ENGINE ASSEMBLY (w/ DPF) INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. Install the engine mounting bracket with the 4 bolts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  2. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket with the 4 bolts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    A01KIFTE01

    1. Install a new gasket onto the engine coolant temperature sensor.

    2. Using SST, install the engine coolant temperature sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Connect the engine coolant temperature sensor connector.

  4. INSTALL WATER OUTLET


    1. Install the water outlet and a new gasket with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  5. INSTALL OIL COOLER COVER SUB-ASSEMBLY


    1. Install a new gasket and oil cooler cover to the cylinder block.

    2. Install the oil cooler cover to the cylinder block with the 12 bolts.

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

    3. Install the No. 2 vacuum transmitting pipe with the bolt and 2 nuts.

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

    4. Connect the vinyl tube to the oil cooler cover.

    5. Connect the oil pressure switch connector.

  6. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Clean the oil filter installation surface.

    2. Apply engine oil to the oil filter gasket.

    3. Lightly screw a new oil filter to the oil cooler cover until the oil filter does not turn.

    4. Using SST, tighten the oil filter an additional 3/4 turn.

      SST
      09228-07501
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  7. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose to the oil cooler cover.

  8. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Install the No. 3 water by-pass hose to the oil cooler cover.

  9. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Temporarily install a new gasket and the No. 2 nozzle leakage pipe assembly with the union bolt and 3 bolts.

    2. A01KIIVE01

      Tighten the union bolt and 3 bolts.

      Torque:
      Union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Text in Illustration
      A01KGZT Union Bolt

  10. INSTALL NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 2 vacuum transmitting pipe with the 2 nuts and bolt.

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

  11. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 1 vacuum transmitting pipe with the nut and bolt.

      Torque:
      Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    2. Connect the vacuum hose.

  12. INSTALL SWIRL CONTROL VALVE ASSEMBLY

    A01KESJE02

    1. Temporarily install a new gasket and the swirl control valve with the 4 bolts and 2 nuts.

      Note

      Make sure that the swirl control valve actuator is not damaged by the surrounding parts.

    2. Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  13. INSTALL VACUUM CONTROL VALVE SET


    1. Install the vacuum control valve set with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01KH8AE01
      Text in Illustration
      *1 Paint Mark

      Connect the 3 vacuum hoses and 2 connectors.

      Tech Tips

      When connecting the hoses, match the color of the paint mark on the hoses to the color of the paint mark on the swirl control valve as shown in the illustration.

  14. INSTALL INTAKE MANIFOLD

    A01KEVYE02

    1. Temporarily install a new gasket and the intake manifold with the 7 bolts and 2 nuts.

    2. Tighten the 7 bolts and 2 nuts in the order shown in the illustration.

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

  15. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator to the intake manifold.

  16. INSTALL NO. 2 CYLINDER BLOCK INSULATOR

  17. INSTALL THERMOSTAT

    A01KHH6E04
    Text in Illustration
    *1 Gasket
    *2 Jiggle valve
    *a Correct
    *b Incorrect
    *c Upward

    1. Install a new gasket to the thermostat.

      Tech Tips

      When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

    2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

      Tech Tips

      The jiggle valve may be set within 30° of vertical in either direction.

  18. INSTALL WATER INLET


    1. Install the water inlet and a new gasket with the 3 bolts.

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

      Note

      Torque the 2 upper bolts first.

  19. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new gasket.

    2. Install the No. 2 water by-pass pipe with the 2 nuts and bolt.

      Torque:
      Nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  20. CONNECT NO. 2 TURBO WATER HOSE


    1. Connect the turbo water hose to the water inlet.

    2. Install the hose clamp with the bolt.

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

  21. INSTALL NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the No. 5 water by-pass pipe with the 2 bolts and nut.

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

  22. INSTALL CRANKSHAFT PULLEY


    1. Align the pulley set key with the key groove of the pulley.

    2. Using SST, install the pulley bolt.

      SST
      09213-58014
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  23. INSTALL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring to the fuel supply pump assembly.

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

    3. A01KIG7E02
      Text in Illustration
      *a Groove

      Align the groove of the injection gear with the set key on the drive shaft.

    4. Temporarily install the fuel supply pump with the 2 nuts.

    5. Install a new O-ring and the nut.

    6. A01KHLVE03

      Using SST, hold the crankshaft pulley and install the set nut.

      SST
      09213-58014
      09330-00021
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    7. Tighten the 2 nuts.

