GLOW PLUG (w/o DPF) INSTALLATION


  1. INSTALL GLOW PLUG

    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. A01KIIK

      Install the 4 glow plugs.

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

  2. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    A01KILK

    1. Install the No. 2 Intake manifold Insulator.

  3. INSTALL NO. 1 GLOW PLUG CONNECTOR

    A01KIEP

    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.

    4. Connect the wire harness to the No. 1 glow plug connector and install the nut.

      Torque:
      2.6 N*m  { 27 kgf*cm, 23 in.*lbf }

    5. Install the screw grommet.

  4. INSTALL MANIFOLD STAY

    A01KGL0E01

    1. Install the manifold stay with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf, for bolt A }
      19 N*m  { 194 kgf*cm, 14 ft.*lbf, for bolt B }

    2. Connect the 3 vacuum hoses and gas filter.

  5. INSTALL COMMON RAIL


    1. A01KI1X

      Install the common rail with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
    2. A01KHC7

      Connect the fuel hose.

    3. Connect the 2 connectors to the common rail.

  6. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01KIQC

    Note

    When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe sub-assembly.


    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. A01KGTAE02
      Text in Illustration
      *1 No. 1 Clamp
      *2 No. 2 Clamp

      Connect the No. 1 injection pipe clamp with the bolt.

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

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01KIQCE02
      Text in Illustration
      *A Common Rail Side
      *B Supply Pump Side

      Using union nut wrench 17mm, tighten the union nut on the common rail 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.

    5. Using union nut wrench 17 mm, tighten the union nut on the supply pump 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.

  7. INSTALL OIL LEVEL GAGE GUIDE (for RHD)


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

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

    3. Install the level gauge with the bolt.

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

  8. INSTALL INJECTION PIPE SUB-ASSEMBLY

    A01KH8X

    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. A01KG8U

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

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    3. A01KFL5

      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. A01KFP6

      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. A01KG0R

      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.

  9. CONNECT NO. 3 AIR HOSE


    1. A01KFE9

      Connect the No. 3 air hose and secure the hose clamps as shown in the illustration.

  10. TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY


    1. A01KFZH

      Temporarily install the EGR cooler assembly.


      1. Temporarily install the EGR cooler assembly with 2 new gaskets with the 2 bolts and 2 nuts.

      2. A01KI8B

        Temporarily install the bolt as shown in the illustration.

      3. A01KEGC

        Tighten the 2 bolts and 2 nuts to the specified torque.

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

  11. TIGHTEN EGR COOLER ASSEMBLY


    1. A01KI8B

      Tighten the EGR cooler assembly.


      1. Tighten the bolt to the specified torque.

        Torque:
        22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01KI9L

      Install the water by-pass hose No. 2 with the clamp.

    3. Install the water by-pass hose No. 4 with the clamp.

    4. Install the oil return hose with the clamp.

  12. 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 }

  13. 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.

  14. 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 }

  15. 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.

  16. 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.

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

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

    A01KFZF

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

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

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

    A01KHZT

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

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

    A01KG08

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

  22. 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.

  23. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  24. 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.

  25. INSPECT 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.

  26. 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.

  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.