Двигатель В Сборе Установка. Corolla Auris

Install the level sensor with the 4 bolts.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}

Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head.

Maximum warpage:

0.40 mm (0.0157 in.)

Install the exhaust manifold and gasket.

Loosely install the 2 collars of the exhaust manifold with the nuts labeled A. Tighten the nuts until the contact surface of the exhaust manifold contacts the cylinder head.

Loosely install the 6 collars with the 6 nuts.

УКАЗАНИЕ:

1. When installing the collars, pay attention to the mounting orientation. The ring groove of the collar should be on the outside. Refer to the illustration.
   
2. Tighten the nuts so that the position of the exhaust manifold can be adjusted in a later step.
   

Install a new gasket and the turbocharger with the 3 nuts.

Момент затяжки:

60 Н*м{612 кгс*см, 44 фунт-сила-футов}

Install the turbocharger stay with the 2 spacers and 2 nuts.

Момент затяжки:

36 Н*м{367 кгс*см, 27 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Do not reuse the turbocharger stay.

Tighten the 8 nuts.

Момент затяжки:

47 Н*м{479 кгс*см, 35 фунт-сила-футов}

Install 2 new gaskets and the turbo oil pipe with the 2 bolts.

Момент затяжки:

35 Н*м{357 кгс*см, 26 фунт-сила-футов}

Install 2 new gaskets and a new O-ring to the EGR cooler.

Temporarily install the EGR cooler with the 2 bolts and 2 nuts.

Temporarily install the 4 bolts.

Tighten the 2 bolts and 2 nuts holding the EGR cooler to the cylinder block.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Tighten the 2 bolts holding the EGR cooler to the exhaust manifold.

Момент затяжки:

16 Н*м{163 кгс*см, 12 фунт-сила-футов}

Tighten the 2 bolts holding the EGR cooler to the cylinder head.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Install a new O-ring to the EGR cooler.

Temporarily install the No. 2 EGR valve assembly, No. 1 EGR pipe, 2 new gaskets, 2 bolts and 2 nuts to the EGR cooler.

Install a new gasket to the No. 1 EGR pipe.

Install a new gasket to the EGR cooler.

Temporarily install the EGR cooler assembly with the 2 bolts and 2 nuts (^*1).

Temporarily install the 4 bolts (^*2).

Tighten the 2 bolts and 2 nuts.

Момент затяжки:

10 Н*м{102 кгс*см, 7 фунт-сила-футов}

Tighten the 2 bolts to the exhaust manifold.

Момент затяжки:

16 Н*м{163 кгс*см, 12 фунт-сила-футов}

Tighten the 2 bolts to the cylinder head.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Tighten the 2 bolts and 2 nuts.

Момент затяжки:

21 Н*м{241 кгс*см, 15 фунт-сила-футов}

Connect the vacuum hose.

Install 2 new gaskets and the outlet pipe with the 4 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Using needle-nose pliers, grip the claws of the clips and slide the clips to install the No. 2 and No. 3 water by-pass hoses.

Install the pipe with the 2 bolts.

Момент затяжки:

28 Н*м{286 кгс*см, 21 фунт-сила-футов}

Install the insulator with the 2 bolts.

Момент затяжки:

20.5 Н*м{209 кгс*см, 15 фунт-сила-футов}

Temporarily install a new gasket and the exhaust manifold converter with the 3 nuts.

Temporarily install the No. 2 exhaust manifold stay with the nut and 2 bolts.

Temporarily install the No. 2 manifold stay with the 3 bolts.

Temporarily install the No. 1 manifold stay with the bolt and nut.

Tighten the 2 bolts holding the No. 2 exhaust manifold stay to the cylinder block (upper bolt → lower bolt).

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

While pushing the manifold converter towards the turbocharger, tighten the 3 nuts holding the exhaust manifold converter to the turbocharger.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Tighten the nut holding the No. 2 exhaust manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt holding the No. 2 manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder block and manifold converter while tightening.

Tighten the 2 bolts holding the No. 2 manifold stay to the cylinder block.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt holding the No. 1 manifold stay to the cylinder head.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder head and manifold converter while tightening.

