Assembly

C: ASSEMBLY

1. LHD MODEL





1) Interconnect pipes C and D.

Tightening torque:
Joint nut
15 ± 5 Nm (1.5 ± 0.5 kg-m, 10.8 ± 3.6 ft-Ib)

CAUTION: Visually check that hose between tank and pipe D is free from bending or twisting.

2) Connect pipe D from oil tank.
3) Connect pipe C from oil pump.

CAUTION: Use a new gasket.

Tightening torque:
34 ± 5 Nm (3.5 ± 0.5 kg-m, 25.3 ± 3.6 ft-Ib)

4) Tighten bolt A.

Tightening torque:
13 ± 3 Nm (1.3 ± 0.3 kg-m, 9.4 ± 2.2 ft-Ib)





5) Temporarily connect pipes C and D to pipes (on the gearbox side).





6) Temporarily install clamp E on pipes C and D.

CAUTION: Ensure that the letter "8" on each clamp side are diagonally opposite each other as shown in the figure.

7) Tighten clamp E firmly.

Tightening torque:
7.4 ± 2.0 Nm (0.75 ± 0.20 kg-m, 5.4 ± 1.4 ft-Ib)

8) Tighten joint nut.

Tightening torque:
15 ± 5 Nm (1.5 ± 0.5 kg-m, 10.8 ± 3.8 ft-Ib)





9) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe B first, and lower pipe A second.

Tightening torque:
13 ± 3 Nm (1.3 ± 0.3 kg-m, 9.4 ± 2.2 ft-Ib)

10) Install jack-up plate.
11) Connect battery minus terminal.
12) Feed the specified fluid and discharge air.

NOTE: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.





13) Finally check clearance between pipes and/or hoses, as shown above.
If clearance between cruise control pump and power steering hose is less than 10 mm (0.39 in), proceed as follows:
(1) Move clamped section (A) (refer to figure above.) down to a point where pipe is close to crossmember.

Pipe-to-crossmember clearance:
10 mm (0.39 in), mm.

(2) Check that clearance between cruise control pump and power steering hose is at least 10 mm (0.39 in). If it is not, bend section (B) down until a clearance of at least 10 mm (0.39 in) is obtained.

2. RHD MODEL





1) Interconnect pipes C and D.

Tightening torque:
Joint nut
15 ± 5 Nm (1.5 ± 0.5 kg-m, 10.8 ± 3.6 ft-Ib)

CAUTION: Visually check that hose between tank and pipe D is free from bending or twisting.

2) Connect pipe D from oil tank.
3) Connect pipe C from oil pump.

CAUTION: Use a new gasket.

Tightening torque:
34 ± 5 Nm (3.5 ± 0.5 kg-m, 25.3 ± 3.6 ft-Ib)

4) Tighten bolt A.

Tightening torque:
13 ± 3 Nm (1.3 ± 0.3 kg-m, 9.4 ± 2.2 ft-Ib)





5) Temporarily connect pipes C and D to control valve of gearbox.





6) Temporarily install clamp F on pipes C and D.

CAUTION: Ensure that the letter "8" side of clamp E is on the pipe C side as shown in the figure.

7) Tighten clamp F firmly.

Tightening torque:
7.4 ± 2.0 Nm (0.75 ± 0.20 kg-m, 54 ± 1.4 ft-Ib)

8) Tighten joint nut.

Tightening torque:
15 ± 5 Nm (1.5 ± 0.5 kg-m, 10.0 ± 3.6 ft-Ib)





9) Connect pipes A and B to four pipe joints of gearbox.
Connect upper pipe A first, and lower pipe B second.

Tightening torque:
13 ± 3 Nm (1.3 ± 0.3 kg-m, 9.4 ± 2.2 ft-Ib)

10) Install jack-up plate.
11) Connect battery negative terminal.
12) Feed the specified fluid and discharge air.





NOTE: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.