ENGINE OIL COOLER 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, clean them with a brush and compressed air.

INSTALL OIL FILTER RECEIVER (w/ DPF)
1. Install the oil filter receiver to the oil cooler cover with the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL OIL COOLER ASSEMBLY
1. Install 2 new gaskets to the oil cooler.
2. Install the oil cooler to the oil cooler cover with the 4 nuts.
  
  Torque:
  
  16 N*m { 163 kgf*cm, 12 ft.*lbf }
INSTALL OIL COOLER COVER SUB-ASSEMBLY
1. w/ DPF:
  1. Install a new gasket and the oil cooler cover with the 12 bolts.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
  2. Connect the No. 2 vacuum transmitting pipe with the 2 nuts and bolt.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
  3. Connect the 2 vinyl tubes.
  4. Install the drain cock plug.
    
    Torque:
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  5. Connect the oil pressure sensor connector.
2. w/o DPF:
  1. Install a new gasket and the oil cooler cover with the 13 bolts.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
  2. Connect the No. 2 vacuum transmitting pipe with the 2 nuts.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
  3. Connect the 2 vinyl tubes.
  4. Connect the oil pressure switch connector.
INSTALL OIL FILTER SUB-ASSEMBLY
1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.
4. Using SST, tighten the oil filter 3/4 of a turn by hand or with a common wrench.
  
  SST
  
  09228-07501
  
  Torque:
  
  17 N*m { 173 kgf*cm, 13 ft.*lbf }
INSTALL NO. 2 WATER BY-PASS HOSE (w/ DPF)
INSTALL NO. 4 WATER BY-PASS HOSE (w/ DPF)
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY (w/ DPF)
1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.
2. Temporarily install a new gasket and the union bolt.
3. Tighten the 3 bolts and union bolt.
  
  Torque:
  
  for union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt A
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY (w/o DPF)
1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.
2. Temporarily install a new gasket and the union bolt.
3. Tighten the 3 bolts and union bolt.
  
  Torque:
  
  for bolt
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  
  for union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Connect the 3 fuel hoses.
INSTALL NO. 3 FUEL PIPE (w/ DPF)
1. Apply a light coat of fuel to the O-ring of the fuel check valve.
2. Temporarily install the No. 3 fuel pipe with the 3 bolts.
3. Temporarily install a new gasket and the fuel check valve.
4. Temporarily install 2 new gaskets and the 2 union bolts.
5. for Engine Rear Side:
  
  Tighten the 2 bolts and union bolt.
  
  Torque:
  
  for union bolt
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  for bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
6. for Engine LH Side:
  1. Tighten the fuel check valve and bolt.
    
    Torque:
    
    for fuel check valve
    
    32 N*m { 321 kgf*cm, 23 ft.*lbf }
    
    for bolt
    
    8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  2. Using a 6 mm hexagon wrench, tighten the union bolt.
    
    Torque:
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
    
    Note
    
    Place the part of the gasket labeled A against the No. 3 fuel pipe as shown in the illustration and tighten the union bolt.
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)
1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)
1. Apply a light coat of fuel to the O-ring of the fuel check valve.
2. Temporarily install the No. 3 nozzle leakage pipe with the bolt.
3. Temporarily install a new gasket and the fuel check valve.
4. Tighten the fuel check valve and bolt.
  
  Torque:
  
  for fuel check valve
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
  
  for bolt
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
5. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
6. Connect the 3 fuel hoses.
INSTALL VACUUM SWITCHING VALVE BRACKET (w/o DPF)
1. Install the vacuum switching valve bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect the 2 vacuum hoses and vacuum switching valve connector.
INSTALL FUEL INLET PIPE SUB-ASSEMBLY (w/o DPF)
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.
- Keep the fuel inlet pipe free of foreign matter.
1. Temporarily install the fuel inlet pipe with the union nuts.
2. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Install the No. 1 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Note
  
  If a No. 1 injection pipe clamp is removed from the fuel inlet pipe, replace the No. 1 injection pipe clamp with a new one.
4. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.
  
  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 a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.
  
  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.
INSTALL STARTER ASSEMBLY (w/ DPF)
- for 2.2 kW Type: Click here
- for 2.7 kW Type: Click here
INSTALL EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY (w/ DPF)

Click here
INSTALL EGR COOLER ASSEMBLY (w/o DPF)

Click here

ADD ENGINE COOLANT

Firmly tighten the drain plugs.

Fill the radiator reservoir with coolant to the top of the inlet.

Standard Capacity

Item	Specified Condition
w/o Heater	13.6 liters (14.4 US qts, 12.0 Imp. qts)
w/ Front Heater	14.6 liters (15.4 US qts, 12.8 Imp. qts)
w/ Front and Rear Heaters	16.6 liters (17.5 US qts, 14.6 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).

Loosen the bleeder plug of the outlet housing.
When air is bled and the coolant drains out, firmly tighten the bleeder plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.
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.
After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

ADD ENGINE OIL

Add new engine oil.

Standard Oil Grade

Item

Oil Grade

Oil Viscosity (SAE)

w/ DPF

ACEA C2

(Using engine oil other than ACEA C2 may damage catalytic converter)

- 0W-30

- 5W-30

w/o DPF

G-DLD1, API CF-4, CF or ACEA B1

(You may also use API CE or CD)

- 5W-30

- 10W-30

- 15W-40

- 20W-50

Standard Capacity (w/ DPF)

Item	Fill Amount
Drain and refill without oil filter change	6.6 liters (7.0 US qts, 5.8 Imp. qts)
Drain and refill with oil filter change	6.8 liters (7.2 US qts, 6.0 Imp. qts)
Dry fill	7.5 liters (7.9 US qts, 6.6 Imp. qts)

Standard Capacity (w/o DPF)

Item	Fill Amount
Drain and refill without oil filter change	6.8 liters (7.2 US qts, 6.0 Imp. qts)
Drain and refill with oil filter change	7.0 liters (7.4 US qts, 6.2 Imp. qts)
Dry fill	7.7 liters (8.1 US qts, 6.8 Imp. qts)

Install the oil filler cap.

BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed 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 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.
  - w/ DPF: Click here
  - w/o DPF: Click here
7. Start the engine.*1
8. 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.
  
  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.
  - w/ DPF: Click here
  - w/o DPF: 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.
INSPECT FOR COOLANT LEAK

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Hot, pressurized 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 and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Turn the intelligent tester on.
Enter the following menus: Powertrain / ECD / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Part	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurize common rail interior and check for fuel leaks	Stop/Start	Fuel pressure inside common rail increased to specified value and engine speed increased to 2000 rpm when Active Test is performed Above conditions preserved while Active Test is being performed

INSPECT ENGINE OIL LEVEL
- w/ DPF: Click here
- w/o DPF: Click here