.)

      Note

      Make sure that the crankshaft pulley's notch is at 30 degree in the counterclockwise direction form the TDC position.

      Tech Tips

      If there is not thrust clearance, disassemble and reassemble the injection pump and pump drive shaft pulley.

  32. INSTALL COMMON RAIL ASSEMBLY


    1. A003FS5E01

      Install the common rail assembly with the 2 bolts.

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

    2. Connect the fuel hose to the fuel pressure limiter.

    3. Connect the fuel pressure sensor connector.

  33. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Apply clean engine oil to the gasket of a new oil filter.

      Note

      Check and clean the oil filter installation surface.

    2. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.

    3. A003GTQE01

      Using SST, tighten the oil filter until the gasket contacts the seat, and then turn it further 3/4.

      SST
      09228-07501

  34. INSTALL INTAKE MANIFOLD


    1. A003H3Z

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

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

    2. Install the manifold stay with the bolt and nut.

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

    3. Connect the ground cable with the bolt.

  35. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. Temporarily install the nozzle leakage pipe with the 2 bolts.

    2. A003CK1

      Install the new gasket and union bolt to the nozzle leakage pipe.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A003DRM

      Tighten the 2 bolts.

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

  36. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    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. Using SST, tighten the injection pipe on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

    3. Using SST, tighten the injection pipe on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

  37. INSTALL INJECTION PIPE

    SST
    09023-12701

    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 clean the joint of the injection pipe.


    1. Install the injection pipes.


      1. A003E87

        Temporarily install the 4 injection pipes.

      2. A003C95

        Install the injection pipe clamp No.3 in 2 nuts.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. A003E87E01

        Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.

        SST
        09023-12701
        Torque:
        Use union nut wrench and torque wrench
        32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  38. 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.

  39. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. A003DG5E01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. A003HC0

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

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

      4. Temporarily tighten the manifold stay with the bolt.

      5. A003H5T

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. A003BEQ

        Install the vacuum regulating valve with the 2 bolts.

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

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

  40. INSTALL INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A003G45E01

      Temporarily install 2 new gaskets and intake air connector No.2 to the intake air connector.

    2. A003EYQ

      Temporarily tighten the intake air connector assembly with the bolt and 2 nuts.

    3. Tighten the manifold stay with the bolt.

    4. Tighten the intake air connector with the bolt and 2 nuts.

    5. Install the vacuum hose to the intake air connector.

  41. INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A003BF9

      Install 2 new gaskets to the cylinder head and the EGR pipe sub-assembly No.1 as shown in the illustration.

    2. A003CG8

      Install the EGR pipe with the 2 bolts and the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A003BPA

      Connect the fuel pressure sensor connector.

  42. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. Install a new gasket to intake air connector.

    2. A003F09

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A003BFR

      Connect the 2 throttle body connectors.

  43. INSTALL FAN PULLEY


    1. Install the fan pulley with the 4 nuts.

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

  44. PERFORM PISTON AND VALVE BREAK PREVENT WORK


    1. A003BHN

      When turning the camshaft with the timing belt removed, turn the crankshaft 90° counterclockwise.

      Note

      When installing the timing belt, it is necessary to return the camshaft to the timing marks and then turn the crankshaft clockwise so that it aligns with the timing marks as shown in the illustration.

  45. INSTALL TIMING BELT


    1. A003D4RE01

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

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

    3. A003C1U

      Set the tensioner to the press upright.

      Note


      • Do not allow the rod end to scratch and deform.

      • Press the tensioner rod in upward.

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

    4. Using a 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 loads 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) or more on the push rod.

    5. Align the holes of push rod and housing, 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 and install the tensioner

    8. Remove the 1.5 mm hexagon wrench from the tensioner.

    9. A003CL8E01

      Turn the crankshaft in the clockwise direction twice, check that the timing marks are aligned as shown in the illustration.

  46. INSTALL TIMING BELT COVER NO.1


    1. A003GME

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

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

  47. INSTALL VANE PUMP ASSEMBLY


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

    2. A003C7IE01

      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.