Tighten the nut holding the No. 1 manifold stay to the exhaust manifold converter.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Temporarily install a new turbine outlet elbow gasket and exhaust manifold converter with the 3 nuts.

Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

Temporarily install the No. 2 manifold stay with the 3 bolts.

Temporarily install the No. 1 manifold stay with the bolt and nut.

Tighten the 2 bolts of the No. 2 exhaust manifold stay to the cylinder block (Upper bolt → Lower bolt).

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the 3 nuts of the exhaust manifold converter to the turbocharger sub-assembly (While pushing the manifold converter towards the turbocharger sub-assembly).

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Tighten the nut of the No. 2 exhaust manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt of the No. 2 manifold stay to the exhaust manifold converter.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder block and manifold converter while tightening.

Tighten the 2 bolts of the No. 2 manifold stay to the cylinder block.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

Tighten the bolt of the No. 1 manifold stay to the cylinder head.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

УКАЗАНИЕ:

Ensure that the stay is pushed flush with the cylinder head and manifold converter while tightening.

Tighten the nut of the No. 1 manifold stay to the exhaust manifold converter.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

Install the manifold converter insulator with the 4 bolts.

Момент затяжки:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

Install the No. 2 manifold converter insulator with the 3 nuts.

Момент затяжки:

29 Н*м{291 кгс*см, 21 фунт-сила-футов}

Install the No. 1 manifold converter insulator with the 5 bolts.

Момент затяжки:

29 Н*м{291 кгс*см, 21 фунт-сила-футов}

Install the bearing bracket with the 3 bolts.

Момент затяжки:

64 Н*м{653 кгс*см, 47 фунт-сила-футов}

Install the 4 glow plugs.

Момент затяжки:

12.3 Н*м{125 кгс*см, 9 фунт-сила-футов}

Install the glow plug connector with the 4 nuts.

Момент затяжки:

2.2 Н*м{22 кгс*см, 19 фунт-сила-дюймов}

Install the wire harness with the nut (A).

Момент затяжки:

4.0 Н*м{41 кгс*см, 35 фунт-сила-дюймов}

Install the 5 grommets.

Install a new gasket and the inlet housing with the 3 nuts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Using needle-nose pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 4 water by-pass hose.

Apply soapy water to a new O-ring and install it to the by-pass pipe.

Install the by-pass pipe to the inlet housing with the 2 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

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

ПРИМЕЧАНИЕ:

Do not apply engine oil to the new O-ring labeled A.

Install the 3 O-rings to the oil cooler bracket.

Install the oil cooler bracket with the 6 bolts and nut.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

УКАЗАНИЕ:

Bolt length: 36 mm (1.42 in.) for bolt A

Bolt length: 49 mm (1.93 in.) for except bolt A

Install the oil pipe and 2 new gaskets with the 2 union bolts.

Момент затяжки:

35 Н*м{357 кгс*см, 26 фунт-сила-футов}

УКАЗАНИЕ:

Be sure to install the union bolt A so that the gasket is positioned as shown in the illustration.

Apply soapy water to a new O-ring and install it to the by-pass pipe.

Install the by-pass pipe with the 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

Install a new gasket to the sensor.

Install the sensor.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Connect the sensor connector.

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

ПРИМЕЧАНИЕ:

Do not apply engine oil to the new O-ring labeled A.

Install the 2 O-rings and the new O-ring labeled A to the oil cooler bracket.

Install the oil cooler with the 5 bolts.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Connect the oil pressure switch connector.

Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head.

Maximum warpage:

0.10 mm (0.0039 in.)

Install a new gasket and the intake manifold with the 7 bolts and 2 nuts.

Момент затяжки:

26 Н*м{265 кгс*см, 19 фунт-сила-футов}

Install a new gasket and the diesel throttle body with the 2 nuts and 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

Connect the throttle position sensor connector.

Connect the throttle motor connector.

Install the common rail assembly with the 2 bolts.

Момент затяжки:

21 Н*м{209 кгс*см, 15 фунт-сила-футов}

Using pliers, slide the clip to connect the No. 4 fuel hose.

