ENGINE ASSEMBLY INSTALLATION

INSTALL INTAKE MANIFOLD
1. Text in Illustration
  
  *1 Seal Packing
  
  Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.
  - Install the intake manifold 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 }
REMOVE INTAKE AIR TEMPERATURE SENSOR
1. Install a new gasket to the intake air temperature sensor.
2. Using a union nut wrench, install the intake air temperature sensor.
  
  Torque:
  
  20 N*m { 200 kgf*cm, 14 ft.*lbf }
  
  Note
  
  Do not damage the intake air temperature sensor.
3. Install the bracket to the intake air temperature sensor connector.
4. Connect the wire harness clamp.
5. Install the bracket with the bolt.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
6. Connect the intake air temperature sensor connector.

Text in Illustration
*1	Seal Packing

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

INSTALL SUPPLY PUMP ASSEMBLY

Install a new O-ring onto the timer cover.
Text in Illustration

*a Matchmark

*b Hole

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

*a Timing Mark

Check that the No. 1 cylinder is at TDC/compression.
Text in Illustration

*a Matchmark

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 }
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).

Text in Illustration
*a	Matchmark
*b	Hole

Text in Illustration
*a	Timing Mark

Text in Illustration
*a	Matchmark

Text in Illustration
*1	Vinyl Tape

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

Tape the screwdriver as shown in the illustration.
Text in Illustration

*1 Service Plug

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

Text in Illustration
*1	Service Plug

Text in Illustration
*1	Timing Chain Cover
*2	Screwdriver
*3	Drive Gear

Insert the screwdriver into the service plug hole.

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

Torque:

13 N*m { 132 kgf*cm, 10 ft.*lbf }

Install the holder clip with the bolt.

Torque:

29 N*m { 291 kgf*cm, 21 ft.*lbf }
Connect the 2 connectors.

INSTALL FUEL RETURN PIPE SUB-ASSEMBLY
1. Temporarily install the fuel return pipe sub-assembly and 5 new gaskets with the 2 union bolts.
2. Tighten the 2 union bolts.
  
  Torque:
  
  Bolt A
  
  20 N*m { 200 kgf*cm, 14 ft.*lbf }
  
  Torque:
  
  Bolt B
  
  10 N*m { 100 kgf*cm, 7 ft.*lbf }
INSTALL COMMON RAIL ASSEMBLY
1. 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 install the clip.
3. Connect the fuel pressure sensor connector.
INSTALL NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY
1. 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.
INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE
1. Using a union nut wrench (17 mm), install the fuel filter to injection pump fuel pipe with the 2 union nuts.
  
  Torque:
  
  35 N*m { 360 kgf*cm, 26 ft.*lbf }
  Note
  
  If the supply pump assembly has been replaced, the fuel filter to injection pump fuel pipe must also be replaced.
  
  Refer to the torque above when not using the union nut wrench. When using the union nut wrench, calculate the torque in accordance with the lengths of the union nut wrench and torque wrench Click here.
2. Install the fuel pipe clamp with the nut. Tighten the nut until the clamp edge makes contact with the engine side clamp edge.
3. Connect the 2 wire harness clamps.
4. Connect the wire harness connector.
INSTALL FUEL PIPE SUB-ASSEMBLY
1. Install the fuel pipe sub-assembly and 2 new gaskets with the union bolt.
  
  Torque:
  
  17 N*m { 170 kgf*cm, 12 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.
INSTALL VACUUM PUMP ASSEMBLY
1. Install the vacuum pump assembly and a new O-ring with the 2 nuts.
  
  Torque:
  
  55 N*m { 560 kgf*cm, 41 ft.*lbf }
INSTALL VACUUM PUMP OIL PIPE SUB-ASSEMBLY
1. Install the vacuum pump oil pipe sub-assembly and new gaskets with the 3 union bolts.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 10 ft.*lbf }
INSTALL VACUUM PIPE
1. Install the vacuum pipe and 2 new gaskets, with the union bolt and bolt.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 10 ft.*lbf }
INSTALL WATER PUMP ASSEMBLY
1. 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 surfaces.
  
  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. Install the water pump assembly with the 8 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Seal Packing
  
  Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.
  - 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 and 2 new O-rings with the 6 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER PIPE SUB-ASSEMBLY
1. Install the water pipe sub-assembly and a new O-ring with the 3 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER OUTLET HOUSING
1. Install the water outlet housing with the 3 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER TEMPERATURE SENDER GAUGE ASSEMBLY
1. Install the water temperature sender gauge assembly and a new gasket.
  
  Torque:
  
  29 N*m { 300 kgf*cm, 22 ft.*lbf }
INSTALL THERMOSTAT
1. 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 surfaces.
  
  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. Install a new gasket onto the thermostat.
3. Align the jiggle valve to the position shown in the illustration and install the thermostat.
4. Install the water outlet with the 3 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER OUTLET SUB-ASSEMBLY
1. Install the water outlet sub-assembly with the 3 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL CAMSHAFT POSITION SENSOR
1. Install the camshaft position sensor and a new O-ring with the bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor and a new O-ring with the bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL OIL COOLER ASSEMBLY
1. Install the oil cooler assembly and 2 new gaskets to the oil filter bracket sub-assembly with the 4 nuts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. 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. 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. Install the wire harness bracket and the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
1. Install the oil pressure switch.
  1. Install the oil pressure switch and a new O-ring by hand, then further tighten it 20 to 30° as shown in the illustration.
2. Connect the oil pressure switch connector.
INSTALL GLOW PLUG ASSEMBLY
1. Using a 12 mm deep socket wrench, install the 4 glow plugs.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }

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

Text in Illustration
*1	Seal Packing

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

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

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

INSTALL GLOW PLUG GROUND WIRE

Text in Illustration
*1	Glow Plug Ground Wire
*2	Wire Harness
*3	Engine Front Side

Install the 3 ground wires so that they overlap as shown in the illustration. Make sure that the ground wire on the front side of the engine is installed first.

Note

If the ground wires are not installed in the correct order, they may deform when the nuts are tightened.

Install the wire harness onto the No. 4 glow plug.
Install the 4 nuts.

Torque:

1.5 N*m { 15 kgf*cm, 13 in.*lbf }

Note

Check that the ground wires do not interfere with the cylinder head or intake manifold.
Install the 4 screw grommets.

INSTALL EXHAUST MANIFOLD

Text in Illustration

*a CORRECT

*b INCORRECT

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

*a Contact

Temporarily install the exhaust manifold.

Tech Tips

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

Text in Illustration
*a	CORRECT
*b	INCORRECT

Text in Illustration
*a	Contact

Text in Illustration
*a	New Exhaust Manifold
*b	Used Exhaust Manifold

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

Torque:: 60 N*m { 612 kgf*cm, 44 ft.*lbf }

Text in Illustration
*a	New Exhaust Manifold
*b	Used Exhaust Manifold

Retighten the exhaust manifold with the nuts and spacers in the order shown in the illustration.

Torque:: 60 N*m { 612 kgf*cm, 44 ft.*lbf }

Install the exhaust manifold cover with the 3 bolts.

Torque:

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

INSTALL TURBOCHARGER SUB-ASSEMBLY

Tech Tips

Click here.
INSTALL RADIATOR PIPE
1. Install the radiator pipe and a new O-ring with the 2 bolts.
  
  Torque:
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf }
INSTALL GENERATOR BRACKET SUB-ASSEMBLY
1. Install the generator bracket with the 3 bolts.
  
  Torque:
  
  55 N*m { 560 kgf*cm, 41 ft.*lbf }
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 }
INSTALL VANE PUMP ASSEMBLY
1. Coat a new O-ring with power steering fluid and install it to the vane pump.
2. Install the vane pump assembly with the 2 bolts.
  
  Torque:
  
  47 N*m { 480 kgf*cm, 35 ft.*lbf }
INSTALL INJECTOR ASSEMBLY
Note

Text in Illustration

*1 Injector Compensation Code

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. Apply a small amount of clean engine oil to 4 new O-rings.
2. Text in Illustration
  
  *1 O-ring
  
  Install the O-ring to each injector as shown in the illustration.
3. Install a new gasket to each injector.
4. 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.
5. 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.
6. Install 4 new holder seals.
  
  Note
  
  Securely insert the tip of each holder seal into each fuel injector.
7. Temporarily install the nozzle leakage pipe assembly and 5 new gaskets with the 5 hollow screws.
  