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

    8. Connect the fuel hose.

    9. Connect the fuel temperature sensor connector and suction control valve connector to the fuel supply pump.

  24. INSTALL PUMP DRIVE SHAFT PULLEY


    1. Install the pump drive shaft pulley and No. 2 camshaft timing pulley flange with the 4 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  25. INSTALL NO. 3 FUEL PIPE


    1. A01KGWWE03
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. Temporarily install 3 new gaskets and the No. 3 fuel pipe with the fuel check valve, 2 union bolts and 3 bolts.

      A01KHGRE02
      Text in Illustration
      *1 Gasket - -
      A01KGZT Union Bolt A01KF96 Fuel Check Valve
      A01KFFI Bolt - -

    3. Tighten the 2 bolts and fuel check valve.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    4. Using a socket hexagon wrench, tighten the 2 union bolts and bolt.

      Torque:
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Union bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  26. INSTALL NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KIBLE03
      Text in Illustration
      *1 O-Ring

      Apply a light coat of fuel to the O-ring of the fuel check valve.

    2. Temporarily install a new gasket and the No. 3 nozzle leakage pipe with the fuel check valve and bolt.

    3. Tighten the fuel check valve and bolt.

      Torque:
      Fuel check valve
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }
      Bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    4. Install the No. 2 injection pipe clamp with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    5. Connect the 3 fuel hoses.

  27. INSTALL GLOW PLUG ASSEMBLY

    Note


    • Measure the resistance of the glow plug when reinstalling it.

      If the result is not as specified, replace it with a new one.

    • Replace the glow plug with a new one when it has been dropped or subjected to a physical impact.

    • Remove any carbon deposits from the glow plug hole when reinstalling it.


    1. A01KHCSE02
      Text in Illustration
      *a Tape

      Wrap tape around a φ 4.4 drill, 118.5 mm (4.665 in.) from its tip.

    2. Insert the drill 118.5 mm (4.665 in.) into the glow plug hole and remove the carbon deposits by manually turning the drill.

    3. Insert the φ 4 drill into the glow plug hole and remove any carbon deposits from the tip end portion of the glow plug hole by manually turning the drill.

    4. Install the 4 glow plugs.

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

      Note

      Do not use any tools, such as air tools, which are liable to cause any impact to the glow plugs, when installing them.

  28. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Temporarily install the No. 1 glow plug connector with the 4 nuts.

    2. Tighten the 4 nuts to the specified torque.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

    3. Install the 4 screw grommets.

  29. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator to the intake manifold.

  30. INSTALL INTAKE MANIFOLD STAY


    1. Install the intake manifold stay with the 2 bolts.

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

  31. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  32. INSTALL FUEL INJECTION PIPE

    Note


    • When replacing the common rail, cylinder head sub-assembly, it is necessary to replace the No. 1 to No. 4 injection pipe sub-assembly with a new one.

    • Before installing the injection pipes and common rail assembly, clean them with a brush and compressed air.


    1. Temporarily install the No. 1 to No. 4 injection pipes.

    2. Install the 3 No. 2 injection pipe clamps to the No. 1 to No. 4 injection pipes with the 3 bolts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    3. Using a 17 mm union nut wrench, install the No. 1 to No. 4 injection pipes.

      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.

  33. INSTALL EGR COOLER ASSEMBLY


    1. Install the new gasket.

    2. Temporarily install the EGR cooler assembly with No. 2 EGR valve assembly with 3 bolts and 2 nuts.

      A01KH1IE03
      Text in Illustration
      *1 Nut - -

    3. Fully tighten the bolts shown in the illustration in order from A to C.

      Torque:
      Bolt A, B
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Bolt C
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    4. Tighten the 2 nuts.

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

  34. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one

    • When replacing the common rail, do not remove the foreign object mixing prevention caps of the common rail until just before the fuel inlet pipe and injection pipe are connected to the common rail.


    1. Temporarily install the inlet fuel pipe with the union nuts.

    2. Install the 2 No. 1 injection pipe clamps with the 2 bolts.

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

    3. Using a 17 mm union nut wrench, install the inlet fuel pipe sub-assembly with the union nut.

      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.

  35. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. A01KH0VE02
      Text in Illustration
      *a Front of Vehicle
      *b Upper

      Connect the water by-pass hose assembly and attach the clamp.

      Tech Tips

      The direction of each hose clamp is indicated in the illustration.

  36. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A01KGIME02
      Text in Illustration
      *a Front of Vehicle

      Connect the No. 3 water by-pass hose and attach the clamp.

      Tech Tips

      The direction of each hose clamp is indicated in the illustration.

  37. INSTALL INTAKE AIR CONNECTOR


    1. Install a new gasket, and install the intake air connector with the 3 bolts.

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

  38. TEMPORARILY TIGHTEN INTAKE AIR CONNECTOR ASSEMBLY


    1. Install a new gasket, and temporarily install the intake air connector assembly with the 2 bolts and 2 nuts.

      Tech Tips

      Do not seat the nut or the bolt.

  39. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Connect the emission control valve wire.

    2. Install the new gasket.

    3. Install the electric EGR control valve assembly.

  40. INSTALL EGR VALVE ADAPTER


    1. Install a new gasket, and temporarily install the EGR valve adapter with the 3 bolts and 2 nuts.

    2. A01KEXJE02

      Tighten the bolt A and 2 nuts shown in the illustration.

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

      Note

      After fully tightening the intake air connector assembly, fully tighten the bolts B shown in the illustration.

  41. FULLY TIGHTEN INTAKE AIR CONNECTOR ASSEMBLY


    1. A01KF1PJ01

      Fully tighten the 2 bolts and 2 nuts shown in the illustration in order from 1 to 4.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01KHLAJ01

      Fully tighten the 2 bolts B shown in the illustration.

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

  42. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  43. INSTALL GAS FILTER BRACKET


    1. Install the gas filter bracket with the bolt.

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

  44. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Install the manifold absolute pressure sensor with the 2 bolts.

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

  45. INSTALL NO. 1 GAS FILTER


    1. Install the No. 1 gas filter to the gas filter bracket.

    2. Connect the 2 vacuum hoses to the No. 1 gas filter.

  46. CONNECT NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the No. 7 water by-pass hose and attach the clamp to the No. 4 water by-pass pipe sub-assembly.

    2. Connect the No. 2 water by-pass to the No. 4 water by-pass pipe sub-assembly.

    3. Install the No. 4 water by-pass pipe sub-assembly with the bolt.

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

  47. CONNECT ENGINE WIRE


    1. Connect the intake air temperature sensor connector.

    2. Connect the manifold absolute sensor connector.

    3. Engage the wire harness clamp.

    4. Install the engine wire harness with the bolt.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  48. INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 3 vacuum transmitting pipe sub-assembly to the 2 bolts.

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

    2. Connect the 2 vacuum hoses.

  49. INSTALL NO. 3 VACUUM SWITCHING VALVE ASSEMBLY


    1. Install the No. 3 vacuum switching valve assembly with the bolts.

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

    2. Connect the 2 vacuum hoses.

    3. Connect the No. 3 vacuum switching valve assembly connector.

  50. CONNECT EMISSION CONTROL VALVE WIRE


    1. Engage the wire harness clamp and install the emission control valve wire.

    2. Connect the emission control valve wire.

  51. CONNECT NO. 7 WATER BY-PASS HOSE


    1. Connect the No. 7 water by-pass hose.

  52. CONNECT NO. 4 WATER BY-PASS HOSE


    1. Connect the No. 4 water by-pass hose.

  53. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  54. INSTALL OIL LEVEL DIPSTICK GUIDE (for RHD)


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

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

    3. Install the engine oil level dipstick guide with the bolt.

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

    4. Install the clamp with the water by-pass hose.

  55. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  56. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY

    A01KH74E03
    Text in Illustration
    *1 O-ring

    1. Apply a light coat of engine oil to the O-ring of the oil pressure switching valve.

      Note

      If reusing the oil pressure switching valve, be sure to inspect the O-ring.

    2. Install the oil pressure switching valve with the bolt.

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

      Note

      Make sure that the O-ring is not cracked or jammed when installing the valve.

    3. Connect the oil pressure switching valve connector.

  57. INSTALL CAMSHAFT POSITION SENSOR


    1. A01KHUYE02
      Text in Illustration
      *1 O-ring

      Apply a light coat of engine oil to the O-ring on the camshaft position sensor.

    2. A01KFV3

      Install the camshaft position sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Make sure that the O-ring is not cracked or jammed when installing the camshaft position sensor.

    3. Connect the camshaft position sensor connector.

  58. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01KHGDE01
      Text in Illustration
      *1 O-ring
      *a Engine Oil

      Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

    2. TYPE A:

      A01KIINE01
      Text in Illustration
      *1 Clamp *2 Wire Harness Clamp (A)
      *3 Wire Harness Clamp (B) *4 Protrusion

      1. Install the crankshaft position sensor with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

        Note

        Make sure that the O-ring is not damaged or does not jump out of position during installation.