Install the cover bracket with the 2 bolts.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

Install the pressure sensor with the bolt.

Момент затяжки:

8.8 Н*м{90 кгс*см, 78 фунт-сила-дюймов}

Install a new gasket and the EGR valve with the 2 bolts.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Connect the EGR valve connector.

Temporarily install 2 new gaskets and the No. 2 EGR pipe with the nut and bolt as shown in the illustration.

Temporarily install the bolt and nut as shown in the illustration.

Tighten the 2 bolts holding the EGR pipe to the cylinder head.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Tighten the 2 nuts holding the EGR pipe to the EGR valve.

Момент затяжки:

24 Н*м{245 кгс*см, 18 фунт-сила-футов}

Install a new O-ring to the dipstick guide.

Install the dipstick guide with the 2 bolts.

Момент затяжки:

33 Н*м{337 кгс*см, 24 фунт-сила-футов}

Install a new O-ring to the supply pump assembly.

Install the supply pump drive coupling.

ПРИМЕЧАНИЕ:

When reusing the coupling, install the coupling in the same orientation (top/bottom, front/back) as when it was removed.

УКАЗАНИЕ:

Line up the coupling with the groove in the camshaft end.

Install the supply pump assembly and the 2 bolts.

Момент затяжки:

21 Н*м{214 кгс*см, 15 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Apply the engine oil to the O-ring of the supply pump assembly.

УКАЗАНИЕ:

Remember the orientation of the supply pump drive coupling when removing the supply pump from the cylinder head.

Connect the suction control valve assembly.

Connect the fuel temperature sensor connector.

Install a new gasket, exhaust fuel addition injector and nozzle holder clamp with the washer and bolt.

Момент затяжки:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

УКАЗАНИЕ:

Install the nozzle holder clamp while holding it.

Install the fuel tube sub-assembly and a new gasket with the union bolt.

Момент затяжки:

23 Н*м{235 кгс*см, 17 фунт-сила-футов}

Turn the retainer in the direction indicated by the arrow until the retainer stops.

Insert the fuel tube connector into the injector.

Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

ПРИМЕЧАНИЕ:

If the fuel tube connector is not inserted to the correct position of the injector, the retainer cannot be turned further in the direction of the arrow.

Connect the exhaust fuel addition injector connector.

Install the No. 2 nozzle leakage pipe, gasket and 2 bolts.

Момент затяжки:

32 Н*м{321 кгс*см, 23 фунт-сила-футов}

Using pliers, grip the claws of the 3 clips and slide the 3 clips to connect the 3 fuel hoses.

Temporarily install the 4 injection pipes.

Using SST, tighten the nut at the common rail end of the injection pipe.

SST

09023-38401

Момент затяжки:

without SST:

30 Н*м{306 кгс*см, 22 фунт-сила-футов}

with SST:

27 Н*м{275 кгс*см, 20 фунт-сила-футов}

УКАЗАНИЕ:

1. Use of proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

Using SST, tighten the nut at the injector end of the injection pipe.

SST

09023-12701

Момент затяжки:

without SST:

34 Н*м{347 кгс*см, 25 фунт-сила-футов}

with SST:

31 Н*м{316 кгс*см, 23 фунт-сила-футов}

УКАЗАНИЕ:

1. Use of proper SST is necessary to ensure that the correct torque is applied to the injection pipe nut.
   
2. Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
   
3. Make sure that the pipe is not deformed or twisted during installation.
   If the pipe is deformed or twisted, or if it cannot be installed properly, replace the pipe with a new one.
   

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

Install the sensor with the bolt.

Момент затяжки:

8.8 Н*м{90 кгс*см, 78 фунт-сила-дюймов}

Connect the sensor connector.

Install the vacuum pump assembly for 1AD-FTV (See page Нажмите здесь).

Install the tensioner with the 3 bolts.

Момент затяжки:

20 Н*м{204 кгс*см, 15 фунт-сила-футов}

ПРИМЕЧАНИЕ:

As the bolts' heads are not as thick as typical bolts, be careful not to damage them during installation.

Set the mounting bracket.

