EGR COOLER (w/ EGR Cooler Bypass Valve) INSTALLATION


  1. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


    1. Install a new gasket and No. 1 EGR pipe sub-assembly with the 2 nuts.

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

  2. INSTALL EGR COOLER ASSEMBLY

    A01KGXSE01

    1. Install a new gasket and EGR cooler assembly with the 2 bolts and 2 nuts.

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

  3. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A01KFGWE02
      Text in Illustration
      *a Front
      *b LH

      Connect the No. 3 water by-pass hose with the clamp as shown in the illustration.

  4. CONNECT WATER BY-PASS HOSE

    A01KFC8E02
    Text in Illustration
    *a Front
    *b Upper
    *c LH

    1. Connect the water by-pass hose with the 2 clamps as shown in the illustration.

  5. CONNECT NO. 4 VACUUM TRANSMITTING HOSE ASSEMBLY

    A01KEQO

    1. Connect the No. 4 vacuum transmitting hoses assembly as shown in the illustration.

  6. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Connect the vacuum hose.

    2. Install 3 new gaskets and electric EGR control valve with intake air connector with the 3 bolts and 2 nuts.

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

    3. Install the vacuum regulating valve with bracket with the 2 bolts.

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

    4. Connect the 2 vacuum hoses to the vacuum regulating valve.

    5. Connect the vacuum regulating valve connector.

  7. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

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

    2. Attach the wire harness.

  8. INSTALL ENGINE ROOM MAIN WIRE


    1. Connect the vacuum hose.

    2. Connect the connector.

    3. Install the wire harness clamp with bolt.

    4. Attach the wire harness clamp.

    5. Attach the 2 wire harness clamps.

    6. Connect the EGR control valve connector.

  9. INSTALL NO. 1 GAS FILTER


    1. Install the gas filter with the bolt.

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

  10. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install a new gasket and diesel throttle body assembly with the 2 bolts and 2 nuts.

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

    2. Connect the 2 diesel throttle body assembly connectors.

    3. Connect the intake air temperature sensor connector.

    4. Install the wire harness clamp with the bolt.

    5. Attach the wire harness clamp.

    6. Connect the turbo pressure sensor connector and No. 1 vacuum switching valve assembly connector.

  11. INSTALL NO. 4 AIR INJECTION SYSTEM HOSE

    A01KIOS

    1. Install the No. 4 air air injection system hose and secure the hose clamps as shown in the illustration.

  12. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


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

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

  13. 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 }

  14. 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.

  15. 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 }

  16. 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.

  17. 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.

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

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

    A01KFZF

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

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

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

    A01KHZT

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

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

    A01KG08

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

  23. 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.

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.4 N*m  { 65 kgf*cm, 56 in.*lbf }

  25. 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.

  26. 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. 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.

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

    A01KIQM

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

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

    A01KGPT

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

  29. INSTALL REAR FLOOR MAT (for Double Cab)

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

    A01KINS

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

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

    A01KF1Z

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

  32. 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 }