      2. Install a new clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Make sure the crankshaft position sensor wire harness is installed in the position shown in the illustration.

      3. Attach the crankshaft position sensor connector to the No. 1 vacuum transmitting pipe.

      4. Connect the crankshaft position sensor connector.

      5. Attach the 2 wire harness clamps (A, B).

    3. TYPE B:

      A01KGP3E01
      Text in Illustration
      *1 Clamp *2 Wire Harness Clamp (A)
      *3 Wire Harness Clamp (B) *4 Protrusion
      *5 Bracket (Clamp) - -

      1. Install the crankshaft position sensor with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

        Note

        Make sure that the O-ring is not damaged or does not jump out of position during installation.

      2. Install the bracket (clamp) with the bolt.

        Torque:
        13 N*m  { 132 kgf*cm, 9.5 ft.*lbf }

      3. Install a new clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Make sure the crankshaft position sensor wire harness is installed in the position shown in the illustration.

      4. Attach the crankshaft position sensor connector to the No. 1 vacuum transmitting pipe.

      5. Connect the crankshaft position sensor connector.

      6. Attach the 2 wire harness clamps (A, B).

      7. Attach the 2 wire harness clamps to the bracket (clamp).

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


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

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

      Note

      Do not reuse the washer.

  60. INSTALL TIMING BELT

    A01KER0E06

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

      Text in Illustration
      *a Timing Marks

      Tech Tips

      If reusing the timing belt, align the points marked during removal, and install the belt with the direction 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. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

    3. A01KGUQE01

      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.

    4. Using a press, slowly push in the push rod using 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) of force.

      Note

      Do not impose a load of over 9807 N (1000 kgf, 2205 lbf) to the push rod.

    5. 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.

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

    7. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the bolts in order to avoid malfunction of the timing belt tensioner.

    8. A01KI6OE01

      Remove the 1.27 mm hexagon wrench from the tensioner.

    9. A01KFPKE06
      Text in Illustration
      *a Matchmarks
      *b Timing Marks

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

  61. INSTALL NO. 1 TIMING BELT COVER


    1. A01KER2E01

      Install the timing belt cover with the 6 bolts (A).

      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 (B).

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

  62. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolt.

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

  63. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Temporarily install the 2 engine mount insulators with the 6 nuts and 4 bolts.

    3. Tighten the engine mounting with the 4 bolts and 4 nuts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

    4. Tighten the engine mount insulator with the 2 nuts.

      Torque:
      76 N*m  { 775 kgf*cm, 56 ft.*lbf }

  64. INSTALL FRONT SUSPENSION MEMBER ASSEMBLY


    1. Temporarily tighten the 4 bolts and install the front suspension member assembly.

    2. Temporarily tighten the 2 nuts and 2 suspension dampers.

    3. Fully tighten the 4 bolts.

      Torque:
      150 N*m  { 1530 kgf*cm, 111 ft.*lbf }

    4. Fully tighten the 2 nuts and 2 suspension dampers.

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

  65. INSTALL ENGINE WIRE

  66. CONNECT PRESSURE FEED TUBE ASSEMBLY

    A01KGVN

    1. Connect the tube with the union bolt and a new gasket.

      Torque:
      42.1 N*m  { 430 kgf*cm, 31 ft.*lbf }

  67. CONNECT STEERING GEAR OUTLET RETURN TUBE

    A01KFQW

    1. Install the return tube.

      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }
    2. A01KEK0

      Face the claw to the vehicle is front, and install the return hose to the PS gear assembly with the clip.

    3. A01KIMS

      Install the hose with bolt (LHD steering position type only).

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

  68. INSTALL STEERING TORQUE SHAFT ASSEMBLY

    A01KEEOE01
    Text in Illustration
    *a Matchmark

    1. Align the matchmarks on the torque shaft and bevel gear.

    2. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    3. A01KFIDE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks on the sliding yoke and steering gear.

    4. Tighten the bolt.

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

  69. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH


    1. Support the front suspension lower arm No. 1 LH with a jack, connect the front suspension lower arm No. 1 LH to the steering knuckle.

    2. Install new castle nut to the steering knuckle.

      Torque:
      140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

    3. Install new cotter pin.

  70. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Connect the RH side using the same procedures as the LH side.

