EGR VALVE (w/ 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.
After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.

INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
1. Install a new gasket and the electric EGR control valve to the intake air connector.
2. Connect the electric EGR control valve connector.

TEMPORARILY INSTALL EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY

Install a new gasket to the stud bolts of the intake air connector.
Install a new gasket to the stud bolts of the cylinder head.
Install the EGR valve adapter to the electric EGR control valve and intake air connector with the 2 nuts and bolt labeled A.
Temporarily install the EGR cooler to the intake manifold with the 2 bolts labeled B in the illustration.

Temporarily install the EGR cooler to the cylinder head with the 2 nuts labeled C in the illustration.

Text in Illustration
*1	New Gasket	*2	EGR Valve Adapter
*3	EGR Cooler	*4	Electric EGR Control Valve
*5	Intake Air Connector	-	-

TIGHTEN EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY
1. Tighten the 2 bolts labeled A in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 nuts labeled B in the illustration.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
3. Install the air connector stay with the 3 bolts labeled C in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
4. Tighten the 2 nuts and bolt labeled D in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
5. Install the No. 1 fuel pipe to the air connector stay with the bolt labeled E.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
  
  Text in Illustration
  
  *1 Air Connector Stay *2 No. 1 Fuel Pipe
6. Connect the fuel pressure sensor connector to the common rail.
7. Connect the 4 injector connectors and attach the 3 wire harness clamps.
INSTALL NO. 4 ENGINE COVER BRACKET
1. Install the No. 4 engine cover bracket with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL ENGINE COVER BRACKET INSULATOR
1. Text in Illustration
  
  *1 Claw
  
  Install the 2 engine cover bracket insulators with the 2 nuts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Tech Tips
  
  Make sure that the claws of the engine cover bracket insulators contact the engine cover brackets.
INSTALL NO. 3 ENGINE COVER BRACKET
1. Install the No. 3 engine cover bracket with the 2 nuts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
INSTALL WIRING HARNESS CLAMP BRACKET
1. Install the wiring harness clamp bracket.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Attach the 2 wire harness clamps and connect the glow plug connector to the wiring harness clamp bracket.
3. Connect the glow plug connector.
INSTALL NO. 1 VACUUM TRANSMITTING PIPE
1. Install the No. 1 vacuum transmitting pipe with the bolt.
  
  Torque:
  
  18 N*m { 178 kgf*cm, 13 ft.*lbf }
2. Connect the vacuum hose to the intake manifold.

Text in Illustration
*1	Air Connector Stay	*2	No. 1 Fuel Pipe

Text in Illustration
*1	Claw

INSTALL WATER BY-PASS HOSE

Tech Tips

When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
The direction of each hose clamp is indicated in the illustration.

Connect the No. 5 water by-pass hose labeled A in the illustration.
Connect the No. 6 water by-pass hose labeled B in the illustration.
Connect the No. 8 water by-pass hose labeled C in the illustration.
Connect the No. 3 water by-pass hose labeled D in the illustration.
Connect the No. 4 water by-pass hose labeled E in the illustration.
Connect the No. 7 water by-pass hose labeled F in the illustration.

Attach the 4 water by-pass hose clamps.

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

CONNECT HEATER WATER PIPE SUB-ASSEMBLY
1. Install the heater water pipe with the bolt.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
2. Attach the water by-pass hose clamp.
INSTALL NO. 1, NO. 2 AND NO. 3 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. 1, No. 2 and No. 3 injection pipes with the union nuts.
2. Install the 2 No. 2 injection pipe clamps with the 2 bolts.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. Install the No. 3 injection pipe clamp with the 2 nuts.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
4. 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.
5. 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 FUEL INLET PIPE SUB-ASSEMBLY
1. Temporarily install the fuel inlet pipe with the union nuts.
  Note
  - When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.
  - Keep the fuel inlet pipe free of foreign matter.
2. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. 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.
4. 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 MANIFOLD STAY WITH VACUUM SWITCHING VALVE
1. Text in Illustration
  
  *1 White Mark
  
  *2 Blue Mark
  
  Install the manifold stay with vacuum switching valve with the 2 bolts and connect the No. 4 vacuum transmitting hose and No. 1 vacuum transmitting hose.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
  
  Note
  
  Make sure the vacuum transmitting hose color matches the connection area color.
2. Text in Illustration
  
  *1 Yellow Mark
  
  *2 No. 2 EGR Valve
  
  Connect the 2 No. 2 vacuum transmitting hoses shown in the illustration.
  Tech Tips
  - Make sure that the vacuum transmitting hose with the yellow mark is connected to the side of the No. 2 EGR valve that has a yellow mark as shown in the illustration.
  - Push on the vacuum transmitting hose until it reaches the bent part of the pipe.
3. Connect the No. 1 vacuum transmitting hose.
4. Connect the 3 vacuum switching valve connectors.
CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY
1. Temporarily install the vane pump oil reservoir with the 3 bolts.
2. Tighten the 3 bolts of the vane pump oil reservoir in the order shown in the illustration.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL INJECTOR DRIVER ASSEMBLY
1. Install the injector driver assembly with the 2 bolts.
  
  Torque:
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
2. Connect the 4 connectors.
INSTALL FRONT FENDER APRON SEAL LH
1. Install the front fender apron seal LH with the 5 clips.
INSTALL FRONT WHEEL LH

Torque:

112 N*m { 1137 kgf*cm, 82 ft.*lbf }
INSTALL DIESEL THROTTLE BODY ASSEMBLY

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.

Text in Illustration
*1	White Mark
*2	Blue Mark

Text in Illustration
*1	Yellow Mark
*2	No. 2 EGR Valve

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 No. 1 and No. 2 inlet and No. 1 and No. 2 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 a speed between 2500 and 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.

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
  
  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. 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 engine switch off.
4. Connect the intelligent tester to the DLC3.
5. Turn the engine 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.
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.

Text in Illustration
*a	Reference (Active Test Operation)

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the engine switch on (IG).
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Part	Control Range	Diagnostic Note
Test the Fuel Leak	Pressurize common rail interior and check for fuel leaks	Stop/Start	The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed. The above conditions are maintained while the Active Test is being performed.

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 front bumper lower cover with the clip and 5 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL UPPER RADIATOR SUPPORT SEAL
1. Install the upper radiator support seal with the 13 clips.