1. Component views
Crankshaft pulley
Part name
- Bolt
- Washer
- Crankshaft pulley (Except freezer specifications)
- Crankshaft pulley (Freezer specifications)
Tightening torque
1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }
1-2: 60 to 90 °
2. Crankshaft pulley installation
1) Apply engine oil to the threaded portions and seating surfaces of the bolts.
2) Install the crankshaft pulley to the crankshaft in the order shown in the diagram.
Note
- Secure the ring gear to prevent the crankshaft from turning when tightening the crankshaft pulley bolt.
Caution
- Do not reuse the bolt.
Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft } 1st time
Tightening Angle : 60 to 90 ° 2nd time
3) Remove the special tool from the starter motor installation section of the flywheel housing.
3. Cooling fan installation
1) Install the cooling fan clutch and cooling fan as a set to the water pump.
Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }
4. Cooling fan belt installation
5. Fan guide installation
1) Install the fan guide to the radiator.
Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }
2) Install the fan shroud to the fan guide.
Legend
- Fan shroud
- Fan guide
- Radiator
6. Radiator upper hose installation
1) Install the radiator upper hose and clamp to the water outlet pipe and radiator.
Note
- Align the painted arrow on the upper hose with the pipe boss section to install.
- Insert the upper hose until it makes full contact with the pipe.
- Soapy water can be applied when installing the upper hose.
Legend
- Radiator upper hose
- Boss section
- Clamp
- Arrow mark
Note
- Align the clamp with the upper hose arrow mark end to install.
Legend
- Clamp
- Arrow mark
Note
- Install the clamp in the direction shown in the following diagram.
- The diagram about the clamp direction shows the state viewed from the vehicle front.
7. Radiator reserve tank installation
1) Clean the radiator reserve tank using detergent.
Note
- Wash with clean water, and drain the water.
2) Assemble the reserve tank hose to the radiator reserve tank.
Caution
- Assemble the reserve tank hose to the dent to fit the radiator reserve tank shape.
Legend
- Radiator reserve tank
- Reserve tank hose
3) Install the radiator reserve tank to the fan guide.
Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }
4) Connect the radiator reserve tank hose to the radiator.
8. Air cleaner installation
1) Install the air cleaner to the vehicle.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }
Legend
- Air cleaner
- MAF and IAT sensor
- Barometric pressure sensor
2) Connect the connector to the barometric pressure sensor.
3) Connect the connector to the MAF and IAT sensor.
9. Air duct installation
1) Align the air duct with the air cleaner and turbocharger.
Legend
- Air duct
2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.
Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }
Legend
- Alignment mark
3) Install the PCV hose to the cylinder head cover and air duct.
Caution
- Align the marks on the pipe side and hose side.
Legend
- PCV hose
- Clamp
4) Install the intake air duct to the air cleaner and radiator core support.
Legend
- Intake air duct
- Clip
10. Underguard installation
11. Preliminary and post procedures
1. Post procedures
1) Lower the vehicle.
2) Connect the battery cable to the battery negative terminal.
3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.
Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".
4) Close the engine hood.
12. Coolant filling
1) Fill with engine coolant up to the radiator filler neck.
Note
- Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
- Fill slowly to prevent air from entering the system.
2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.
Note
- Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant lowers.
Caution
- Repeat the operation until the coolant level no longer drops.
3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend
- Radiator reserve tank
- MAX line
- MIN line
4) Install the radiator cap to the radiator.
5) Start and idle the engine.
Caution
- Idle the engine for 5 minutes or more.
6) Stop the engine.
7) Remove the radiator cap from the radiator.
Warning
- Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
- When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.
8) Fill with engine coolant up to the radiator filler neck.
Note
- If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.
9) Install the radiator cap to the radiator.
10) Start the engine.
11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.
12) With the engine running, check that the thermostat valve is open.
Note
- Touch the radiator upper hose, and confirm that it has become warm.
- If it has not become warm, go back to Step 11.
Caution
- Do not try determining it by using only an engine coolant temperature gauge.
13) Idle the engine for 5 minutes.
14) Stop the engine.
15) Remove the radiator cap from the radiator.
Warning
- Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
- When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.
16) Fill with engine coolant up to the radiator filler neck.
Note
- Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
17) Add engine coolant up to the MAX line of the radiator reserve tank.
18) Install the radiator cap to the radiator.
19) Repeat steps 10 to 18 until the coolant level no longer lowers.
Caution
- If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.