  71. CONNECT FRONT STABILIZER BAR

    A01KHO7

    1. Install the 4 bolts and connect the stabilizer bar.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  72. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH

    A01KF92

    1. Install the front shock absorber assembly LH and bolt, temporarily tighten the nut.

  73. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Temporarily tighten the RH side using the same procedures as the LH side.

  74. CONNECT TIE ROD END SUB-ASSEMBLY LH


    1. Connect the tie rod end to the knuckle arm.

    2. Install the nuts and new cotter pin.

      Torque:
      91 N*m  { 928 kgf*cm, 67 ft.*lbf }

  75. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Connect the RH side using the same procedures as the LH side.

  76. TEMPORARILY TIGHTEN EXHAUST MANIFOLD

    A01KET1

    1. Install a new gasket and the turbocharger with 3 new nuts to the exhaust manifold.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

      Note

      The claws of the gasket must face the turbocharger.

    2. Install a new gasket to the cylinder head.

    3. Temporarily tighten the exhaust manifold with turbocharger, 8 plate washers, 8 collars with 8 new nuts.

      Note

      Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

    4. Connect the 3 water hoses.

  77. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KG5FE03
      Text in Illustration
      *1 Claw
      *a Outside
      *b Wide
      *c Narrow

      Install 2 new gaskets to the turbo oil inlet pipe.

      Note

      Insert the gasket with its claws facing the turbo oil inlet pipe.

    2. Temporarily tighten the gasket and turbo inlet pipe with the 2 bolts, 2 nuts and union bolt.

  78. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. Temporarily tighten the turbocharger stay with the 2 bolts and a new nut.

  79. FULLY TIGHTEN EXHAUST MANIFOLD


    1. Fully tighten the 8 exhaust manifold installation nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  80. FULLY TIGHTEN TURBOCHARGER STAY


    1. Fully tighten the 2 bolts and nut to the specified torque and install the turbocharger stay.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  81. FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KHCKE03
      Text in Illustration
      *1 Union Bolt

      Fully tighten the 2 bolts, 2 nuts and union bolt to the specified torque and install the turbo oil inlet pipe.

      Torque:
      Bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Nut
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      Union Bolt
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  82. TEMPORARILY TIGHTEN NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Temporarily tighten the No. 1 exhaust manifold heat insulator with the 3 bolts.

  83. INSTALL NO. 1 TURBO INSULATOR


    1. Temporarily tighten the No. 1 turbo insulator with the 2 bolts.

    2. Fully tighten the 5 bolts to the specified torque and install the No. 1 exhaust manifold heat insulator and No. 1 turbo insulator.

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

  84. INSTALL TURBINE OUTLET ELBOW


    1. Connect the No. 4 water by-pass pipe to the No. 13 water by-pass pipe.

    2. Temporarily tighten the turbine outlet elbow with a new gasket and 3 new nuts.

    3. Temporarily tighten the No. 3 fuel pipe with a new gasket and union bolt.

    4. Fully tighten the 3 nuts to the specified torque and install the turbine outlet elbow.

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

    5. Fully tighten the union bolt to the specified torque and install the No. 3 fuel pipe.

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

    6. Install a new gasket and No. 4 water by-pass pipe with the union bolt.

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

    7. Connect the No. 1 turbo water hose.

    8. Connect the addition injector connector.

  85. INSTALL NO. 2 FUEL PIPE CLAMP

    A01KHBDE01
    Text in Illustration
    *1 No. 2 Fuel Pipe Clamp
    *2 No. 3 Fuel Pipe Clamp

    1. Install the No. 2 fuel pipe clamp with the bolt.

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

    2. Install the No. 3 fuel pipe clamp with the bolt.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  86. INSTALL CATALYTIC WITH PIPE CONVERTER ASSEMBLY

    A01KI6QE01

    1. Fully tighten the 3 (A) nuts to the specified torque and install the catalytic with pipe converter.

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

    2. Fully tighten the 2 (B) 2 bolts to the specified torque and install the turbine outlet stay.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    3. Fully tighten the 2 (C) 2 bolts to the specified torque and install the turbine outlet stay.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  87. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 3 exhaust manifold heat insulator with the 2 bolts.

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

  88. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

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

  89. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. Install the ventilation pipe with the bolt.

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

  90. INSTALL ENGINE WIRE HARNESS


    1. Install the engine wire harness bracket with the 2 bolts.

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

    2. Connect the turbocharger stroke sensor connector.

  91. INSTALL NO. 2 AIR CLEANER HOSE


    1. Install the No. 2 air cleaner hose.

      Torque:
      Hose clamp
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Connect the turbocharger motor connector.