  48. REMOVE ENGINE STAND

  49. INSTALL FRONT SUSPENSION CROSS MEMBER


    1. Install the engine assembly to 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 }

  50. CONNECT PRESSURE FEED TUBE ASSEMBLY


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

    2. A003HCJE01

      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.

  51. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1


    1. A003BRFE01

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

  52. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  53. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolt.

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

  54. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A003FDJE01

      Fix the crankshaft with SST.

      SST
      09213-58013
      09330-00021
    2. A003BGDE02

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A003AKXE01

      For manual transmission


      1. Install the flywheel with the 8 bolts.

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

    4. For automatic transmission.


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

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

  55. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)


    1. A003DDKE01

      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.

  56. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A003H0AE02

      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.

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


    1. A003G6I

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

      Maximum non-alignment
      1.3 mm (0.051 in.)
    2. A003CZWE01

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

      SST
      09333-00013

  58. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

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

    Click here

  60. INSTALL STARTER ASSEMBLY (for 2.0 kW Type)


    1. A003FMLE01

      Install the starter with the bolt and 2 nuts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }
    2. A003EM1E01

      Connect the wire harness to terminal 30 and install the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Close the terminal cap.

    4. Connect the terminal 50 connector to the starter assembly.

    5. A003CHWE01

      for Wide body:

      Install the ground cable with the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  61. INSTALL STARTER ASSEMBLY (for 2.2 kW Type)


    1. Connect the wiring harness clamp bracket and install the starter assembly with the 2 bolts.

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

    2. Install the starter wire with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the starter connector.

    4. Install the No. 2 terminal cap.

  62. INSTALL STARTER ASSEMBLY (for 2.7 kW Type)


    1. A003FMLE01

      Install the starter with the bolt and 2 nuts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }
    2. A003EM1E01

      Connect the wire harness to terminal 30 and install the nut.

      Torque:
      21 N*m  { 215 kgf*cm, 16 ft.*lbf }

    3. Close the terminal cap.

    4. Connect the terminal 50 connector to the starter assembly.

    5. A003CHWE01

      for Wide Body:

      Install the wire ground cable with the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  63. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION


    1. Using a engine lifter, install the engine assembly w/ transmission to the vehicle.

    2. A003E2LE05

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

      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  { 1,530 kgf*cm, 111 ft.*lbf }

    3. Connect the rear engine mount.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

      Note

      Tighten the nut side when installing the mount.

    4. Remove the engine lifter slowly.

  64. CONNECT STEERING TORQUE SHAFT ASSEMBLY


    1. A003D4SE01

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

    2. A003FSCE01

      Install bolt (B) and tighten the 2 bolts.

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

  65. CONNECT OIL COOLER TUBE (for Automatic Transmission)


    1. Connect the oil cooler inlet tube and oil cooler outlet tube with the clamp to the oil cooler.

  66. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transmission)


    1. A003CCGE02

      Fix the transmission control cable assembly to the control cable bracket with a clip.

    2. Install the transmission control cable assembly to the control shaft lever with the nut.

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

  67. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A003D9DE01

      Coat a new O-ring with ATF and install the oil filler tube.

    2. Install the oil filler tube with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 8 ft.*lbf }

  68. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)


    1. A003CKV

      Install the clutch release cylinder with the 2 bolts.

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

  69. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)


    1. A003GZ9E01

      Install 2 new clips to the transmission control cable bracket No.1.

    2. Install the transmission control cable assembly to the transmission control cable bracket No.1.

      Note


      • Be sure that A claws of the clips are firmly engaged into the bracket grooves.

      • Be sure the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.

    3. Align the matchmarks on the control cable assembly and the outer lever.

    4. A003H3DE01

      Install the transmission control cable assembly to the outer levers with the 2 nuts.

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

  70. CONNECT SHOCK ABSORBER ASSEMBLY FRONT LH

    Click here

  71. CONNECT SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  72. CONNECT FRONT SUSPENSION SUB-ASSEMBLY UPPER LH


    1. A003DF6E02

      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.

  73. CONNECT FRONT SUSPENSION SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  74. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A003HGAE01

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

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

  75. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

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


    1. A003DFLE01

      Connect the front speed sensor with the 2 bolts and 2 clips.

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

      Note


      • Do not twist the sensor wire when installing.