Temporarily tighten the 2 bolts (B) and 2 nuts.

Tighten the 2 bolts (A).

Момент затяжки:

28 Н*м{286 кгс*см, 21 фунт-сила-футов}for bolt A

Tighten the 2 bolts (B) and 2 nuts.

Момент затяжки:

80 Н*м{816 кгс*см, 59 фунт-сила-футов}for bolt B

Apply soapy water to a new O-ring and install it to the by-pass pipe.

Install the No. 4 water by-pass pipe with the bolt.

Момент затяжки:

11 Н*м{112 кгс*см, 8 фунт-сила-футов}

Install the idler pulley with the bolt.

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

Install the idler pulley cover plate.

Install the idler pulley with the bolt.

Момент затяжки:

40 Н*м{408 кгс*см, 30 фунт-сила-футов}

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

Install the sensor with the bolt.

Момент затяжки:

8.8 Н*м{90 кгс*см, 78 фунт-сила-дюймов}

Connect the sensor wire harness clamp.

Connect the sensor connector to the bracket.

Connect the sensor connector.

Install the generator assembly with the 3 bolts.

Момент затяжки:

25 Н*м{255 кгс*см, 18 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Make sure that the wire harness of the crankshaft position sensor does not get caught between the cylinder block and the generator assembly when installing the generator assembly.

Connect the generator wire to terminal B with the nut and bolt.

Момент затяжки:

for Nut:

9.8 Н*м{100 кгс*см, 87 фунт-сила-дюймов}

for Bolt:

7.7 Н*м{79 кгс*см, 68 фунт-сила-дюймов}

Install the terminal cap.

Connect the generator connector.

Install the sling device and chain block to the engine and hang the engine.

Remove the engine stand.

Hold the crankshaft with SST.

SST

09213-58013
09330-00021

Using several steps, install and tighten 8 new bolts with a T55 "TORX" socket wrench uniformly in the sequence shown in the illustration.

Момент затяжки:

71 Н*м{724 кгс*см, 52 фунт-сила-футов}

ПРИМЕЧАНИЕ:

1. Do not reuse the flywheel installation bolts.
   
2. Be sure to check the tightening torque within 5 minutes after tightening.
   
3. Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
   
4. Make sure there is no oil on the bolts.
   

УКАЗАНИЕ:

Make sure that the seating surface of the flywheel installation bolts and the installation surfaces of the crankshaft and flywheel are free from oil or foreign matter.

Install the clutch disk assembly for EA61 (See page Нажмите здесь).

Install the clutch cover assembly for EA61 (See page Нажмите здесь).

Inspect and adjust clutch cover assembly for EA61 (See page Нажмите здесь).

Install the manual transaxle assembly for EA61 (See page Нажмите здесь).

Install the stiffener plate LH for EA61 (See page Нажмите здесь).

Install the stiffener plate RH for EA61 (See page Нажмите здесь).

Install the oil pan insulator for EA61 (See page Нажмите здесь).

Install the front engine mounting bracket for EA61 (See page Нажмите здесь).

Install the rear engine mounting bracket for EA61 (See page Нажмите здесь).

Install the No. 1 air tube for EA61 (See page Нажмите здесь).

Install the engine wire to the engine.

С помощью SST снимите передний приводной вал.

SST

09520-00031
09520-01010

ПРИМЕЧАНИЕ:

1. Будьте осторожны, чтобы не повредить сальник картера трансмиссии в блоке с главной передачей, чехол внутреннего шарнира и пылезащитный чехол приводного вала.
   
2. Старайтесь не уронить приводной вал.
   

Выверните 2 болта и вытяните приводной вал вместе с корпусом подшипника вала.

Снимите приводной вал с трансмиссии в блоке с главной передачей.

ПРИМЕЧАНИЕ:

1. Будьте осторожны, чтобы не повредить чехол внутреннего шарнира и пыльник приводного вала.
   
2. Старайтесь не уронить приводной вал.
   

Install the bolt which secures the engine mounting bracket to the mounting insulator.

Момент затяжки:

95 Н*м{969 кгс*см, 70 фунт-сила-футов}

Place the engine on a floor jack.

