ENGINE ASSEMBLY INSTALLATION


  1. INSTALL INTAKE MANIFOLD


    1. A01CHPUE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as 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 timing chain cover within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the intake manifold with the 8 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  2. INSTALL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring onto the timer cover.

    2. A01CH8BE01

      Turn the drive gear and align the hole with the matchmark as shown in the illustration.

    3. A01CJ11E01

      Check the No. 1 cylinder to TDC/compression.

    4. A01CH2IE01

      Align the matchmarks of the timer cover and the front end plate, and then install the supply pump assembly with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
    5. A01CHOV

      When the crankshaft position sensor's installation hole can be accessed directly:


      1. Check that the knock pin of the injection pump drive gear is at the center of the hole. If not, perform steps (b), (c), and (d) again. Then, proceed to step (g).

    6. A01CH68E01

      When the crankshaft position sensor's installation hole cannot be accessed directly:


      1. Tape the screwdriver as shown in the illustration.

      2. A01CIOUE02

        Remove the service plug and gasket from the timing chain cover sub-assembly.

      3. A01CJEHE01

        Insert the screwdriver into the service plug hole.

      4. Check that the tape end and timing chain cover sub-assembly are aligned as shown in the illustration. If not, perform steps (b) and (c) again.

      5. Install the service plug and gasket to the timing chain cover sub-assembly.

    7. A01CIH3

      Install the holder clip with the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

    8. Connect the 2 connectors.

  3. INSTALL FUEL RETURN PIPE SUB-ASSEMBLY


    1. A01CHNN

      Temporarily install the fuel return pipe sub-assembly with the 2 union bolts and 5 new gaskets.

    2. Tighten the 2 union bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 15 ft.*lbf }

  4. INSTALL COMMON RAIL ASSEMBLY


    1. A01CIXW

      Install the common rail assembly with the 2 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

    2. Connect the fuel hose and tighten the clip.

    3. Connect the fuel pressure sensor connector.

  5. INSTALL NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY


    1. A01CIVD

      Install 4 new gaskets and the No. 3 nozzle leakage pipe with the 2 union bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

    2. Install the fuel pipe clamp with the nut. Tighten the nut until the clamp's edge makes contact with the engine side clamp's edge.

  6. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. Install the fuel pipe sub-assembly with the union bolt and 2 new gaskets.

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

    2. Install the 3 fuel pipe clamps with the 2 bolts and nut. Tighten the 2 bolts and nut until the clamp edges make contact with the engine side clamp edges.

  7. INSTALL FUEL PIPE SUB-ASSEMBLY


    1. Install the fuel pipe sub-assembly with the union bolt and 2 new gaskets.

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

    2. Install the 3 fuel pipe clamps with the 2 bolts and nut. Tighten the 2 bolts and nut until the clamp edges make contact with the engine side clamp edges.

  8. INSTALL VACUUM PUMP ASSEMBLY


    1. A01CGOV

      Install the vacuum pump assembly with a new O-ring and the 2 nuts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  9. INSTALL VACUUM PUMP OIL PIPE SUB-ASSEMBLY


    1. A01CJ9E

      Install the vacuum pump oil pipe sub-assembly with a new gasket and the 3 union bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  10. INSTALL VACUUM PIPE


    1. Install the vacuum pipe with 2 new gaskets, the union bolt, and the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  11. INSTALL WATER PUMP ASSEMBLY


    1. A01CH6IE03

      Apply a continuous bead of seal packing (diameter 1.5 to 2.5 mm (0.06 to 0.10 in.)) as 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 water pump within 3 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    2. A01CIV9

      Install the water pump assembly with the 8 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CI1KE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as 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 water by-pass pipe sub-assembly within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the water by-pass pipe sub-assembly with the clamp and the 6 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  13. INSTALL WATER PIPE SUB-ASSEMBLY


    1. A01CIX4

      Install the water pipe sub-assembly with a new O-ring and the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  14. INSTALL WATER OUTLET HOUSING


    1. A01CHN1

      Install the water outlet sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  15. INSTALL WATER TEMPERATURE SENDER GAUGE ASSEMBLY


    1. A01CJ4L

      Install the water temperature sender gauge assembly with a new gasket.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  16. INSTALL THERMOSTAT


    1. A01CIICE03

      Apply a continuous bead of seal packing (diameter 1.5 to 2.5 mm (0.06 to 0.10 in.)) as 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 water pump within 3 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    2. A01CI6X

      Install a new gasket onto the thermostat.

