COMMON RAIL INSTALLATION

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 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 INJECTION PIPE SUB-ASSEMBLY
1. 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 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 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. 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 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 EGR VALVE BRACKET
1. Install the EGR valve bracket with the 4 bolts.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
INSTALL 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 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 WATER BY-PASS PIPE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Bolt
  
  *2 Union Bolt
  
  Install 4 new gaskets and the 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 { 291 kgf*cm, 21 ft.*lbf }
2. Connect the 3 wire harness clamps.
3. Connect the 2 hoses to the EGR valve.
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. 4 AIR HOSE
1. Install the No. 4 air hose with 2 new clamps.
INSTALL NO. 1 AIR HOSE
1. Text in Illustration
  
  *a Upper Side
  
  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 }
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 }
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.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
BLEED AIR FROM FUEL SYSTEM

Tech Tips

Click here.

Text in Illustration
*1	Seal Packing

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

Text in Illustration
*1	Bolt
*2	Union Bolt

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

Text in Illustration
*a	Upper Side

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

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.

INSPECT FOR 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.
INSTALL ENGINE UNDER COVER