УКАЗАНИЕ:

Place the engine on wooden blocks or equivalent so that the engine is level.

Using the floor jack, slowly install the engine to the vehicle.

ПРЕДОСТЕРЕЖЕНИЕ:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

ПРИМЕЧАНИЕ:

1. Make sure that the engine is clear of all wiring and hoses.
   
2. While raising the engine into the vehicle, do not allow it to contact the vehicle.
   

Install the engine mounting insulator LH with the bolt and nut.

Момент затяжки:

56 Н*м{571 кгс*см, 41 фунт-сила-футов}

УКАЗАНИЕ:

While holding the bolt in place, tighten the nut.

Install the engine mounting insulator RH with the bolt and 2 nuts.

Момент затяжки:

for bolt, nut A:

95 Н*м{969 кгс*см, 70 фунт-сила-футов}

for nut B:

52 Н*м{530 кгс*см, 38 фунт-сила-футов}

Connect the 3 clamps and wire harness.

Remove the 2 bolts and No. 1 and No. 2 engine hangers.

Install the 4 bolts and front crossmember sub-assembly.

Момент затяжки:

96 Н*м{979 кгс*см, 71 фунт-сила-футов}

Install the through bolt and nut.

Момент затяжки:

145 Н*м{1479 кгс*см, 107 фунт-сила-футов}

Подоприте поперечину передней подвески телескопическим гидравлическим домкратом.

Поочередно вставляя SST в контрольные отверстия на правом и левом подрамниках передней подвески, в несколько приемов затяните 2 болта A, 2 болта B и 2 гайки с правой и левой сторон с номинальным моментом затяжки.

SST

09670-00020

Момент затяжки:

Болт A:

145 Н*м{1479 кгс*см, 107 фунт-сила-футов}

Болт B:

95 Н*м{969 кгс*см, 70 фунт-сила-футов}

Гайка:

93 Н*м{948 кгс*см, 69 фунт-сила-футов}

Введите в зацепление 2 зажима и захват, и установите жгут проводов кислородного датчика на подрамник передней подвески в сборе.

Установите нижнее усиление переднего кронштейна опоры двигателя и закрепите его 2 болтами.

Момент затяжки:

96 Н*м{979 кгс*см, 71 фунт-сила-футов}

Установите левую заднюю скобу элемента передней подвески и закрепите ее 3 болтами.

Момент затяжки:

Болт A:

145 Н*м{1479 кгс*см, 107 фунт-сила-футов}

Болт B :

93 Н*м{948 кгс*см, 69 фунт-сила-футов}

Установите левое усиление элемента передней подвески и закрепите его 4 болтами.

Момент затяжки:

96 Н*м{979 кгс*см, 71 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Предварительно затяните болты A и B, а затем полностью затяните 4 болта в следующем порядке: C, B, D и A.

Установите правое усиление элемента передней подвески и закрепите его 4 болтами.

Момент затяжки:

96 Н*м{979 кгс*см, 71 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Предварительно затяните болты A и B, а затем полностью затяните 4 болта в следующем порядке: C, B, D и A.

Совместите метки и подсоедините передний приводной вал в сборе к левой передней полуоси в сборе.

Подсоедините нижний рычаг передней подвески к переднему нижнему шаровому шарниру и закрепите болтом и 2 гайками.

Момент затяжки:

89 Н*м{908 кгс*см, 66 фунт-сила-футов}

Установите стойку переднего стабилизатора в сборе на передний амортизатор с цилиндрической винтовой пружиной, закрепив ее гайкой.

Момент затяжки:

74 Н*м{755 кгс*см, 55 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Если шаровой шарнир поворачивается вместе с гайкой, зафиксируйте болт пальца с помощью шестигранного ключа (на 6 мм).

Подсоедините наконечник левой рулевой тяги в сборе к поворотному кулаку и закрепите его гайкой.

Момент затяжки:

49 Н*м{500 кгс*см, 36 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Если отверстия под шплинт не совпадают, дополнительно затяните гайку (до 60°).

Установите новый шплинт.

