CAMSHAFT (w/o DPF) 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.

INSTALL CAMSHAFT

Text in Illustration

*1 Key

Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

Tech Tips

Set the No. 1 cylinder to 90° BTDC/compression to prevent the top of the piston from hitting against the valve head.

Text in Illustration
*1	Key

Install the camshaft.

Apply MP grease to the thrust portion of the camshaft.

Place the camshaft on the cylinder head with the key groove facing upward.

Text in Illustration
*1	Key Groove
*a	Upward

Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

Remove any old seal packing (FIPG material) from the camshaft bearing cap.
Apply seal packing to the specified areas shown in the illustration.

Text in Illustration

*1 Seal Packing

*2 Oil Passage

Seal packing

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

Standard seal diameter

4 mm (0.157 in.)
Note
- Do not allow seal packing to contact the oil passage of the bearing cap.
- After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.
- Do not start the engine for at least 2 hours after installation.
1. Install the 5 bearing caps to their proper locations.
2. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.
3. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
Install a new camshaft oil seal.
1. Apply MP grease to the lip of a new oil seal.
2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.
  
  SST
  
  09608-06041

INSTALL NO. 2 TIMING BELT COVER
1. Text in Illustration
  
  *1 Seal Packing
  
  Apply seal packing (FIPG) to the specified areas shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Note
  
  After applying seal packing, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.
2. Install the No. 2 timing belt cover with the 4 bolts and nut.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL CAMSHAFT TIMING PULLEY
1. Install the camshaft timing pulley.
2. Install the bolt of the camshaft timing pulley while holding the camshaft with a wrench.
  
  Torque:
  
  98 N*m { 1000 kgf*cm, 72 ft.*lbf }
INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
1. Using a 10 mm hexagon wrench, install a new washer and the No. 1 timing belt idler with the bolt.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
2. Check that the idler pulley moves smoothly.
  
  If the idler pulley does not move smoothly, check the installation condition of the idler and washer.
INSTALL TIMING BELT
1. Text in Illustration
  
  *1 Timing Mark
  
  Check that the timing marks are aligned as shown in the illustration.
  
  Tech Tips
  
  If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of crankshaft revolution.
  Note
  
  Make sure that the engine is cold.
  
  When turning the crankshaft, the valve heads will hit against the piston. Do not turn the crankshaft more than necessary.
2. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.
3. Place the tensioner upright. Then set a press on the top of the tensioner.
  Note
  
  Do not scratch or deform the rod end.
  
  Press in the tensioner rod.
  
  Protect the tip of the push rod with a cloth in order to prevent damage.
4. Using the press, slowly push in the push rod using 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) of force.
  
  Note
  
  Do not apply a load of over 9807 N (1000 kgf, 2205 lbf) to the push rod.
5. Align the holes of the push rod and housing. Then pass a 1.5 mm hexagon wrench through the holes to fix the push rod in place.
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.
8. Remove the 1.5 mm hexagon wrench from the tensioner.
9. Text in Illustration
  
  *1 Timing Mark
  
  Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.
INSPECT AND ADJUST VALVE CLEARANCE

Click here
INSTALL NO. 1 TIMING BELT COVER
1. Install the timing belt cover and 6 washers with the 6 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }

Text in Illustration
*1	Seal Packing
*2	Oil Passage

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

Standard seal diameter
4 mm (0.157 in.)

Text in Illustration
*1	Seal Packing

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

Text in Illustration
*1	Timing Mark

Text in Illustration
*1	Timing Mark

INSTALL FAN SHROUD

Install the fan pulley to the engine water pump assembly.
Install the No. 2 water by-pass hose to the water inlet.
Temporarily install the shroud together with the coupling fan to the engine water pump assembly with the 4 nuts. Tighten the nuts as much as possible by hand.
Attach the claws of the shroud to the radiator as shown in the illustration.
Install the fan shroud to the radiator with the 2 bolts.

Torque:

5.0 N*m { 51 kgf*cm, 44 in.*lbf }
Install the fan and generator V belt Click here.
Install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.

Torque:

23 N*m { 235 kgf*cm, 17 ft.*lbf }
Attach the No. 2 water by-pass hose to the clamp on the fan shroud.

for Automatic Transmission:

Text in Illustration
*a	RH Side
*b	2 to 7 mm

Connect the 2 oil cooler hoses.

Tech Tips

Position the hose clamps as shown in the illustration.
Position the clips so that the distance from the end of hose is 2 to 7 mm (0.0787 to 0.275 in.).

Attach the 2 oil cooler hoses to the clamp on the fan shroud.

Connect the No. 2 water by-pass hose to the radiator reservoir.
Connect the No. 1 water by-pass hose to the fan shroud and attach the 2 clamps.
Install the radiator reservoir assembly with the 3 bolts.

Torque:

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

INSTALL NO. 1 RADIATOR HOSE

Text in Illustration
*1	Protrusion
*2	Paint Mark
*a	Upper
*b	LH Side

Install the radiator hose and attach the clamp.

Tech Tips

Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL INJECTOR ASSEMBLY
Note

Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.
1. Install 4 new injection nozzle seats to the cylinder head.
2. Apply a small amount of clean engine oil to 4 new O-rings.
3. Text in Illustration
  
  *1 New O-Ring
  
  Install an O-ring to each injector as shown in the illustration.
4. Insert the 4 injectors into the cylinder head.
  Note
  - Insert the injector until it touches the injection nozzle seat surface.
  - After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
  - Always return an injector to the same place it was removed from.
5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.
6. Text in Illustration
  
  *1 Washer
  
  *a Downward
  
  Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.
  
  Tech Tips
  
  Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.
7. Temporarily install the 4 injection pipes with the union nuts.
  
  Tech Tips
  
  To position the injectors, loosely tighten the union nut.
8. Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.
  
  If scratches or dents are present, replace the nozzle leakage pipe.
9. Text in Illustration
  
  *1 Union Bolt
  
  *2 Hollow Screw
  
  Set the leakage pipe and 5 new gaskets in place.
10. Apply a small amount of oil to the 4 injector hollow screws and union bolt.
11. Temporarily install the leakage pipe with the 4 injector hollow screws and union bolt.
12. Tighten the 4 holder clamp bolts.
  
  Torque:
  
  22 N*m { 220 kgf*cm, 16 ft.*lbf }
13. Text in Illustration
  
  *1 Union Bolt
  
  Tighten the 4 hollow screws in order from 1 to 4.
  
  Torque:
  
  16 N*m { 163 kgf*cm, 12 ft.*lbf }
  
  Note
  
  If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.
14. Tighten the union bolt.
  
  Torque:
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
  
  Note
  
  If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.
15. Remove the 4 injection pipes.

Text in Illustration
*1	New O-Ring

Text in Illustration
*1	Washer
*a	Downward

Text in Illustration
*1	Union Bolt
*2	Hollow Screw

Text in Illustration
*1	Union Bolt

INSPECT FOR FUEL LEAK

Check that there are no leaks from the nozzle leakage pipe connection.

Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

Part No.
23762-27010 (No. 2 nozzle leakage pipe)
90904-30012 (Gasket)

SST: 09280-00010

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

Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.
Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, maintain 100 kPa (1.0 kgf/cm², 15 psi) of pressure for 60 seconds and check that no bubbles form.

SST

09992-00242
After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.
Remove SST, the No. 2 nozzle leakage pipe and gasket.

Note

Never reinstall the disassembled union bolt to the engine.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Text in Illustration
*1	No. 3 Cylinder Head Cover Gasket
*2	Cylinder Head Cover

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

Note

Do not install the No. 3 cylinder head cover gaskets at an angle.
Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

Remove any old seal packing (FIPG material) from the cylinder head.
Text in Illustration

*1 Seal Packing

Apply seal packing to the areas shown in the illustration.

Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Note
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.
Install a new gasket and the cylinder head cover with the 10 bolts and 2 nuts.

Torque:

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

INSTALL NOZZLE HOLDER SEAL
1. Install 4 new nozzle holder seals.
INSTALL VENTILATION PIPE
1. Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover to the cylinder head sub-assembly with the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. Type A
  
  Connect the No. 3 turbo water hose and No. 4 turbo water hose to the ventilation pipe, and slide the 2 clamps to secure the hose.
INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the No. 2 cylinder head cover with the 4 bolts.
  
  Torque:
  
  for bolt A
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
  
  for bolt B
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL WIRE HARNESS
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. Text in Illustration
  
  *1 Union Bolt
  
  Temporarily install the No. 2 nozzle leakage pipe with the 4 bolts.
2. Temporarily install a new gasket and the union bolt.
3. Tighten the 4 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. 4 INJECTION PIPE SUB-ASSEMBLY
Note
- When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
- Keep the joints of the injection pipe clean.
1. Temporarily install the No. 4 injection pipe with the union nuts.
2. Install the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  Note
  - If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
  - Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
  - When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
3. Text in Illustration
  
  *a Common Rail Side
  
  *b Injector Side
  
  Using a 17 mm union nut wrench, tighten the injection 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.
4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector 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.

Text in Illustration
*1	Seal Packing

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

Text in Illustration
*1	Union Bolt

Text in Illustration
*a	Common Rail Side
*b	Injector Side

INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE

Text in Illustration
*A	w/o EGR System
*B	w/ EGR System
*1	White Mark
*2	Blue Mark

Install the manifold stay with vacuum switching valve with the 2 bolts and connect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

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

Note

Make sure the vacuum hose color matches the connection area color.

w/ EGR Cooler:

Connect the No. 3 vacuum transmitting hose.
Text in Illustration

*1 Yellow Mark

*2 Pink Mark

w/ EGR System:

Connect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.
Note
- Make sure the vacuum hose color matches the connection area color.
- Push on the hose until it reaches the bent part of the pipe.
Connect the No. 1 vacuum transmitting hose.
Connect the vacuum switching valve connector.
1. w/o EGR System:
  
  Connect the connector.
2. w/ EGR System without EGR Cooler:
  
  Connect the 2 connectors.
3. w/ EGR System with EGR Cooler:
  
  Connect the 3 connectors.

INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)
1. Set a new gasket on the intake manifold.
  
  Note
  
  Make sure the claw of the gasket face the intake manifold as shown in the illustration.
2. Install the intake air connector with diesel throttle body with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration.
3. Connect the throttle position sensor connector.
CONNECT ENGINE WIRE (w/o EGR System)
1. for LHD:
  
  Connect the engine wire with the clamp and install the 2 bolts.
  
  Torque:
  
  for bolt A
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  22 N*m { 220 kgf*cm, 16 ft.*lbf }
2. for RHD:
  
  Connect the engine wire with the bolt.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
INSTALL AIR CONNECTOR STAY (w/o EGR System)
1. Temporarily install the air connector stay with the 3 bolts.
2. Tighten the bolt labeled A.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Tighten the 2 bolts labeled B.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL INJECTION PIPE (w/o EGR System)
Note
- When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
- Keep the joints of the injection pipe clean.
1. Text in Illustration
  
  *1 No. 2 Injection Pipe
  
  Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.
2. Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Tech Tips
  
  If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.
3. *a for Common Rail Side
  
  *b for Injector Side
  
  Using a 17 mm union nut wrench, tighten the injection pipe union nuts 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.
4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector 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 THROTTLE BODY BRACKET (w/o EGR System)
1. Install the throttle body bracket with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Install the gas filter with gas filter bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Connect the vacuum hose.

Text in Illustration
*1	Yellow Mark
*2	Pink Mark

Text in Illustration
*1	No. 2 Injection Pipe

INSTALL NO. 2 EGR VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

Using a 6 mm hexagon wrench, install the EGR valve adapter, No. 2 EGR valve, EGR cooler, 2 new gaskets, 3 plate washers with the 3 hexagon bolts.