      • Keep the sensor tip free from foreign matter.

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

    Tech Tips

    Use the same procedures described for the LH side.

  78. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)


    1. A003BT1E01

      Remove the SST from the extension housing.

    2. Install the propeller with center bearing shaft assembly in the extension housing.

    3. A003C3U

      Install the center support bearing assembly No.1, and temporarily tighten the 2 bolts.

    4. A003AD9E01

      Align the matchmarks on the propeller shaft flange and differential flange.

    5. Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

      Torque:
      74 N*m  { 755 kgf*cm, 54 ft.*lbf }
    6. A003CNLE01

      Check that the center line of the bracket is at right angles to the shaft axial direction.

    7. A003IAIE01

      Adjust the center support bearing assembly No.1.

      Tech Tips


      • With the vehicle unladen, adjust the center support bearing No.1 to maintain the angles, as shown.

      • In the same conditions, check the center line in the axial direction. Adjust the bearing if necessary.

      • The center bearing center line and center bearing housing center line must be adjusted to within -1.0 to 1.0 mm (-0.0394 to 0.0394 in.) of each other in the vehicle's longitudinal direction with the vehicle unladen.

    8. Tighten the 2 bolts.

      Torque:
      36 N*m  { 369 kgf*cm, 27 ft.*lbf }

  79. INSTALL PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    1. A003BT1E01

      Remove the SST from the extension housing.

    2. Install the propeller shaft assembly in the extension housing.

    3. Align the matchmarks on the propeller shaft flange and differential flange.

    4. A003AD9E01

      Install the propeller shaft assembly with the 4 nuts, 4 bolts and 4 washers.

      Torque:
      74 N*m  { 755 kgf*cm, 54 ft.*lbf }

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


    1. Connect the exhaust pipe supports and install the exhaust pipe assembly center and a new gasket with the 2 bolts to the exhaust pipe assembly tail.

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

  81. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for Super Long Wheelbase)


    1. Inspect the compression spring.


      1. A003DPX

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5mm(1.594 in.)

        Tech Tips

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

    2. A003FTXE03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the front exhaust manifold.

    3. Connect the exhaust pipe support, and install the exhaust pipe assembly front and a new gasket with the 4 bolts, 2 compression springs and 2nuts.

      Torque:
      Exhaust manifold side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Exhaust pipe assembly center side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front .

  82. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for Long Wheelbase)


    1. Inspect the compression spring.


      1. A003DPX

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5mm (1.594 in.)

        Tech Tips

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

    2. A003FTXE03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the front exhaust manifold.

    3. Connect the exhaust pipe support, and install the exhaust pipe assembly front with the 4 bolts, 2 compression springs and 2 nuts.

      Torque:
      exhaust manifold side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      exhaust pipe assembly front side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front.

  83. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A003E43E01

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

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

  84. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A003GDEE01

    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.

    2. Tighten 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.

  85. 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. A003HGCE03

      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 ECM connector Click here.

  86. CONNECT VACUUM HOSE


    1. A003CWC

      Connect the vacuum hose to the vacuum pump assembly.

  87. CONNECT FUEL HOSE NO.1


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

  88. CONNECT FUEL HOSE NO.2


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

  89. CONNECT WATER BY-PASS HOSE NO.3


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

  90. CONNECT RADIATOR HOSE NO.4


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

  91. CONNECT RADIATOR HOSE INLET


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

  92. CONNECT AIR HOSE NO.4


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

  93. CONNECT OIL RETURN HOSE (w/ Intercooler)


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

  94. INSTALL COMPRESSOR OUTLET ELBOW


    1. A003EV8E01

      Install the compressor outlet elbow with the 2 bolts and 2 clamps.

      Torque:
      Bolt (A)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  95. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. Install the air cleaner hose assembly with the clamp.