Установите передний датчик частоты вращения и передний гибкий шланг на передний амортизатор, закрепив их болтом и зажимом.

Момент затяжки:

29 Н*м{296 кгс*см, 21 фунт-сила-футов}

ПРИМЕЧАНИЕ:

Не допускайте перекручивания переднего датчика частоты вращения при установке.

УКАЗАНИЕ:

Сначала установите передний гибкий шланг, а затем кронштейн жгута проводов датчика частоты вращения.

Установите передний датчик частоты вращения на поворотный кулак и закрепите его болтом.

Момент затяжки:

8,5 Н*м{87 кгс*см, 76 фунт-сила-дюймов}

ПРИМЕЧАНИЕ:

Не допускайте перекручивания переднего датчика частоты вращения при установке.

С помощью молотка и зубила накерните гайку ступицы переднего колеса.

Установите фиксатор B на кузов, а также установите на кузов кожух выходного отверстия рулевой колонки № 1 в сборе и закрепите его фиксатором A.

ПРИМЕЧАНИЕ:

Убедитесь, что кромка кожуха выходного отверстия рулевой колонки №1 в сборе не повреждена.

Совместите метки на промежуточном валу № 2 рулевого управления в сборе и промежуточном валу рулевого управления в сборе.

Заверните болт.

Момент затяжки:

35 Н*м{360 кгс*см, 26 фунт-сила-футов}

Установите шумоизолирующую накладку кожуха выходного отверстия рулевой колонки и закрепите ее 2 фиксаторами.

Расправьте напольный коврик.

Install the exhaust pipe supports, then install the front exhaust pipe assembly with the 2 compression springs and 2 bolts.

Момент затяжки:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

Install the 2 compression springs and 2 bolts.

Момент затяжки:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

Install the exhaust pipe supports, then install the front exhaust pipe assembly with the 2 compression springs and 2 bolts.

Момент затяжки:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

Install the 2 compression springs and 2 bolts.

Момент затяжки:

43 Н*м{439 кгс*см, 32 фунт-сила-футов}

Install the air fuel ratio sensor connector and clamp.

Connect the release cylinder and flexible hose bracket with the 7 bolts.

Момент затяжки:

12 Н*м{122 кгс*см, 9 фунт-сила-футов}

Install the transmission control cable assembly to the control cable bracket with the 2 new clips.

Install the transmission control cable assembly to the transaxle with the 2 clips.

Install the compressor assembly with pulley for 1AD-FTV (See page Нажмите здесь).

Using SST and a 22 mm wrench, rotate the tensioner pulley counterclockwise, and then install the V-ribbed belt.

SST

09216-42010

ПРИМЕЧАНИЕ:

1. Make sure that the belt is set properly at each pulley.
   
2. Make sure SST is installed as shown in the illustration. If not, SST and/or the belt may not be able to be removed.
   

ПРЕДОСТЕРЕЖЕНИЕ:

1. Be careful as the wrench only fits loosely on the belt tensioner tool set point. The wrench may come off the set point and cause injuries.
   
2. Be careful that your hands do not become jammed between parts such as the belt, pulleys, etc.
   

Connect the air hoses No.2 and No.3.

ПРИМЕЧАНИЕ:

1. Check that retainer is closed, when the connector is inserted.
   
2. If replacing the hose, check for deposits in the intercooler and air hoses No.2 and No.3. If necessary, wipe up deposits.
   
3. If replacing the hose, apply fresh oil to the O-ring.
   
4. The connector should be inserted until a sound indicates that the installation is complete. Check that the connector cannot be disconnected by pulling after inserted.
   
5. Do not use a quick connector that has been dropped.
   

Insert the No. 4 air hose to the diesel throttle body.

Insert the No. 2 air tube to the No. 4 air hose as described below.

1. Align the embossed mark of the No. 2 air tube within the paint mark of the No. 4 air hose.
   





2. Temporarily install the 2 hose clamps.
   

   ПРИМЕЧАНИЕ:

   Each hose clamp should be installed so that the paint mark can be seen on either side of the clamp band as shown in the illustration.

Install the No. 2 air tube with the bolt.