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }

Using a 5 mm hexagon wrench, install the bolt labeled A.

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

Text in Illustration
*1	EGR Cooler with Pipe	*2	New Gasket
*3	No. 2 EGR Valve	*4	EGR Valve Adapter

INSTALL EGR COOLER WITH PIPE (w/ EGR System with EGR Cooler)

Install a new gasket and the EGR cooler with pipe to the electric EGR control valve and No. 2 EGR valve with the 2 bolts.

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

Tech Tips

Make sure the claws of the gasket face the electric EGR control valve.

Text in Illustration
*1	EGR Cooler with Pipe and No. 2 EGR Valve	*2	New Gasket
*3	Electric EGR Control Valve	-	-

TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

Note

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

Text in Illustration
*1	No. 2 Intake Air Connector	*2	Electric EGR Control Valve
*3	Intake Air Connector	*4	New Gasket
*a	0 to 2 threads	-	-

Set a new gasket on the intake manifold.

Tech Tips

Make sure the claws of the gasket face the intake manifold.
Temporarily install the intake air connector to the intake manifold with the 3 bolts in the illustration.
Temporarily install the EGR cooler with pipe and new gasket to the cylinder head with the bolt and 2 nuts.

Text in Illustration

*1 Electric EGR Control Valve *2 New Gasket
Connect the No. 2 vacuum transmitting hose to the No. 2 EGR valve.

TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)
1. Tighten the 3 nuts labeled A in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 3 bolts labeled B in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration.
3. Tighten the bolt labeled C in the illustration.
  
  Torque:
  
  22 N*m { 224 kgf*cm, 16 ft.*lbf }
4. Tighten the 2 nuts labeled D in the illustration.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Text in Illustration
  
  *a Front - -

Text in Illustration
*a	Front	-	-

INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)

Install a new gasket and the No. 1 EGR pipe to the electric EGR control valve with the 2 bolts.

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

Tech Tips

Make sure the claws of the gasket face the electric EGR control valve.

Text in Illustration
*1	Electric EGR Control Valve	*2	New Gasket
*3	No. 1 EGR Pipe	-	-

TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

Note

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

Text in Illustration
*1	No. 2 Intake Air Connector	*2	Electric EGR Control Valve
*3	Intake Air Connector	*4	New Gasket
*a	0 to 2 threads	-	-

Set a new gasket on the intake manifold.

Tech Tips

Make sure the claws of the gasket face the intake manifold.
Temporarily install the intake air connector to the intake manifold with the 3 bolts.
Temporarily install the No. 1 EGR pipe and a new gasket to the cylinder head with the 2 nuts.

Text in Illustration

*1 Electric EGR Control Valve *2 New Gasket

TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)
1. Tighten the 3 nuts labeled A in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 3 bolts labeled B in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration.
3. Tighten the 2 nuts labeled C in the illustration.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Text in Illustration
  
  *a Front - -
INSTALL AIR CONNECTOR STAY (w/ EGR System)
1. Temporarily install the air connector stay with the 3 bolts.
2. Tighten the bolt labeled A.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Tighten the 2 bolts labeled B.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)
1. Install the E-VRV bracket with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Install the gas filter and the gas filter bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
3. Text in Illustration
  
  *1 Yellow Mark
  
  *2 Pink Mark
  
  Connect the 5 vacuum hoses.
  
  Note
  
  Install the vacuum hoses so that they completely cover the pipes.
4. Connect the 2 connectors to the electric EGR control valve and E-VRV.
5. Attach the wire harness clamp.
INSTALL EGR VALVE BRACKET (w/ EGR System)
1. Install the EGR valve bracket with the 2 nuts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT ENGINE WIRE (for LHD)
1. Attach the clamp.
2. Connect the engine wire with the 2 bolts.
  
  Torque:
  
  for bolt A
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
  
  for bolt B
  
  22 N*m { 220 kgf*cm, 16 ft.*lbf }
CONNECT ENGINE WIRE (for RHD)
1. Connect the engine wire with the bolt.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
INSTALL INJECTION PIPE (w/ EGR System)
Note
- When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
- Keep the joints of the injection pipe clean.
1. Text in Illustration
  
  *1 No. 2 Injection Pipe
  
  Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.
2. Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Tech Tips
  
  If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.
3. *a for Common Rail Side
  
  *b for Injector Side
  
  Using a 17 mm union nut wrench, tighten the injection pipe union nuts 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.
4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector 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.

Text in Illustration
*a	Front	-	-

Text in Illustration
*1	Yellow Mark
*2	Pink Mark

Text in Illustration
*1	No. 2 Injection Pipe

CONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

Text in Illustration
*1	Lower Side
*2	Upper Side
*3	LH Side of Vehicle

Connect the No. 4 water by-pass hose to the EGR cooler.

Tech Tips

The direction of the hose clamp is indicated in the illustration.
Insert the outlet hose into the stopper.

CONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)
1. Connect the No. 3 water by-pass hose to the EGR cooler.
  Tech Tips
  - The direction of the hose clamp is indicated in the illustration.
  - Insert the outlet hose into the stopper.
2. Install the clamp.
INSTALL DIESEL THROTTLE BODY ASSEMBLY (w/ EGR System)
1. Install a new gasket and the diesel throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect the throttle position sensor connector.
INSTALL NO. 1 INTAKE PIPE
1. Connect the No. 1 intake pipe with the air hose and install the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 clamps of the No. 1 air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. Tighten the clamp of the intercooler air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
4. Connect the vacuum hose to the manifold absolute pressure sensor connector.
5. Connect the 3 connectors to the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.
6. Attach the 2 clamps.
CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
1. Connect the No. 4 vacuum transmitting pipe with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
CONNECT INLET HEATER WATER HOSE
1. Connect the inlet heater water hose with the bolt.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
1. Install the cowl top ventilator louver Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.
  Note
  
  The maximum hand pump pumping speed is 2 strokes per second.
  
  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. Start the engine.
  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 the 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 on (IG) and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. Text in Illustration
  
  *a
  Reference
  
  Active Test Operation
  
  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 5th 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 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.

Text in Illustration
*a	Reference Active Test Operation

OK
No DTCs are output.

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
for Automatic Transmission	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
for Manual Transmission	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

Tech Tips

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).
Please contact your TOYOTA dealer for further details.
for Cold Area Specification Vehicles:

Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

Note

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
Bleed air from the cooling system.
1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
2. Maintain the engine speed at 2500 to 3000 rpm.
3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
  CAUTION:
  
  When pressing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
4. Stop the engine and wait until the coolant cools down to ambient temperature.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
After the coolant cools down, check that the coolant level is at the FULL line.

If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

INSPECT FOR COOLANT LEAK

Note

Before each inspection, turn the A/C switch off.

CAUTION:

Do not remove the radiator reservoir 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.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and check that the pressure does not drop.
  
  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 head.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
INSPECT FOR FUEL LEAK
CAUTION:
- During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
- During Active Test mode, fuel becomes highly pressurized. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.
1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.
2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.
3. Disconnect the return hose from the common rail.
4. Start the engine and check for fuel leaks from the return pipe.
  
  If there is fuel leakage, replace the common rail.
5. Connect the intelligent tester to the DLC3.
6. Start the engine and turn the intelligent tester on.
7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.
8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
9. Check that there are no leaks from any part of the fuel system.
  
  Note
  
  A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
  
  If there is fuel leakage, repair or replace parts as necessary.
10. Reconnect the return hose to the common rail.
INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
1. Install the No. 1 engine under cover with the 4 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL FRONT BUMPER LOWER COVER
1. Install the lower front bumper cover with the clip and 5 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSPECT ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.
  
  If low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.