  92. INSTALL COMPRESSOR OUTLET ELBOW


    1. Install the compressor outlet elbow with the bolt and hose clamp.

      Torque:
      Bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Hose clamp
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  93. INSTALL NO. 1 AIR HOSE


    1. Connect the No. 1 air hose.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  94. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A01KI8ME06

    1. Install the V-ribbed belt 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 areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

  95. INSTALL GENERATOR ASSEMBLY


    1. A01KHPRE01

      Temporarily install the generator assembly and generator bracket with the 3 bolts.

    2. Tighten the 3 bolts to the specified torque.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf, for bolt A }
      36 N*m  { 367 kgf*cm, 27 ft.*lbf, for bolt B }

    3. Install the wire harness with the nut to terminal B.

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

    4. Install the terminal cap.

    5. Connect the generator connector.

    6. Apply a small amount of engine oil to a new O-ring and install it to the engine oil level dipstick guide.

    7. Install the engine oil level dipstick guide with the bolt.

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

    8. Install the engine oil level dipstick sub-assembly.

    9. Install the engine wire harness with the 2 bolts and connect the 2 connectors.

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

  96. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

    A01KELJE01

    1. Temporarily install the No. 1 compressor mounting bracket with the 4 bolts.

    2. Fully tighten the 4 bolts in the order shown in the illustration.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

      Tech Tips

      Make sure that the No. 1 compressor mounting bracket is in contact with the cylinder block.

  97. INSTALL COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

    A01KHTUE01

    1. Temporarily install the cooler compressor with the 4 bolts.

    2. Fully tighten the 4 bolts in the order shown in the illustration.

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

  98. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (for LHD)


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

    2. Install the O-ring to the level gauge.

    3. Install the engine oil level dipstick guide with the bolt.

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

    4. Install the wire harness clamp bracket with the 2 bolts.

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

    5. Connect the wire harness to the wire harness clamp bracket.

  99. INSTALL VACUUM PUMP ASSEMBLY


    1. Apply engine oil to 2 new O-rings.

    2. A01KHU9

      Install the 2 O-rings and the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }
    3. A01KHR8E02
      Text in Illustration
      *a Paint Mark

      Connect the vacuum hose (A) to the vacuum pump union.

    4. Connect the vacuum hose (B) to the vacuum pump union with the clip.

      Note

      Set the vacuum hose so that the paint mark faces upward.

  100. INSTALL VANE PUMP ASSEMBLY


    1. Install a new O-ring to the vane pump.

    2. Install the vane pump with the 2 nuts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  101. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. Install the vane pump oil reservoir with the 2 bolts.

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

  102. INSTALL NO. 3 AIR HOSE


    1. Install the No. 3 air hose and tighten the 2 hose clamps.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Connect the vacuum hose.

    3. Engage the vacuum hose clamp.

  103. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Clean the bolt and its hole.

    2. A01KEUDE05
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

    3. Using SST, hold the crankshaft.

      SST
      09213-58014
      09330-00021

    4. Install the flywheel on the crankshaft.

    5. A01KFUTE01

      Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      178 N*m  { 1815 kgf*cm, 132 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after the installation.

  104. INSTALL CLUTCH DISC ASSEMBLY


    1. A01KFHCE02

      Insert SST into the clutch disc assembly, then insert them into the flywheel sub-assembly.

      Text in Illustration
      A01KFFI Flywheel Side
      SST
      09301-00110

      Note

      Take care not to insert the clutch disc assembly in the wrong direction.

  105. INSTALL CLUTCH COVER ASSEMBLY


    1. A01KHCHE04
      Text in Illustration
      *a Matchmark
      *b Temporarily

      Align the matchmarks on the clutch cover assembly with the one on the flywheel sub-assembly.

    2. Following the procedures shown in the illustration, tighten the 6 bolts starting from the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips


      • Evenly tighten the bolts by following the order shown in the illustration.

      • Tighten the bolts after checking that the disc is in the center by lightly moving SST up and down, left and right.