    3. Align the jiggle valve to the position shown in the illustration and install the thermostat.

    4. A01CGNU

      Install the water outlet with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  17. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. A01CITH

      Install the water outlet sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  18. INSTALL CAMSHAFT POSITION SENSOR


    1. A01CHJI

      Install the camshaft position sensor with a new O-ring and the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  19. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01CI7P

      Install the crankshaft position sensor with a new O-ring and the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  20. INSTALL OIL COOLER ASSEMBLY


    1. A01CH3V

      Install the oil cooler assembly and 2 new gaskets to the oil filter bracket sub-assembly with the 4 nuts.

      Torque:
      12 N*m  { 125 kgf*cm, 9.0 ft.*lbf }
    2. A01CJ4BE01

      Apply a continuous bead of seal packing (diameter 1.5 to 2.5 mm (0.06 to 0.10 in.)) as 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 oil filter bracket within 3 minutes of applying the seal packing.

      • Do not start the engine for at least 2 hours after the installation.

    3. A01CJ6BE01

      Install the oil cooler assembly with the oil filter bracket and the 15 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CJFB

      Install the wire harness bracket and the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  21. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01CHFVE02

      Install the oil pressure switch.


      1. Install the oil pressure switch with a new O-ring by hand, then further tighten it by 20 to 30° as shown in the illustration.

    2. Connect the oil pressure switch connector.

  22. INSTALL EXHAUST MANIFOLD


    1. A01CIBDE01

      Install 4 new gaskets to the cylinder head as shown in the illustration.

    2. Temporarily install the exhaust manifold. Uniformly and temporarily tighten the 8 nuts and 8 spacers in the order shown in the illustration.

      A01CH0ZE02

      Tech Tips

      The stud bolts should contact the exhaust manifold as shown in the illustration

    3. A01CJE1E02

      Tighten the 8 nuts in the order shown in the illustration.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }
    4. A01CJE1E01

      Tighten the 8 nuts in the order shown in the illustration.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }
    5. A01CHCI

      Install the exhaust manifold heat insulator sub-assembly with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  23. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Tech Tips

    Click here

  24. INSTALL RADIATOR PIPE


    1. A01CIP1

      Install the radiator pipe with a new O-ring and the 2 bolts.

      Torque:
      18 N*m  { 180 kgf*cm, 13 ft.*lbf }

  25. INSTALL GENERATOR BRACKET SUB-ASSEMBLY


    1. A01CHR0

      Install the generator bracket with the 3 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  26. INSTALL GENERATOR BELT ADJUSTING BAR


    1. Install the generator belt adjusting bar with the 2 bolts.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

  27. INSTALL VANE PUMP ASSEMBLY


    1. Coat a new O-ring with power steering fluid and install it to the vane pump.

    2. A01CHBB

      Install the vane pump assembly with the 2 bolts.

      Torque:
      47 N*m  { 480 kgf*cm, 35 ft.*lbf }

  28. INSTALL INJECTOR ASSEMBLY

    Note

    A01CJFWE03

    Register the injector compensation code of a new fuel injector in the ECM when replacing the fuel injector. Register the injector compensation code in advance so that it can be installed in the correct position Click here.


    1. A01CIDA

      Attach tags to identify the cylinder (#1 to #4) to the new injector assemblies so that each injector assembly can be inserted into the correct cylinder during installation.

    2. Apply a small amount of clean engine oil to 4 new O-rings.

    3. A01CI6EE01

      Install the O-ring to each injector as shown in the illustration.

    4. Install a new No. 2 cylinder head cover gasket to each injector.

    5. Referring to each cylinder number identification tag attached to the fuel injector assemblies, insert the fuel injector assembly, nozzle holder clamp, and nozzle holder clamp bolt for each cylinder.

      Note


      • Check that the tip of the fuel injector has no foreign matter attached.

      • When reusing the fuel injectors, reinstall them to the same cylinder they were removed from. Otherwise, it could cause the engine to malfunction.

