ДВИГАТЕЛЬ В СБОРЕ УСТАНОВКА

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 front engine mounting insulators to the 2 front engine mounting brackets with the 2 nuts.

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

  2. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  3. INSTALL ENGINE HANGER

    Click here

  4. REMOVE ENGINE FROM ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.


    1. Attach an engine sling device and hang the engine assembly with a chain block.

    2. Remove the engine assembly from the engine stand.

  5. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine assembly into the engine compartment.

    2. Install the engine assembly to the body with the 4 bolts and 4 nuts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Tech Tips


      • Make sure to tighten the side with the nut.

      • When installing a bolt with a claw (stopper), make sure that the claw (stopper) does not damage the body of the vehicle.

    3. Remove the 2 bolts, No. 1 engine hanger upper and No. 2 engine hanger.

  6. INSTALL REAR END PLATE


    1. Install the rear end plate to the cylinder block sub-assembly with the bolt.

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

  7. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Clean the bolt holes.

    2. B00256ON01

      Using SST, hold the crankshaft pulley sub-assembly.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

    3. Install the flywheel sub-assembly to the crankshaft to the crankshaft with 8 new bolts.

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

      Note

      Do not start the engine for at least 1 hour after installation.

  8. INSTALL CLUTCH DISC ASSEMBLY


  9. INSTALL CLUTCH COVER ASSEMBLY


  10. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


  11. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY


  12. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  13. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

    Click here

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. Connect the cooler compressor assembly to the No. 1 compressor mounting bracket with the 4 bolts.

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

  16. CONNECT PRESSURE FEED TUBE ASSEMBLY


    1. Using a 17 mm union nut wrench, connect the pressure feed tube assembly to the vane pump assembly.

      Torque:
      Specified tightening torque
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here


      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 380 mm (15.0 in.)): 40.8 N*m (416 kgf*cm, 30 ft.*lbf)

    2. Connect the oil reservoir to pump hose to the vane pump assembly, and slide the clamp to secure the hose.

  17. INSTALL BATTERY TRAY

  18. INSTALL BATTERY

  19. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the battery clamp sub-assembly to the battery with the 2 nuts.

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

  20. CONNECT WIRE HARNESS


    1. Connect the engine room main wire to the battery positive cable with the nut.

      Torque:
      7.1 N*m  { 72 kgf*cm, 63 in.*lbf }

    2. Attach the clamp and connect the No. 2 engine wire with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    3. Connect the 2 connectors to the engine room relay block sub-assembly.

    4. Connect the wire to wire to the engine room relay block sub-assembly with the nut.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    5. Attach the 2 clips and install the No. 1 relay block cover side to the engine room relay block sub-assembly.

    6. Attach the 3 clips and install the No. 1 relay block cover upper to the engine room relay block sub-assembly.

  21. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure the hose.

  22. CONNECT FUEL HOSE


    1. Connect the 2 fuel hoses to the No. 2 nozzle leakage pipe assembly and fuel supply pump assembly, and slide the 2 clamps to secure the hose.

  23. CONNECT WATER HOSE SUB-ASSEMBLY


    1. Connect the water hose sub-assembly to the water outlet and heater pipe, and slide the 2 clamps to secure the 2 hoses.

  24. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  25. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  26. INSTALL AIR CLEANER CAP AND HOSE

    Click here

  27. CONNECT ENGINE WIRE


    1. Pass the engine wire into the cabin.

    2. Attach the grommet to the body.

      Tech Tips

      Make sure the direction of grommet is shown in the illustration.

      B0025TBN01

    3. Connect the 3 connectors to the injector driver.

    4. Install the ECM.

      Click here

  28. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  29. INSTALL NO. 1 INTAKE PIPE


    1. Connect the pipe (with the 2 air hoses) and install the bolt.

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

    2. Tighten the 2 clamps.

    3. Connect the vacuum hose to the gas filter.

    4. Connect the manifold absolute pressure sensor connector.

  30. INSTALL RADIATOR ASSEMBLY

    Click here

  31. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood sub-assembly to the 2 hood hinge assemblies with the 4 bolts.

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

    2. Connect the washer nozzle hose to the hood sub-assembly.

  32. ADD POWER STEERING FLUID

  33. ADD MANUAL TRANSMISSION OIL


  34. ADD ENGINE OIL

    Click here

  35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  36. BLEED AIR FROM FUEL SYSTEM

    Click here

  37. ADD ENGINE COOLANT

    Click here

  38. BLEED AIR FROM POWER STEERING SYSTEM

    Click here

  39. INSPECT POWER STEERING FLUID LEVEL

    Click here

  40. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes.

      Click here

    2. Perform pilot quantity learning.

      Click here

  41. INSPECT FOR COOLANT LEAK

    Click here

  42. INSPECT FOR OIL LEAK

    Click here

  43. INSPECT FOR EXHAUST GAS LEAK

    Click here

  44. INSPECT FOR FUEL LEAK

    Click here

  45. CHECK ENGINE IDLE SPEED AND MAXIMUM SPEED

    Click here

  46. INSPECT ENGINE OIL LEVEL

    Click here

  47. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  48. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for 4WD and Pre-Runner)

    Torque:
    for M6 bolt
    11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }
    for M8 bolt
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }