COMMON RAIL INSTALLATION


  1. 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.

  2. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE


    1. A01CJB8

      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 SST. When using SST, calculate the torque in accordance with the lengths of SST and the 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. A01CHXB

      Connect the 2 wire harness clamps.

    4. Connect the wire harness connector.

  3. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. A01CHN3

      Temporarily install the injection pipe sub-assembly with the 8 union nuts.

      Note

      If the common rail has been replaced, the injection pipes must also be replaced.

    2. 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.

  4. INSTALL INJECTION PIPE CLAMP


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

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

    3. A01CJ0C

      Temporarily install the 2 injection pipe clamps and oil level gauge guide.

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

  5. 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 }

  6. 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 }

  7. INSTALL 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 }

  8. 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.

  9. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CJ9R

      Install 4 new gaskets and water by-pass pipe sub-assembly with the 2 union bolts and 3 bolts.

      Torque:
      for Union Bolt
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for Bolt
      29 N*m  { 29 kgf*cm, 21 ft.*lbf }
    2. A01CJ16

      Connect the 2 hoses to the EGR valve.

  10. 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.

  11. INSTALL NO. 4 AIR HOSE


    1. A01CJ8A

      Install the No. 4 air hose with 2 new clamps.

  12. INSTALL NO. 1 AIR HOSE


    1. A01CJCPE01

      Install the No. 1 air hose with the 2 bolts and a new hose clamp as shown in the illustration.

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

  13. 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 }

  14. 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.

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  16. BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    Click here.

  17. 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.

  18. INSPECT FOR 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.

  19. INSTALL ENGINE UNDER COVER

  20. SUPPLY PUMP INITIALIZATION

    Tech Tips

    Click here.

  21. PERFORM INITIALIZATION

    Tech Tips

    Click here.