      • Carefully insert the fuel injector so that the O-ring is not caught between the cylinder head and the injector.

    6. A01CGOO

      Temporarily install the 4 nozzle holder clamps with the 4 clamp bolts.

      Note

      Be sure to install the holder clamps and bolts in their original positions.

    7. A01CIVM

      Install 4 new holder seals.

      Note

      Securely insert the tip of each holder seal into each fuel injector.

    8. A01CGPT

      Temporarily install the nozzle leakage pipe assembly through 5 new gaskets by hand with the union bolt and the 5 hollow screws.

      Note

      Make sure that the hollow screws and nozzle leakage pipe assembly are not deformed or damaged.

    9. A01CHN3

      Temporarily tighten the union nuts of new injection pipes No. 1, No. 2, No. 3 and No. 4 by hand.

      Note

      If an injector has been replaced, the corresponding injection pipe must also be replaced.

    10. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      After tightening the nozzle holder clamp bolts, check that the fuel injector and the nozzle holder clamp do not interfere with the valve spring.

    11. Tighten the 5 hollow screws.

      Torque:
      12 N*m  { 125 kgf*cm, 9 ft.*lbf }

      Note

      Do not reuse the nozzle leakage pipe assembly that has been tightened to more than the specified torque.

    12. A01CHN3

      Using a union nut wrench (17 mm), tighten the 8 union nuts.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

      Note

      Refer to the torque above when not using SST. When using SST, calculate the torque in accordance with the lengths of SST and the torque wrench Click here.

  29. INSTALL OIL LEVEL GAUGE GUIDE


    1. Install the oil level gauge guide with a new O-ring.

  30. INSTALL INJECTION PIPE CLAMP


    1. Install a new O-ring to the oil level gauge guide.

      Note

      Apply a small amount of clean engine oil to the new O-ring.

    2. A01CGTY

      Temporarily install the 2 pipe clamps and oil level gauge guide to the intake manifold.

    3. Install the 2 injection pipe clamps with the 2 nuts. Tighten the 2 nuts until the clamp edges make contact with the engine side clamp edges.

  31. INSTALL VENTURI ASSEMBLY


    1. A01CI8SE01

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as 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 intake pipe with the EGR valve within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the venturi assembly with the 4 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  32. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CHXRE01

      Install the water by-pass pipe sub-assembly with the 3 bolts and 2 union bolts.

      Torque:
      Union bolt
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      Bolt
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  33. INSTALL EGR VALVE BRACKET


    1. A01CGLD

      Install the EGR valve bracket with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  34. CONNECT WIRE HARNESS AND CONNECTORS


    1. A01CJDO

      Connect the 3 connectors and 3 connector clamps and then install the bolt.

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

  35. INSTALL DIESEL THROTTLE BODY


    1. Remove any seal packing material from the contact surface.

    2. A01CJAVE01

      Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.

      Tech Tips


      • Remove any oil from the contact surface.

      • Install the diesel throttle body assembly within 3 minutes of applying the seal packing.

      • Do not run the engine for at least 2 hours after installing.

    3. A01CH93

      Install the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CHFJ

      Connect the 2 diesel throttle body connectors.

  36. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install a new cylinder head cover gasket onto the No. 2 cylinder head cover.

    2. A01CGZM

      Install the No. 2 cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    3. Install the cylinder head cover cushion rubber.

    4. Connect the ventilation hose.

  37. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01CJGU

      Install the cylinder head cover sub-assembly with a new gasket and the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  38. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. A01CJFY

      Install the oil filler cap sub-assembly.

  39. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Install the EGR cooler with a new gasket and the 2 bolts.

      Torque:
      Flange
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }
      Engine
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Connect the water by-pass hose.

  40. INSTALL ENGINE ASSEMBLY


    1. A01CISZ

      Install the engine hanger with the 2 bolts.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }
    2. A01CGMU

      Install the engine to the engine mounting brackets with the 2 nuts.