Момент затяжки:

48 Н*м{489 кгс*см, 35 фунт-сила-футов}

Tighten the 2 hose clamps.

Момент затяжки:

6.3 Н*м{64 кгс*см, 56 фунт-сила-дюймов}

Connect the sensor connector.

Install the No. 3 air hose.

1. Tighten the hose clamp.
   

   Момент затяжки:

   6.3 Н*м{64 кгс*см, 56 фунт-сила-дюймов}

2. Connect the No. 3 air hose to the intercooler.
   

   ПРИМЕЧАНИЕ:

   1. Check that the retainer is closed when the connector is inserted.
      
   2. If replacing or reusing the hose, check for deposits in the intercooler and air hose. If necessary, wipe off the deposits.
      
   3. If replacing or reusing the hose, apply fresh oil to the O-ring.
      
   4. The connectors should be inserted until a clinking sound indicating that they are completely connected is heard. Then, check that the connectors cannot be disconnected by pulling on them.
      
   5. Do not use a quick connector that has been dropped.
      

Connect the No. 2 radiator hose.

Connect the No. 2 radiator hose.

Connect the water by-pass hose.

Install the 3 bolts and air cleaner bracket.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}

Install the fuel filter support with the 3 bolts.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}

Install the vacuum switching valve bracket and vacuum transmitting pipe with the 3 bolts.

Момент затяжки:

9.0 Н*м{92 кгс*см, 80 фунт-сила-дюймов}

Connect the air tube No. 2.

Connect the vacuum pump hose.

Connect the 2 injector driver connectors and install the 2 clamps.

Connect the 2 heater hoses.

Connect the 2 fuel hoses.

Connect the ECM connector and lock lever.

Connect the 2 clamps and 2 connectors.

Connect the 3 connectors and 2 nuts, and install the engine room No. 1 junction block.

Момент затяжки:

8.4 Н*м{86 кгс*см, 74 фунт-сила-дюймов}

Connect the 2 clamps.

Connect the clamp and ground cable with the bolt.

Момент затяжки:

8.4 Н*м{86 кгс*см, 74 фунт-сила-дюймов}

Install the engine room No. 1 junction block cover.

Install the fuel filter assembly.

1. Install the fuel filter assembly with the 2 nuts.
   

   Момент затяжки:

   17 Н*м{173 кгс*см, 13 фунт-сила-футов}

2. Connect the level warning switch connector.
   

Connect the 4 fuel hoses. (without combustion type power heater)

1. Connect the No. 3 fuel hose as shown in the illustration (^*1).
   

2. Connect the No. 2 fuel hose as shown in the illustration (^*2).
   

3. Connect the No. 1 fuel hose as shown in the illustration (^*3).
   





4. Connect the No. 4 fuel hose as shown in the illustration (^*4).
   

Connect the 5 fuel hoses. (without combustion type power heater)

1. Connect the No. 3 fuel hose as shown in the illustration (^*1).
   

2. Connect the No. 2 fuel hose as shown in the illustration (^*2).
   

3. Connect the No. 1 fuel hose as shown in the illustration (^*3).
   

4. Connect the heater fuel hose as shown in the illustration (^*4).
   





5. Connect the No. 4 fuel hose as shown in the illustration (^*5).
   

Install the 6 bolts and battery carrier.

Момент затяжки:

19 Н*м{190 кгс*см, 14 фунт-сила-футов}

Install the 3 bolts and air cleaner case.

Момент затяжки:

7.0 Н*м{71 кгс*см, 62 фунт-сила-дюймов}

Install the air cleaner filter element.

Install the air cleaner cap sub-assembly, and connect the 2 clamps and band.

Connect the No. 2 ventilation hose.

Connect the mass air flow meter connector.

Install the battery clamp.

Момент затяжки:

for bolt:

17 Н*м{168 кгс*см, 12 фунт-сила-футов}

for nut:

3.5 Н*м{36 кгс*см, 31 фунт-сила-дюймов}

Add manual transaxle oil for EA61 (See page Нажмите здесь).

Inspect manual transaxle oil for EA61 (See page Нажмите здесь).