      SST
      09301-00110

  106. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  107. INSTALL RADIATOR ASSEMBLY

    Click here

  108. INSTALL INJECTOR DRIVER

    Click here

  109. INSTALL TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)


    1. Install the transmission service hole cover with the 12 bolts.

  110. INSTALL NO. 4 MAT SET PLATE (for Double Cab)


    1. Install the mat set plate with the 8 screws.

  111. INSTALL REAR FLOOR MAT (for Double Cab)

  112. INSTALL REAR DOOR SCUFF PLATE LH (for Double Cab)


    1. Install the rear door scuff plate with the 3 screws.

  113. INSTALL REAR DOOR SCUFF PLATE RH (for Double Cab)


    1. Install the rear door scuff plate with the 3 screws.

  114. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)

    A01KEH0

    1. Install the engine service hole sub cover with the 7 bolts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  115. INSTALL PARKING BRAKE LEVER ASSEMBLY (for Double Cab)

    A01KH1U

    1. Install the parking brake lever with the 4 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Connect the connector.

  116. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)

    A01KGMH

    1. Install the transmission floor shift with the 4 bolts.

      Torque:
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

  117. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (for Double Cab)


    1. A01KHBQ

      Install the floor shift cable transmission control select with clip and washer.

    2. Install a new clip.

  118. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (for Double Cab)


    1. A01KEIB

      Install the floor shift cable transmission control shift with the nut and washer.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

    2. Install a new clip.

  119. INSTALL NO. 1 FRONT FLOOR MAT REAR (for Double Cab)

  120. INSTALL FRONT FLOOR PANEL BRACE (for Double Cab)

    A01KFZF

    1. Install the front floor panel brace with the 3 clips.

  121. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Double Cab)

  122. INSTALL PARKING BRAKE HOLE COVER (for Double Cab)

    A01KHZT

    1. Install the parking brake hole cover with the screw.

  123. INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)

    A01KG08

    1. Install the front door scuff plate LH with the 4 screws.

  124. INSTALL FRONT SEAT ASSEMBLY LH (for Double Cab)


    1. Install the front seat LH with the 4 bolts.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    2. Connect the connector.

  125. INSTALL FRONT WHEEL

    Torque:
    Full Just Low
    365 N*m  { 3722 kgf*cm, 270 ft.*lbf }
    except Full Just Low
    135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

  126. FULLY TIGHTEN STEERING SLIDING YOKE SUB-ASSEMBLY

    A01KEYSE01
    Text in Illustration
    *a Matchmark

    1. Fully tighten the bolt.

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

    2. Install the steering link protector UPR and steering link protector LWR with the 3 bolts.

  127. STABILIZE SUSPENSION


    1. Install the front wheel and jack down the vehicle.

      Torque:
      Full just low
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }
      Except full just low
      135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

    2. Bounce the vehicle up and down several times to stabilize the suspension.

  128. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH

    A01KF92

    1. Fully tighten the nut.

      Torque:
      105 N*m  { 1071 kgf*cm, 77 ft.*lbf }

  129. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Fully tighten the RH side using the same procedures as the LH side.

  130. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

  131. PERFORM REGISTRATION


    1. Perform registration of the injector compensation code Click here.

  132. BLEED AIR FROM FUEL SYSTEM


    1. A01KETN

      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. Check if the engine starts.

      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. A01KI71E05
      Text in Illustration
      *a

      Reference

      (Active Test Operation)

      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.

      A01KH8CE14
      Text in Illustration
      *a Active Test Operation *b ON
      *c OFF *d time
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes - -

      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.

  133. ADD POWER STEERING FLUID

  134. BLEED POWER STEERING FLUID

  135. ADD ENGINE OIL


    1. Add fresh oil and install the oil filler cap.

      Engine oil
      Item Oil Grade Oil Viscosity (SAE)
      w/ DPF

      • ACEA C2

      (Using engine oil other than ACEA C2 may damage catalytic converter)

      • 0W-30

      • 5W-30
      w/o DPF

      • G-DLD1, API CF-4, CF or ACEA B1

      • 5W-30


      • 10W-30


      • 15W-40


      • 20W-50
      Capacity
      Item Fill Amount
      Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Drain and refill without oil filter change 6.8 liters (7.2 US qts, 6.0 Imp. qts)
      Dry fill 7.7 liters (8.1 US qts, 6.8 Imp. qts)

  136. ADD ENGINE COOLANT


    1. Pour coolant into the radiator until it overflows.

      Capacity
      Specification Capacity
      w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts)
      w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    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 securely.

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

    5. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    6. Maintain the engine speed at 2000 to 2500 rpm.

    7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

      CAUTION:


        When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

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

    9. Remove the radiator cap and check the coolant level inside the radiator.

    10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

    11. Check the coolant level inside the radiator reservoir tank again.

      If it is below the full level, add coolant.

