WATER PUMP INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. A01BCAP

      Install a new gasket and the water pump with the 5 bolts and 2 nuts.

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

  2. INSTALL TIMING BELT COVER NO.2


    1. A01BD2NE02

      Remove old seal packing (FIPG) from the timing gear case.

    2. Apply seal packing to the specific places shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • After applying FIPG, install the timing belt No.2 cover within 3 minutes and tighten its bolts and nuts within 15 minutes.

      • Do not start the engine 2 hours after the installation.

    3. Fix the timing belt cover No.2 with the 4 bolts and nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A01BH1Y

      Using a 10 mm socket hexagon wrench, install the new plate washer and timing belt idler No.1.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  4. INSTALL CAMSHAFT TIMING PULLEY


    1. A01BHHN

      Install the camshaft timing pulley.

    2. Tighten the bolt for the camshaft timing pulley while holding the camshaft with a monkey wrench.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

  5. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BE87E02

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover as shown in the illustration.

      Note


      • Do not install the gaskets at an angle.

      • Keep the lip of the gasket free from foreign materials.

    2. Install a new cylinder head cover gasket to the cylinder head cover.

    3. Remove old seal packing (FIPG) from the cylinder head.

    4. A01BHVSE01

      Apply a seal packing to the specific places described in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • After applying the seal packing, parts must be assembled within 3 minutes, and then tighten within 15 minutes.

      • Otherwise the material must be removed and reapplied.

      • Do not start the engine 2 hour after the installation.

    5. Install the cylinder head cover with 10 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    6. Connect the ventilation hose.

    7. Install a new nozzle holder seal.

  6. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    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. Using SST, tighten the injection pipe on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

    3. Using SST, tighten the injection pipe on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

  7. INSTALL INJECTION PIPE

    SST
    09023-12701

    Note


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

    • Keep clean the joint of the injection pipe.


    1. Install the injection pipes.


      1. A01BFG2

        Temporarily install the 4 injection pipes.

      2. A01BC89

        Install the injection pipe clamp No.3 in 2 nuts.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. A01BFG2E01

        Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.

        SST
        09023-12701
        Torque:
        Use union nut wrench and torque wrench
        32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  8. INSTALL OIL LEVEL GAGE GUIDE


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

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

    3. 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.

  9. INSTALL INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BEP8E01

      Temporarily install 2 new gaskets and intake air connector No.2 to the intake air connector.

    2. A01BDK1

      Temporarily tighten the intake air connector assembly with the bolt and 2 nuts.

    3. Tighten the manifold stay with the bolt.

    4. Tighten the intake air connector with the bolt and 2 nuts.

    5. Install the vacuum hose to the intake air connector.

  10. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. A01BACYE01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. A01BH7Q

        Temporarily tighten the intake air connector with EGR valve assembly to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose to the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

      5. A01BAPE

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. A01BHSL

        Install the vacuum regulating valve with the 2 bolts.

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

      2. Connect the 2 vacuum hoses and the regulating valve connector.

  11. INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BG49

      Install the 2 gaskets to the cylinder head and EGR pipe sub-assembly as shown in the illustration.

    2. A01BD88

      Install the EGR pipe sub-assembly with the 2 bolts and 2 nuts.

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

    3. Tighten the intake air connector with the bolt and the 2 nuts.

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

    4. Tighten the manifold stay.

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

  12. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. Remove the 3 bolts, the 2 nuts, and the EGR pipe sub-assembly.

    2. Remove the 2 gaskets.

  13. INSTALL ENGINE SERVICE HOLE COVER NO.2


    1. Install the engine service hole cover No.2 with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A01BFN9

      Return the carpet.

  14. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

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


    1. Install a new gasket to intake air connector.

    2. A01BBJH

      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.

  15. INSTALL AIR HOSE NO.4


    1. A01BGX6

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

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

  16. INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BG49

      Install 2 new gaskets to the cylinder head and the EGR pipe sub-assembly No.1 as shown in the illustration.

    2. A01BD88

      Install the EGR pipe with the 2 bolts and the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A01BGWP

      Connect the fuel pressure sensor connector.

  17. INSTALL OIL RETURN HOSE (w/ Intercooler)

  18. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

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

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

  19. INSTALL TIMING BELT


    1. A01BC61E01

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

    2. Install the timing belt to pump drive shaft pulley, camshaft timing pulley and timing belt idler No.1 in sequence.

    3. A01BAP9

      Set the tensioner to the press upright.

      Note


      • Do not allow the rod end to scratch and deform.

      • Press the tensioner rod in upward.

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

    4. Using a 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 loads 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) or more on the push rod.

    5. Align the holes of push rod and housing, 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 and install the tensioner

    8. Remove the 1.5 mm hexagon wrench from the tensioner.

    9. A01BB9ZE01

      Turn the crankshaft in the clockwise direction twice, check that the timing marks are aligned as shown in the illustration.

  20. INSTALL TIMING BELT COVER NO.1


    1. A01BHT6

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

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

    2. Install the wire harness clamp.

  21. INSTALL FAN PULLEY


    1. Install the fan pulley with the 4 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  22. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01BFC7E01

      Temporarily install the V-ribbed belt tensioner with the 4 bolts.

      Tech Tips

      Make sure that the V-ribbed belt tensioner is in contact with the engine block at points A shown in the illustration.

    2. Tighten the V-ribbed belt tensioner with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  23. INSTALL GENERATOR ASSEMBLY


    1. A01BCVDE01

      Install the generator assembly with the bolt.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Install the generator wire to terminal B with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  24. INSTALL GENERATOR BRACKET


    1. A01BCXBJ01

      Install the generator bracket with the 2 bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  25. INSTALL IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01BETHJ01

      Install the idle No.2 pulley assembly and washer with the bolt.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  26. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BCJBE01

      Install the compressor outlet elbow with the 2 bolts and 2 clamps.

      Torque:
      Bolt (A)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  27. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. Install the air cleaner hose assembly with the clamp.

  28. INSTALL AIR TUBE ASSEMBLY


    1. Install the air tube assembly with the 2 clamps and 2 bolts.

  29. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. A01BFJ0

      Install the compressor and magnetic clutch with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

  30. 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.

  31. INSTALL FENDER APRON MUDGUARD SEAL RH

  32. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


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

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

  33. CONNECT BATTERY NEGATIVE CABLE

  34. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Click here

    Tech Tips

    Perform the same procedure as RH side on the LH side.

  35. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

    Click here

    Tech Tips

    Perform the same procedure as RH side on the LH side.

  36. INSTALL FRONT DOOR SCUFF PLATE RH

  37. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs and fill the radiator reserve tank assembly with coolant to the top of the inlet.

    2. Loosen the bleeder plug of outlet housing.

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

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

      Coolant capacity
      Condition Capacity
      w/ rear heater 17.0 liters (18.0 US qts, 15.0 imp. qts)
      w/o rear heater 15.0 liters (15.9 US qts, 13.2 imp. qts)

    5. Warm up the engine.

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

  38. CHECK FOR ENGINE COOLANT LEAKAGE

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  39. INSTALL ENGINE UNDER COVER NO.1