  Note
  
  Make sure that the hollow screws and nozzle leakage pipe assembly are not deformed or damaged.
8. Temporarily tighten the union nuts of the 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.
9. 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.
10. Tighten the 5 hollow screws.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 10 ft.*lbf }
  
  Note
  
  If the nozzle leakage pipe assembly has been tightened to more than the specified torque, replace it with a new one.
11. 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 the union nut wrench. When using the union nut wrench, calculate the torque in accordance with the lengths of the union nut wrench and torque wrench Click here.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install the engine oil level dipstick guide and a new O-ring.
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. 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.
4. Install the oil level gauge.
INSTALL VENTURI ASSEMBLY
1. Text in Illustration
  
  *1 Seal Packing
  
  Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.
  - Install the venturi within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
2. Install the venturi assembly with the 4 bolts and 2 nuts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
3. Install the bracket with the bolt.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Gasket
  
  Install the water by-pass pipe sub-assembly and new gaskets 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 }
INSTALL EGR VALVE BRACKET
1. Install the EGR valve bracket with the 4 bolts.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
CONNECT WIRE HARNESS AND CONNECTORS
1. Connect the 3 connectors and 4 wire harness clamps and then install the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL DIESEL THROTTLE BODY
1. Remove any seal packing material from the contact surface.
2. Text in Illustration
  
  *1 70 mm (2.75 in.)
  
  *2 Seal Packing
  
  Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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. Install the diesel throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
4. Connect the 2 diesel throttle body connectors.
INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install a new cylinder head cover gasket onto the No. 2 cylinder head cover.
2. Install the No. 2 cylinder head cover sub-assembly, cushions and spacers with the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
3. Install the cylinder head cover cushion rubber.
4. Install the wire harness.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the cylinder head cover sub-assembly with the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler cap sub-assembly.
INSTALL EGR COOLER SUB-ASSEMBLY
1. Install the EGR cooler, bracket and 2 new gaskets with the 6 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.
INSTALL ENGINE ASSEMBLY
1. Install the engine hanger with the 2 bolts.
  
  Torque:
  
  125 N*m { 1275 kgf*cm, 92 ft.*lbf }
2. 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.
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSTALL MANUAL TRANSMISSION ASSEMBLY
INSTALL NO. 1 ENGINE MOUNTING BRACKET
INSTALL NO. 3 ENGINE MOUNTING BRACKET
INSTALL PARKING BRAKE PLATE SUB-ASSEMBLY
INSTALL PARKING BRAKE DRUM SUB-ASSEMBLY
INSTALL REAR MANUAL TRANSMISSION OUTPUT SHAFT SET NUT
INSTALL WIRE HARNESS
1. Install the wire harness.
CONNECT FUEL HOSE
1. Connect the 2 fuel hoses.
CONNECT PRESSURE FEED HOSE
1. Install the pressure feed hose and a new gasket.
2. Using a union nut wrench (19 mm), install the pressure feed hose.
  
  Torque:
  
  44 N*m { 450 kgf*cm, 32 ft.*lbf }
CONNECT NO. 2 OIL RESERVOIR TO PUMP HOSE
1. Connect the No. 2 oil reservoir to pump hose.
CONNECT TRANSMISSION CONTROL SHIFT CABLE
CONNECT TRANSMISSION CONTROL SELECT CABLE
INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY
INSTALL PROPELLER INTERMEDIATE SHAFT ASSEMBLY
INSTALL PROPELLER SHAFT ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Install a new gasket and the front exhaust pipe assembly, and temporarily tighten 3 new nuts.
2. Temporarily tighten a new 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 }
INSTALL EXHAUST RETARDER ASSEMBLY
1. Install 2 new gaskets and exhaust retarder assembly with 4 new bolts.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
2. Connect the vacuum hose.
INSTALL STARTER ASSEMBLY
1. Install the starter assembly with the bolt and nut.
  
  Torque:
  
  154 N*m { 1570 kgf*cm, 114 ft.*lbf }
2. 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 }
5. Connect the 2 wire harness clamps.
INSTALL GENERATOR ASSEMBLY
1. Temporarily install the generator assembly with the bolt (A).
2. Temporarily install the generator belt adjusting bar to the generator assembly with the bolt (B).
3. Install the generator belt adjusting bar with the 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 }
INSTALL RADIATOR ASSEMBLY
1. Install the radiator assembly with the fan shroud.
INSTALL NO. 3 RADIATOR BRACKET
1. Install the No. 3 radiator bracket with the 3 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL NO. 4 RADIATOR BRACKET
1. Install the No. 4 radiator bracket with the 3 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL HEATER HOSE
1. Install the heater hose with the 5 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
CONNECT OUTLET RADIATOR HOSE
1. Install the outlet radiator hose.
CONNECT INLET RADIATOR HOSE
1. Install the inlet radiator hose.
INSTALL NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT (w/ Air Conditioning System)
1. Install the No. 1 V (cooler compressor to crankshaft pulley) belt.
INSTALL FAN PULLEY
1. Install the fan pulley.
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 }

Text in Illustration
*1	Injector Compensation Code

Text in Illustration
*1	O-ring

Text in Illustration
*1	Seal Packing

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

Text in Illustration
*1	Gasket

Text in Illustration
*1	70 mm (2.75 in.)
*2	Seal Packing

INSPECT DRIVE BELT

Text in Illustration
*1	Fan Pulley
*2	Generator
*3	Crankshaft Pulley

Check the fan and generator V belt deflection.

