COMMON RAIL (w/o DPF) INSTALLATION

INSTALL INJECTION PIPE SUB-ASSEMBLY

Note

When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipe sub-assemblies No. 1, No. 2, No. 3 and No. 4.

1. Temporarily install the injection pipe sub-assembly.

2. 

   Install the 2 injection pipe clamp No. 2 with the 2 bolts.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

3. 

   Using union nut wrench 17 mm, tighten the union nut on the fuel injector side to the specified torque.

   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.

4. 

   Using union nut wrench 17 mm, tighten the union nut on the common rail side to the specified torque.

   Torque:

   35 N*m  { 357 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.

5. 

   Install the wire harness with the 3 bolts.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

6. Connect the fuel injector connector and harness clamp.

TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY

TIGHTEN EGR COOLER ASSEMBLY

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

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

   Torque:

   12 N*m  { 120 kgf*cm, 9 ft.*lbf }

INSTALL PARKING BRAKE LEVER ASSEMBLY (for Double Cab)

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

   Torque:

   17 N*m  { 175 kgf*cm, 13 ft.*lbf }

2. Connect the connector.

INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)

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

   Torque:

   18 N*m  { 185 kgf*cm, 13 ft.*lbf }

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

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

INSTALL FRONT FLOOR PANEL BRACE (for Double Cab)

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

INSTALL PARKING BRAKE HOLE COVER (for Double Cab)

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

INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab)

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

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.

BLEED AIR FROM FUEL SYSTEM

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.

INSPECT FOR 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. 

   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.

INSPECT FOR FUEL LEAK

1. PERFORM ACTIVE TEST

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch ON.

   3. Turn the intelligent tester ON.

   4. Start the engine.

   5. Enter the following menus: Powertrain / ECD / Active Test.

   6. 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/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected Above conditions preserved while test is ON

   7. Make sure that there is no fuel leakage in the fuel system during the Active Test.

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

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

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

1. Install the mat set plate with the 6 screws.

INSTALL REAR DOOR SCUFF PLATE LH (for Double Cab)

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

INSTALL REAR DOOR SCUFF PLATE RH (for Double Cab)

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