OIL PUMP (w/o DPF) INSTALLATION


  1. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. A01DU0FE10
      Text in Illustration
      *1 New Gasket
      *2 Seal Packing

      Apply seal packing to the timing gear case as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5 mm (0.197 in.)

      Note

      After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

    3. A01DUTEE04
      Text in Illustration
      *1 New Gasket

      Install a new gasket to the groove of the timing gear case.

    4. A01DNXAE02
      Text in Illustration
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block.

    5. A01DTMPE01

      Align the "2" marks of the balanceshaft driven gear No. 1 and oil pump drive gear.

    6. Align the mark on the oil pump drive gear with the mark on the timing gear case.

    7. A01DTVVE02

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      for union bolt (A)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    8. A01DRIFE01

      Remove the screw plug and gasket.

    9. Pour approximately 50 cc (3.05 cu. in.) of engine oil into the oil pump.

    10. Install a new gasket and the screw plug.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  2. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.

    2. Install a new gasket to the cylinder block.

    3. A01DQ31E01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    4. Install the oil pan with the 22 bolts and 2 nuts.

      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }

  3. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer with the 2 nuts.

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

  4. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. A01DOSQE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the No. 2 oil pan as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installation.

    3. Install the No. 2 oil pan with the 13 bolts and 2 nuts.

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

  5. INSTALL CRANKSHAFT TIMING GEAR

    A01DRQTE01

    1. Position the crankshaft timing gear with timing mark 1 facing forward.

    2. Align the key groove of the crankshaft timing gear with the set key on the crankshaft.

    3. Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  6. INSTALL INJECTION GEAR


    1. Install a new O-ring and the supply pump with the 2 nuts.

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

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Fit the key (protrusion) of the supply pump into the key slot of the injection gear.

    3. A01DT2NE01

      Align the "3" marks of the balanceshaft driven gear No. 2 and injection gear.

    4. A01DMAGE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    5. A01DO8ZE02

      Install the injection gear set nut.

    6. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  7. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01DUCJE01
      Text in Illustration
      *1 Engine Oil

      Apply a coat of engine oil to the No. 1 idle gear shaft.

    2. A01DQXPE07
      Text in Illustration
      *1 Oil Hole

      Install the gear shaft as shown in the illustration.

  8. INSTALL NO. 1 IDLE GEAR


    1. A01DQVCE03
      Text in Illustration
      *1 Turn

      Align the "5" timing marks of the idle gear and crankshaft timing gear.

    2. Using SST, turn the injection gear and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. A01DQ8YE02
      Text in Illustration
      *1 Service Bolt

      Position the thrust plate with the protrusion facing forward.

    4. Align the bolt holes and install the thrust plate with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    5. Remove the service bolt.

  9. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A01DNRTE01

    1. Align the key groove of the sensor plate with the set key.

    2. Install the sensor plate with the cupped side facing outward.

  10. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. A01DMO4E01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the timing gear cover as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note

      After applying seal packing, install the timing gear cover within 3 minutes and tighten the bolts within 15 minutes.

    3. A01DSMEE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the timing gear case.

    4. A01DTHSE01

      Install the timing gear cover with the 14 bolts and 2 nuts.

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

  11. INSTALL WATER PUMP ASSEMBLY


    1. A01DSBV

      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 }

  12. INSTALL NO. 2 TIMING BELT COVER


    1. A01DQJWE02
      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 }

  13. 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 }

  14. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.


    1. A01DSZPE01

      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. A01DUW7E08
      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. A01DSN9E06
      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. A01DQZTE01

      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. A01DU2EE05
      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. A01DRUWE05
      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.

  15. INSPECT FOR FUEL LEAK


    1. A01DO7YE03

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


      1. 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 }

      2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

      3. A01DTC7E02

        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

      4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

      5. Remove SST, the No. 2 nozzle leakage pipe and gasket.

        Note

        Never reinstall the disassembled union bolt to the engine.

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DQ7HE01
      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.

    2. Remove any old seal packing (FIPG material) from the cylinder head.

    3. A01DP0AE05
      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.

    4. 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 }

  17. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new nozzle holder seals.

  18. INSTALL NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. Install the No. 1 oil pan cover with the 4 bolts.

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

  19. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 1 vacuum transmitting pipe with the bolt and nut.

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  20. INSTALL SUPPLY PUMP ASSEMBLY


    1. A01DTVOE01

      Check that the injection gear in the timing gear case moves back and forth smoothly.

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

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    3. A01DUCOE01

      Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

      Standard thrust clearance
      0.15 to 0.55 mm (0.00590 to 0.0217 in.)

      If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.