Tech Tips

The specified deflection values per belt are shown in the following table.
When inspecting the V belt deflection, apply 98 N (10 kgf, 22 lbf) tensile force to it.

Deflection

Item	Specified Condition
New belt	10.5 to 12.5 mm (0.413 to 0.492 in.)
Used belt	12.5 to 16.0 mm (0.492 to 0.630 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.

Text in Illustration
*1	Idler Pulley
*2	A/C Compressor
*3	Crankshaft Pulley

Check the No. 1 V (cooler compressor to crankshaft pulley) belt deflection (w/ Air Conditioning System).

Tech Tips

The specified deflection values per belt are shown in the following table.
When inspecting the V belt deflection, apply 98 N (10 kgf, 22 lbf) tensile force to it.

Deflection

Item	Specified Condition
New belt	8.5 to 10.0 mm (0.335 to 0.394 in.)
Used belt	10.0 to 12.0 mm (0.394 to 0.472 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.

INSTALL INTERCOOLER ASSEMBLY
1. Install the intercooler assembly with the 4 bolts.
  
  Torque:
  
  7.5 N*m { 77 kgf*cm, 66 in.*lbf }
INSTALL NO. 2 AIR HOSE
1. Install the No. 2 air hose with 2 new hose bands.
INSTALL NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE
1. Connect the No. 1 intake air pipe with No. 4 air hose with a new hose band.
2. Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
3. Install the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
4. Install the No. 1 intake air pipe with No. 4 air hose with a new hose band.
INSTALL NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY
1. Install the No. 3 cab mounting bracket with the 8 bolts.
  
  Torque:
  
  120 N*m { 1224 kgf*cm, 89 ft.*lbf }
2. Install the No. 1 air hose assembly with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
3. Install the air cleaner case with the 4 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
4. Connect the connector (w/ Cab tilt warning).
INSTALL NO. 2 INTAKE PIPE
1. Install the No. 2 intake pipe and No. 1 air hose with the 3 bolts and 2 new hose bands.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
INSTALL INJECTOR DRIVER ASSEMBLY
1. 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.
INSTALL VACUUM RESERVOIR SUB-ASSEMBLY
INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH
INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH
INSTALL RADIATOR RESERVE TANK ASSEMBLY
1. Install the radiator reserve tank assembly with the bolt and 3 nuts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 9 ft.*lbf }
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE OIL

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

Engine oil

Oil Grade	Oil Viscosity (SAE)
API (CF, CF-4, CH-4, CI-4, CG-4, CJ-4) JASO (DH-1, DH-2) ACEA (E-3, E-4, E-5, E-6)	10W-30 20W-20 15W-40 30 40

Capacity

Item	Fill amount
Drain and refill with oil filter change	6.5 liters (6.9 US qts, 5.7 Imp. qts)
Drain and refill without oil filter change	5.2 liters (5.5 US qts, 4.6 Imp. qts)
Dry fill	7.8 liters ( 8.3 US qts, 6.9 Imp. qts)

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 is 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 sub-assembly.
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 sub-assembly 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.
ADD POWER STEERING FLUID
BLEED AIR FROM FUEL SYSTEM
1. Connect the drain hose to the air bleed plug.
2. 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 piece of cloth.
3. While covering the drain hose with a piece of cloth, press and release the priming pump until the fuel from the drain hose does not have any bubbles.
4. Tighten the air bleed plug.
  
  Note
  
  Do not use any tools.
INSPECT FOR ENGINE OIL LEAK
INSPECT FOR ENGINE COOLANT LEAK
1. Remove the radiator cap sub-assembly.
  
  CAUTION:
  
  Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
2. Text in Illustration
  
  *1 Radiator Cap Tester
  
  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 sub-assembly.
BLEED POWER STEERING SYSTEM
INSPECT FOR POWER STEERING FLUID LEAK
INSPECT FOR EXHAUST GAS LEAK

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

Text in Illustration
*1	Radiator Cap Tester

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Start the engine.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurizes common rail internal fuel pressure, and checks for fuel leaks	Stop or Start	Fuel pressure inside common rail is pressurized to specified value and engine speed is increased to 2000 rpm when Start is selected. Above conditions preserved while Start is selected.

INSTALL ENGINE UNDER COVER