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

    3. Remove the engine hanger.

  41. INSTALL CLUTCH DISC ASSEMBLY

  42. INSTALL CLUTCH COVER ASSEMBLY

  43. INSTALL MANUAL TRANSMISSION ASSEMBLY

  44. INSTALL NO. 1 ENGINE MOUNTING BRACKET

  45. INSTALL NO. 3 ENGINE MOUNTING BRACKET

  46. INSTALL PARKING BRAKE PLATE SUB-ASSEMBLY

  47. INSTALL PARKING BRAKE DRUM SUB-ASSEMBLY

  48. INSTALL MANUAL TRANSMISSION OUTPUT SHAFT REAR SET NUT

  49. INSTALL WIRE HARNESS


    1. Install the wire harness.

  50. CONNECT FUEL HOSE


    1. A01CIXU

      Connect the 2 fuel hoses.

  51. CONNECT PRESSURE FEED HOSE


    1. Install the pressure feed hose with a new gasket.

    2. A01CH96

      Using a union nut wrench (19 mm), install the pressure feed hose.

      Torque:
      44 N*m  { 450 kgf*cm, 32 ft.*lbf }

  52. CONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE


    1. A01CHED

      Connect the No. 2 oil reservoir to pump hose.

  53. CONNECT TRANSMISSION CONTROL SHIFT CABLE

  54. CONNECT TRANSMISSION CONTROL SELECT CABLE

  55. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

  56. REMOVE PROPELLER INTERMEDIATE SHAFT ASSEMBLY

  57. INSTALL PROPELLER SHAFT ASSEMBLY

  58. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01CI20E01

      Install a new gasket and front exhaust pipe assembly, and temporarily tighten 3 new nuts.

    2. A01CHG1

      Temporarily tighten the bolt.

    3. Tighten the 3 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    4. Tighten the bolt.

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

  59. INSTALL EXHAUST RETARDER ASSEMBLY


    1. A01CHNOE01

      Install 2 new gaskets and exhaust retarder assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    2. A01CIBFE01

      Connect the vacuum hose.

  60. CONNECT HEATER HOSE

  61. INSTALL STARTER ASSEMBLY


    1. A01CGQR

      Install the starter assembly with the bolt and nut.

      Torque:
      154 N*m  { 1570 kgf*cm, 114 ft.*lbf }
    2. A01CICI

      Install the starter wire to terminal C with the bolt, and install the terminal cap.

      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

    3. Install the starter wire to terminal B with the nut, and install the terminal cap.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    4. Install the wire harness clamp bracket with the bolt.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  62. INSTALL GENERATOR ASSEMBLY


    1. A01CJ2NE01

      Temporarily install the generator assembly with bolt A.

    2. Temporarily install the generator bracket to the generator assembly with bolt B.

    3. Install the generator bracket with 2 bolts C.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

    4. Connect the 3 wire harness clamps.

    5. Connect the connector to the generator.

    6. Install the wire harness to terminal B with the nut, and install the terminal cap.

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

  63. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly with the fan shroud.

  64. INSTALL NO. 3 RADIATOR BRACKET


    1. A01CJBO

      Install the No. 3 radiator bracket with the 3 bolts.

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

  65. INSTALL NO. 4 RADIATOR BRACKET


    1. A01CIT5

      Install the No. 4 radiator bracket with the 3 bolts.

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

  66. INSTALL HEATER HOSE


    1. A01CJFI

      Install the heater hose with the 5 bolts.

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

  67. CONNECT RADIATOR HOSE OUTLET


    1. Install the radiator hose outlet.

  68. CONNECT RADIATOR HOSE INLET


    1. Install the radiator hose inlet.

  69. INSTALL FAN PULLEY


    1. A01CI13

      Install the fan pulley.

  70. INSTALL FAN


    1. Temporarily install the fan with the 4 nuts.

    2. Install the fan and generator V belt Click here.

    3. Holding the V belt, tighten the 4 nuts completely to install the fan pulley and fan properly.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  71. INSPECT DRIVE BELT


    1. A01CHS3E01

      Check the fan and generator V belt deflection.

      Tech Tips

      The specified deflection values per belt are shown in the following table.

      Deflection
      Item Specified Condition
      New belt 10.5 to 12.5 mm (0.41 to 0.49 in.)
      Used belt 12.5 to 16.0 mm (0.49 to 0.63 in.)

      Note


      • Check the V belt deflection at the specified point.

