EGR COOLER (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 and fuel inlet pipe, clean them with a brush and compressed air.


  1. INSTALL EGR COOLER ASSEMBLY WITH NO. 2 EGR VALVE 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 }

  2. INSTALL INTAKE AIR TEMPERATURE SENSOR


    1. Using a 22 mm ball joint lock nut wrench, install a new gasket and the intake air temperature sensor.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench Click here.

    2. Connect the intake air temperature sensor connector.

  3. INSTALL INLET FUEL 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.

  4. 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.

  5. 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.

  6. 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 }

  7. 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.

  8. 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.

  9. 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.

  10. 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 }

  11. INSTALL INTAKE AIR TEMPERATURE SENSOR


    1. Using a 22 mm ball joint lock nut wrench, install a new gasket and the intake air temperature sensor.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench Click here.

    2. Connect the intake air temperature sensor connector.

  12. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

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

  13. INSTALL GAS FILTER BRACKET


    1. Install the gas filter bracket with the bolt.

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

  14. 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 }

  15. 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.

  16. 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 }

  17. 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 }

  18. 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.

  19. 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.

  20. INSTALL EMISSION CONTROL VALVE WIRE


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

    2. Connect the emission control valve wire.

  21. CONNECT NO. 7 WATER BY-PASS HOSE


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

  22. CONNECT NO. 4 WATER BY-PASS HOSE


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

  23. INSTALL EGR VALVE BRACKET


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

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

  24. INSTALL ENGINE OIL DIPSTICK GUIDE


    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.

  25. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  26. INSTALL INJECTOR DRIVER

    Click here

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


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

  28. INSTALL REAR FLOOR MAT (for Double Cab)

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


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

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


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

  31. 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.

  32. 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.

  33. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize the common rail interior and check for fuel leaks Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when ON is selected.

        • Above conditions preserved while test is ON

          Tech Tips

          If this Active Test is performed when the engine is cold, combustion may become unstable. However, this is not a malfunction. It is only necessary to confirm that the pressure rises to the target pressure and that there are no fuel leaks.

  34. 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.

  35. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH (for Double Cab)


    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 }