  137. INITIALIZATION AND REGISTRATION

    Click here

  138. PERFORM REGISTRATION


    1. Perform pilot quantity learning Click here.

  139. INSPECT FOR ENGINE OIL LEAK


    1. Warm up the engine and inspect for oil leak.

  140. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

    2. A01KH30E02
      Text in Illustration
      *1 Radiator Cap Tester

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

    3. Warm up the engine.

    4. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.

    5. Reinstall the radiator cap.

  141. INSPECT FOR FUEL LEAK

  142. INSPECT FOR EXHAUST GAS LEAK

  143. INSPECT ENGINE OIL LEVEL


    1. Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.

      If low, check for leakage and add oil up to the full level mark.

      Note

      Do not fill engine oil above the full level mark.

  144. CHECK POWER STEERING FLUID LEVEL

  145. INSPECT FOR POWER STEERING FLUID LEAK

  146. CHECK ENGINE IDLING SPEED AND MAXIMUM SPEED

    Note

    Turn all the electrical systems OFF.


    1. Warm up and stop the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Select the following menu items:

        Powertrain / Engine and ECT / Data List / Engine Speed.

        Tech Tips

        Refer to the intelligent tester operator's manual for further information regarding the selection of Data List.

      4. Inspect the engine idling speed.

        Idling speed
        700 to 800 rpm

      5. Fully depress the accelerator pedal.

      6. Check the maximum speed.

        Maximum speed
        4500 to 4700 rpm

      7. Turn the ignition switch to OFF.

      8. Disconnect the intelligent tester from the DLC3.

    3. A01KGMAE15
      Text in Illustration
      *a Front view of DLC3

      When not using the intelligent tester:


      1. Install SST to terminal 9 (TAC) of DLC3, then connect a tachometer.

        SST
        09843-18040

        Note

        Examine the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      2. Turn the ignition switch to ON.

      3. Inspect the engine idling speed.

        Idling speed
        700 to 800 rpm

      4. Fully depress the accelerator pedal.

      5. Check the maximum speed.

        Maximum speed
        4500 to 4700 rpm

      6. Turn the ignition switch to OFF.

      7. disconnect the tachometer.

      8. Remove SST from terminal 9.

  147. INSPECT COMPRESSION


    1. Warm up and stop the engine.

    2. Remove the common rail Click here.

    3. Remove the No. 1 intake manifold insulator.

    4. Reinstall the common rail Click here.

    5. Remove the 4 glow plugs Click here.

      Note

      In order to avoid shorting the circuit of the wire harness connected to the glow plug No. 1 connector, wrap vinyl tape around the wire harness terminal portion.

    6. Disconnect all the connectors from the 4 injectors.

    7. Connect the cable to negative battery terminal.

      Torque:
      6.4 N*m  { 65 kgf*cm, 57 in.*lbf }

    8. Crank the engine to remove foreign objects before measuring the compression.

    9. A01KFVIE01

      Install SST into the glow plug hole.

      SST
      09992-00026   ( 09992-00121 )
      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    10. A01KHC5E01

      Connect a compression gauge to SST.

      SST
      09992-00026   ( 09992-00211 )

    11. While cranking the engine, measure the compression pressure.

      Standard pressure
      2000 kPa (20.1 kgf/cm2, 290 psi)
      Minimum pressure
      1630 kPa (16.6 kgf/cm2, 236 psi)
      Difference between each cylinder
      500 kPa (5.0 kgf/cm2, 71 psi) or less

      Note


      • Use a fully-charged battery so that the engine speed can be increased to 250 rpm or more.


      • Inspect the other cylinders in the same way.


      • Measure the compression pressure in as short a time as possible.

      If the cylinder compression is low, pour a light coat of engine oil into the cylinder through the glow plug hole, then inspect it again.

      Tech Tips


      • If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged.


      • If the pressure stays low, a valve may be stuck or seated improperly, or there may be leakage from the gasket.

    12. Remove the compression gauge and SST.

    13. Disconnect the cable from the negative battery terminal.

    14. Connect all the connectors to the 4 injectors.

    15. Install the 4 glow plugs Click here.

    16. Remove the common rail Click here.

    17. Reinstall the No. 1 intake manifold insulator.

    18. Install the common rail Click here.

  148. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  149. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH


    1. for Double Cab:

      Install the engine side cover LH with the 4 bolts.

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

    2. for Single Cab:

      Install the engine side cover LH with the 3 bolts.

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

  150. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH


    1. for Double Cab:

      Install the engine side cover RH with the 4 bolts.

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

    2. for Single Cab:

      Install the engine side cover RH with the 3 bolts.

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