WATER PUMP (w/o EGR Cooler) INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. A01DWA8

      Install a new gasket and the water pump with the 5 bolts and 2 nuts.

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

  2. INSTALL NO. 2 TIMING BELT COVER


    1. A01E1J8E01

      Apply seal packing (FIPG) to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

    2. Install the No. 2 timing belt cover with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      Install the camshaft timing pulley.

    2. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  4. INSTALL TIMING BELT

    A01E2G9E02

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

      Tech Tips

      If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

      Note


      • The engine should be cold.

      • When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

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

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

    3. Check that the idler pulley moves smoothly.

      If it does not move smoothly, check the idler sub-assembly and washer.

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

    5. A01E2YJE01

      Place the tensioner upright. Then set the press to the top of the tensioner.

      Note


      • Do not scratch or deform the rod end.

      • Press in the tensioner rod upward.

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

    6. Using a press, slowly push in the push rod using 981 to 9800 N (100 to 999 kgf, 220 to 2203 lbf) of force.

      Note

      Do not impose a load of over 9800 N (999 kgf, 2203 lbf) to the push rod.

    7. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    8. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    9. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the 2 bolts and install the tensioner.

    10. A01DZUHE01

      Remove the 1.5 mm hexagon wrench from the tensioner.

    11. A01DWQTE02

      Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

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

  6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DZAXE01

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

    2. Remove any old seal packing (FIPG) material from the cylinder head.

    3. A01E1YSE03

      Apply seal packing to the specific areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the head cover within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the seal packing.

    4. Install a new cylinder head cover gasket and the cylinder head cover with the 10 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    5. Install 4 new nozzle holder seals.

    6. Connect the ventilation hose.

    7. Connect the 4 connectors and install the 3 bolts.

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

  7. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

    • Keep the joints of the injection pipe clean.


    1. Temporarily install the No. 4 injection pipe with the union nuts.

    2. Install the 2 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      Note


      • If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.

      • Make sure that the inner-rubbers of the injection pipe fit inside the clamps.

      • When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.

    3. A01E0ONE01

      Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  8. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

    • Keep the joints of the injection pipe clean.


    1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

    2. A01E2KZE01

      Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

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

      Tech Tips

      If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

    3. A01DZLXE01

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  9. INSTALL NO. 1 TIMING BELT COVER


    1. Install the timing belt cover with the 6 bolts.

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

    2. Install the wire harness clamp.

    3. Install the water hose clamp with the bolt.

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

  10. INSTALL CHARGE AIR COOLER ASSEMBLY


    1. Install the CAC Click here.

  11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A01DYTCE02

    1. Install the tensioner with the 4 bolts.

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

      Tech Tips

      Firmly press and hold the tensioner against the cylinder block to eliminate any gaps in the A areas in the illustration. Then uniformly tighten the 4 bolts.

  12. INSTALL GENERATOR ASSEMBLY

    A01DXLFE01

    1. Install the generator with the 2 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf, for bolt A }
      25 N*m  { 255 kgf*cm, 18 ft.*lbf, for bolt B }

    2. Install the generator wire with the nut.

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

    3. Connect the generator connector.

  13. INSTALL COOLER COMPRESSOR ASSEMBLY


    1. Install the compressor with the 4 bolts.

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

  14. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Install the shroud together with the coupling fan between the radiator and engine component.

      Note

      Be careful not to damage the radiator core.

    3. Install the fluid coupling fan to the fan pulley with the 4 nuts.

      Tighten the nuts as much as possible by hand.

    4. A01DZVX

      Attach the shroud's claws to the radiator.

    5. Install the shroud with the 2 bolts.

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

    6. Install the drive belt Click here.

    7. Tighten the 4 nuts of the fluid coupling fan.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    8. A01DVHL

      Install the radiator reservoir with the 2 bolts.

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

    9. Connect the No. 1 and No. 2 water by-pass hoses to the tank upper and lower.

    10. A01DZXC

      Install the oil reservoir with the 3 bolts.

      Torque:
      4.5 N*m  { 46 kgf*cm, 40 in.*lbf }

  15. CONNECT RADIATOR HOSE INLET

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  17. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01DYVNE01

      Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

      Standard capacity
      Item Specified Condition
      A/T 11.1 liters (11.7 US qts, 9.8 Imp. qts)
      M/T 9.8 liters (10.4 US qts, 8.6 Imp. qts)

      Tech Tips


      • 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).


      • Please contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. Bleed air from the cooling system.


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

      2. Maintain the engine speed at 2,500 to 3,000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.


        • Be careful as the radiator hoses are hot.


        • Keep your hands away from the radiator fan.

      4. Stop the engine and wait until the coolant cools down to ambient temperature.

        CAUTION:

        Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    8. A01E2D9E01

      After the coolant cools down, check that the coolant level is at the F line.

      If the coolant level is below the F line, add TOYOTA SLLC to the F line.

  18. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Start the engine.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE03

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01DYT1E05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  19. CHECK FOR ENGINE COOLANT LEAKS


    1. Check for the coolant leaks Click here.

  20. CHECK FOR ENGINE OIL LEAKS

  21. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the cover with the 4 bolts.

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

  22. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      CAUTION:

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.