      • When inspecting a belt which has been used for over 5 minutes, apply the used belt specifications.

  72. INSTALL INTERCOOLER ASSEMBLY


    1. A01CGO8E01

      Install the intercooler assembly with the 4 bolts.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

  73. INSTALL NO. 2 AIR HOSE


    1. A01CJB7

      Install the No. 1 air hose with the 2 new hose bands.

  74. INSTALL NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE


    1. A01CJ3X

      Connect the No. 1 intake air pipe with No. 4 air hose with a new hose band.

    2. A01CHDR

      Connect the intake air temperature sensor connector.

    3. A01CIPV

      Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A01CGN2

      Install the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    5. A01CJ0J

      Install the No. 1 intake air pipe with No. 4 air hose with a new hose band.

  75. INSTALL NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY


    1. A01CIY0

      Install the No. 3 cab mounting bracket with the 8 bolts.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
    2. A01CIIG

      Install the No. 1 air hose assembly with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    3. A01CJGK

      Install the air cleaner case with the 4 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A01CH0N

      Connect the connector. (w/ Cab tilt warning)

  76. INSTALL NO. 2 INTAKE PIPE


    1. A01CHOY

      Install the No. 2 intake pipe with the 3 bolts and 2 bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  77. INSTALL INJECTOR DRIVER ASSEMBLY


    1. A01CHLQ

      Install the injector driver assembly with the 2 bolts.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

    2. Connect the wire harness clamp and connector to the injector driver assembly.

    3. Connect the 2 injector driver connectors.

  78. INSTALL VACUUM RESERVOIR SUB-ASSEMBLY

  79. INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH

  80. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH

  81. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. A01CGLT

      Install the radiator reserve tank assembly with the bolt and 3 nuts.

      Torque:
      12 N*m  { 120 kgf*cm, 10 ft.*lbf }

  82. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH

  83. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH

  84. CONNECT NEGATIVE BATTERY TERMINAL

  85. ADD ENGINE OIL


    1. Add fresh oil and install the oil filler cap sub-assembly.

      Engine oil
      Oil Grade Oil Viscosity (SAE)

      • API CD, CE, CF, CH-4, or CI-4 (May also use API CE, or CD.)

      • 10W-30

      • 20W-20

      • 15W-40

      • 30

      • 40
      Capacity
      Item Fill amount
      Drain and refill with oil filter change 7.1 liters (7.5 US qts, 6.2 Imp. qts)
      Drain and refill without oil filter change 5.9 liters (6.2 US qts, 5.2 Imp. qts)
      Dry fill 7.8 liters ( 8.3 US qts, 6.9 Imp. qts)

  86. ADD ENGINE COOLANT


    1. Add engine coolant.

      Specified capacity
      14.7 liters (15.5 US qts, 12.9 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      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).

      • Contact your TOYOTA dealer for further details.

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.

    3. Install the radiator cap.

    4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

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

        Note


        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down.

    7. Remove the radiator cap and check the coolant level.

    8. If the coolant level has dropped, add coolant.

    9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.

  87. ADD POWER STEERING FLUID

  88. BLEED AIR FROM FUEL SYSTEM


    1. A01CGS9

      Loosen the fuel filter's air bleed plug.

      Note


      • Do not use any tools.

      • Do not allow any fuel to spill.

      • If any fuel spills on any part of the engine, wipe it clean with a shop rag or a piece of cloth.

    2. A01CGKM

      While covering the drain pipe with a shop rag or a piece of cloth, press and release the priming pump until the fuel from the drain pipe does not have any bubbles.

    3. A01CIWK

      Tighten the air bleed plug.

      Note

      Do not use any tools.

  89. INSPECT FOR ENGINE OIL LEAK

  90. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

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

    2. A01CIGLE01

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

    3. Warm up the engine.

    4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    5. Install the radiator cap.

  91. BLEED POWER STEERING SYSTEM

  92. INSPECT FOR POWER STEERING FLUID LEAK

  93. INSPECT FOR EXHAUST GAS LEAK

  94. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Select the following menu items: Powertrain / Engine / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Fuel leaks (common rail internal fuel pressure is raised) Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.

  95. INSTALL ENGINE UNDER COVER