  96. INSTALL FENDER APRON MUDGUARD SEAL

  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. 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 }

  99. INSTALL FRONT DOOR SCUFF PLATE

  100. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  101. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  102. CONNECT BATTERY NEGATIVE CABLE

  103. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1,050 kgf*cm, 76 ft.*lbf }

  104. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  105. ADD ENGINE OIL


    1. Add the engine oil.

      Standard capacity
      Item Capacity
      Drain and refill with oil filter change 6.5 liters (6.9 US qts, 5.7 Imp. qts)
      Drain and refill without oil filter change 6.3 liters (6.7 US qts, 5.5 Imp. qts)
      Dry fill 7.2 liters (7.6 US qts, 6.3 Imp. qts)

    2. Install the oil filler cap.

  106. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

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

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)
      w/ Front Heater 14.2 liters (15.0 US qts, 12.5 Imp. qts)
      w/ Front and Rear Heaters 16.2 liters (17.1 US qts, 14.3 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 engine coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A003EJI

      Add engine coolant up to the B line mark in the radiator reservoir assembly and install the radiator reservoir cap sub-assembly.

    6. Warm up the engine until the thermostat opens.


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

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. A003FFY

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

  107. ADD POWER STEERING FLUID

  108. BLEED FUEL LINE


    1. Push the priming pump for several times to fill up the fuel lines with fuel.

  109. 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. A003CWUE03

      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.

  110. INSPECT FUEL LEAK


    1. PERFORM ACTIVE TEST


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch on.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        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

  111. INSPECT ENGINE OIL LEAKS

  112. INSPECT ENGINE COOLANT LEAKS

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot 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 or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  113. INSPECT POWER STEERING FLUID LEAK

  114. INSPECT POWER STEERING FLUID LEVEL

  115. INSPECT MANUAL TRANSMISSION OIL (for Manual Transmission)


    1. A003AJCE01

      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
      API GL-4
      Viscosity
      SAE 75W-90
      Capacity
      2.6 liters (2.7 US qts, 2.3 Imp.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 }

  116. INSPECT AUTOMATIC TRANSMISSION FLUID (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. A003EB4E01

      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.

  117. 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.

  118. ADJUST SHIFT LEVER POSITION (for Automatic Transmission)


    1. A003CCGE02

      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. A003HNXE05

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

    3. A003HJP

      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.

  119. INSPECT EXHAUST GAS LEAKS

  120. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  121. INSTALL ENGINE SIDE UNDER COVER RH (w/ Engine Side Under Cover RH)

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

  122. INSTALL ENGINE SIDE UNDER COVER LH (w/ Engine Side Under Cover LH)

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

  123. INSTALL ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)

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

  124. INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

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

  125. CHECK IDLE SPEED

    Note

    This checking procedure should be done under the following condition.

    Tech Tips


    • Regarding the details about the intelligent tester, refer to its operator's manual.

    • If the intelligent tester is not available, a tachometer's tester probe can substitute for it.


    1. Connect the intelligent tester to the DLC3.

    2. A003AU4E01

      If the tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18030

    3. Start the engine and check the idle speed.

      Idle speed
      700 to 800 rpm

      Tech Tips

      If the idle speed is not as specified, check by troubleshooting in the diagnostics section.

    4. In case of the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe from terminal 9 of the DLC3 with SST.

    5. Disconnect the intelligent tester from the DLC3.

  126. INSPECT MAXIMUM ENGINE SPEED

    Note

    This checking procedure should be done under the following condition.

    Tech Tips


    • Regarding the details about the intelligent tester, refer to its operator's manual.

    • If the intelligent tester is not available, a tachometer's tester probe can substitute for it.


    1. Connect the intelligent tester to the DLC3.

    2. A003AU4E01

      If the tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18030

    3. Start the engine.

    4. Depress the accelerator pedal all the way to the limit.

    5. Check the maximum speed.

      Maximum speed
      4500 to 4700 rpm

      Tech Tips

      If the maximum speed is not as specified, check by troubleshooting in the diagnostics section.

    6. In case of the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe from terminal 9 of the DLC3 with SST.

    7. Disconnect the intelligent tester from the DLC3.

  127. INSPECT ABS SENSOR SIGNAL

    Click here

  128. INSPECT FUNCTION OF THROTTLE BODY


    1. Inspect the throttle control motor.


      1. A003AM7

        Using an ohmmeter, measure the resistance between the terminals.

        Standard resistance
        Tester Connection Specified Condition
        1 (DUTY) - Body ground Infinity

  129. PERFORM INITIALIZATION

    Click here