FUEL TEMPERATURE SENSOR INSTALLATION


  1. INSTALL FUEL TEMPERATURE SENSOR

    A01BBNFE01

    1. Apply a light coat of light oil to a new O-ring.

    2. Install the O-ring onto the fuel temperature sensor.

    3. Using the SST, install the fuel temperature sensor.

      SST
      09922-10010
      Torque:
      22 N*m  { 224 kgf*cm, 16 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.

  2. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring and the pulley key onto the fuel supply pump.

    2. Aligning the projecting edge of the fuel supply pump head to the key-slot of the supply pump gear, install the pump onto the timing gear case.

    3. While holding the fuel supply pump by hand, push the supply pump gear rearward to engage the pump gear and drive shaft.

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

    5. A01BHHYE01

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    6. Install the supply pump gear set nut.

      Tech Tips

      Set a new O-ring before tightening the supply pump gear set nut.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    7. A01BGD8

      Temporarily install the supply pump stay with the 2 nuts on the engine block side.

    8. Tighten the 2 nuts to the specified torque.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    9. A01BCD7

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

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

  3. INSTALL VANE PUMP ASSEMBLY

    Click here

  4. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01BDF3

    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.

    • Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.


    1. Temporarily install the fuel inlet pipe.

    2. A01BC23

      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. Using SST, tighten the union nut on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective when SST is parallel to a torque wrench.

    5. Using SST, tighten the union nut on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf, for use without SST }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

      • This torque value is effective when SST is parallel to a torque wrench.

  5. INSTALL OIL LEVEL GAUGE GUIDE


    1. Install a new O-ring onto the oil level gauge guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. A01BF6Z

      Install the oil level gauge guide with the bolt.

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

    4. Install the oil level gauge.

  6. TEMPORARILY TIGHTEN EGR COOLER ASSEMBLY

    A01BGO0

    1. Temporarily tighten the EGR cooler assembly.


      1. Temporarily tighten the EGR cooler assembly and new gaskets.

      2. A01BBGP

        Temporarily tighten the EGR cooler assembly stay bolt.

      3. A01BEW1

        Tighten the EGR cooler assembly with the 2 nuts and 2 bolts.

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

  7. TIGHTEN EGR COOLER ASSEMBLY

    A01BBGP

    1. Tighten the EGR cooler assembly stay bolt.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01BH3G

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

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

  8. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. A01BBJH

      Install a new gasket onto the intake air connector.

    2. Install the throttle body with the 2 bolts and the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A01BCMO

      Connect the 2 throttle body connectors.

  9. INSTALL NO. 4 AIR HOSE

    A01BGX6

    1. Install the No. 4 air hose with the 2 clamps.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  10. CONNECT OIL RETURN HOSE

    A01BCQX

    1. Connect the oil return hose with the 2 clips.

  11. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

    A01BBMO

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

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

  12. INSTALL TIMING BELT


    1. A01BC61E03

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

      Tech Tips

      If reusing the timing belt, align the matchmarks 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 pump drive shaft pulley, camshaft timing pulley and No.1 timing belt idler in sequence.

    3. A01BAP9

      Place the tensioner upright into a press. Then set the press to the top of tensioner.

      Note


      • Do not scratch and deform the rod end.

      • Press the tensioner rod in upward.

      • Protect the tip of the push rod with a shop rag or piece of cloth in order to prevent damage.

    4. Using the press, slowly apply 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force to the push rod.

      Note

      Do not apply a load of 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) or more to the push rod.

    5. Align the holes of the push rod and housing and pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    6. Temporarily 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 2 bolts when installing the tensioner

    8. Remove the 1.27 mm hexagon wrench from the tensioner.

    9. A01BB9ZE03

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

  13. INSTALL NO. 1 TIMING BELT COVER


    1. A01BDL8

      Install the No.1 timing belt cover with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the wire harness clamp.

  14. INSTALL FAN & GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  15. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover sub-assembly with the 5 bolts.

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

  16. INSTALL FRONT DOOR SCUFF PLATE RH

  17. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  18. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  19. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with coolant to the top of the inlet.

      Coolant capacity
      Condition Capacity
      w/ rear heater 18.2 liters (19.2 US qts, 16.0 lmp. qts)
      w/o rear heater 16.2 liters (17.0 US qts, 14.0 lmp. 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly install the bleeder plug.

    5. A01BGFB

      Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap.

    6. 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.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  20. BLEED FUEL LINE


    1. A01BEO7E01

      Using a hand pump, bleed air from the fuel system until pumping becomes difficult.

  21. INSPECT FOR ENGINE COOLANT LEAK

  22. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch ON.

      3. Turn the intelligent tester ON.

      4. Select the following menu items: Powertrain / ECD / Active Test.

      5. 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

  23. INSPECT FOR OIL LEAK

  24. INSPECT FOR EXHAUST GAS LEAK

  25. PERFORM INITIALIZATION


    1. Perform initialization procedures Click here.

      Note

      Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.