Install the oil pan drain plug and a new gasket.

Момент затяжки:

38 Н*м{387 кгс*см, 28 фунт-сила-футов}

Add engine oil according to the table below.

Engine oil:

Oil Grade	Oil Viscosity (SAE)
ACEA C2 (If ACEA C2 cannot be obtained, you may also use ACEA B1.) (Using engine oil other than ACEA C2(or B1) may damage the catalytic converter.)	5W-30

Standard capacity:

Item	Capacity
Drain and refill with oil filter change	6.3 liters (6.7 US qts, 5.5 Imp. qts)
Drain and refill without oil filter change	5.9 liters (6.2 US qts, 5.2 Imp. qts)
Dry fill	7.1 liters (7.5 US qts, 6.2 Imp. qts)

Tighten the radiator drain cock plug.

Tighten the cylinder block drain cock plug.

Момент затяжки:

13 Н*м{130 кгс*см, 9 фунт-сила-футов}

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Standard capacity:

Item	Specified Condition
w/o Power heater	7.4 liters (7.8 US qts, 6.5 lmp. qts)
w/ Power heater	7.8 liters (8.2 US qts, 6.8 lmp. qts)

УКАЗАНИЕ:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).
   
2. Contact your TOYOTA dealer for further details.
   

ПРИМЕЧАНИЕ:

Never use water as a substitute for engine coolant.

Remove the radiator cap and air-bleeding valve and add coolant to line B of the reservoir tank.

Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level is low, add coolant.

Install the cap and valve, and warm up the engine sufficiently.

Bleed air from the cooling system.

ПРИМЕЧАНИЕ:

1. Before starting the engine, turn the A/C switch OFF.
   
2. Adjust the air conditioner set temperature to MAX (HOT).
   
3. Adjust the air conditioner set blower to Lo.
   

1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
   

   УКАЗАНИЕ:

   The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

   ПРЕДОСТЕРЕЖЕНИЕ:

   When squeezing the radiator hose:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

2. After the engine has warmed up, run the engine using the following cycle for at least 7 minutes: at 3000 rpm for 5 seconds, at idle speed for 45 seconds. (Repeat this cycle at least 8 times.)
   

3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
   

   ПРЕДОСТЕРЕЖЕНИЕ:

   When squeezing the radiator hose:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

After the engine has cooled down, check that the coolant level is between FULL and LOW.
If the coolant level is low, add coolant to the reservoir tank FULL line.

Register the injector compensation code (see page Нажмите здесь).

Start the engine. Make sure that no oil leaks from the connection point of the oil filter cap.

Remove the radiator reservoir cap.

ПРЕДОСТЕРЕЖЕНИЕ:

To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

Fill the radiator with coolant, and then attach a radiator cap tester.

Warm up the engine.

Pump the radiator cap tester to 108 kPa (1.1 kgf/cm², 15.6 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage.
If there are no signs of external coolant leaks, check the heater core, cylinder block and head.

Reinstall the radiator reservoir cap.

PERFORM ACTIVE TEST

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch on (IG).
   

3. Turn the intelligent tester on.
   

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

5. Perform the Active Test.
   
   

   Tester Display	Test Part	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 2000 rpm when ON is selected Above conditions preserved while test is ON

Check that there are no exhaust gas leaks from the points (jointed parts of the exhaust pipes and installed parts of each sensor) shown in the illustration.

Warm up and stop the engine.

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch ON.
   

3. Select the following items:
   Powertrain / Engine / Data List / Engine SPD.
   

   УКАЗАНИЕ:

   Refer to the intelligent tester operator's manual if you need help selecting the Data List.

When not using the intelligent tester:

1. Connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.
   

   SST

   09843-18030
   

Inspect the engine idle speed.

Standard idle speed:

750 to 850 rpm

Turn the ignition switch OFF.

Disconnect the intelligent tester from the DLC3.

Start the engine.

Fully depress the accelerator pedal.

Check the maximum engine speed.

Maximum engine speed:

5100 to 5250 rpm

Install the 6 clips and upper radiator air deflector.

Attach the 4 clips to install the engine cover.