  21. 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. A01DS7XE02
      Text in Illustration
      *a for Common Rail Side
      *b for Fuel Supply Pump Side

      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.

    3. 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.

  22. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A01DSHRE04
      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.

    2. w/ EGR Cooler:

      Connect the No. 3 vacuum transmitting hose.

    3. A01DUDJE01
      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.

    4. Connect the No. 1 vacuum transmitting hose.

    5. 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.

  23. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. A01DQMH

      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. A01DNG1E01

      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.

  24. INSTALL AIR CONNECTOR STAY (w/o EGR System)


    1. A01DM26E01

      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 }

  25. 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. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

    2. A01DTU4E01
      Text in Illustration
      *1 No. 2 Injection Pipe

      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. A01DLVFE01
      Text in Illustration
      *a Common Rail Side
      *b 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.

  26. 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.

  27. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Install the electric EGR control valve Click here.

  28. INSTALL CRANKSHAFT PULLEY


    1. Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

    2. A01DMRSE01

      Using SST, install the pulley bolt.

      SST
      09213-58014
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  29. 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.

  30. INSTALL TIMING BELT


    1. Install the timing belt Click here.

  31. INSTALL CRANKSHAFT POSITION SENSOR


    1. Attach the clamp and install the crankshaft position sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  32. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the camshaft position sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  33. INSTALL VANE PUMP ASSEMBLY


    1. Install a new O-ring and the vane pump with the 2 nuts.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  34. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. Install the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

  35. INSTALL TIMING GEAR COVER INSULATOR


    1. Install the timing gear cover insulator with the bolt.

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

  36. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DS9DE01

      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 }

  37. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


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

    2. Apply a small amount of clean engine oil to the O-ring.

    3. Install the engine oil level dipstick guide to the cylinder block sub-assembly with the 2 bolts.

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

    4. Install the engine oil level dipstick.

  38. 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.

  39. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 5 bolts.

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

  40. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolts.

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

  41. INSTALL GENERATOR ASSEMBLY


    1. A01DSSJE01

      Install the generator with the 2 bolts.

      Torque:
      for bolt A
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }
      for bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  42. REMOVE ENGINE FROM ENGINE STAND


    1. A01DSKBE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Tech Tips

      Part No.

      No. 1 engine hanger 12284-30020
      No. 2 engine hanger 12282-67030
      Bolt 91552-81014 and 91642-81030
      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

    2. Attach an engine sling device and hang the engine with a chain block.

    3. Remove the engine from the engine stand.

  43. INSTALL ENGINE ASSEMBLY


    1. Install the engine Click here.

  44. ADD ENGINE OIL


    1. 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

      (0W-30 is best choice for fuel economy and good starting in cold weather)
      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
      Item Specified Condition
      Drain and refill without oil filter change 6.7 liters (7.1 US qts, 5.9 Imp. qts)
      Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Dry fill 7.5 liters (7.9 US qts, 6.6 Imp. qts)

    2. Install the oil filler cap.

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  46. BLEED AIR FROM FUEL SYSTEM


    1. A01DS6C

      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. A01DLTIE05
      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.

      A01DUBQE04

      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.

  47. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

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

    3. 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)
      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)
      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.

    4. 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.

    5. Install the radiator reservoir cap.

    6. Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. 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.

    8. 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.

  48. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  49. 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.

  50. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  51. INSPECT ENGINE IDLE SPEED

    Tech Tips


    • For more information about the intelligent tester, refer to its operator's manual.

    • If an intelligent tester is not available, use a tachometer's tester probe as a substitute.


    1. Connect the intelligent tester to the DLC3.

    2. A01DR2AE07
      Text in Illustration
      *a Front view of DLC3

      If a tester is not available, connect the tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18040

    3. Inspect the idle speed.

      Tech Tips


      • Make sure that the engine is warmed up.

      • Make sure that the A/C switch is off.

      • w/ DPF:

        Make sure that PM regeneration is not being performed.


      1. Start the engine and measure the idle speed.

        Idle Speed
        Item Specified Condition
        for Automatic Transmission 650 to 750 rpm
        for Manual Transmission w/ DPF 650 to 750 rpm
        w/o DPF 610 to 710 rpm

    4. Inspect the maximum speed.


      1. Start the engine.

      2. Fully depress the accelerator pedal.

      3. Measure the maximum speed.

        Maximum Speed
        Item Specified Condition
        w/ DPF 4500 to 4700 rpm
        w/o DPF 4450 to 4750 rpm

    5. If the tester probe of a tachometer is connected to the DLC3, disconnect the tester probe together with SST from terminal 9 of the DLC3.

    6. Disconnect the intelligent tester from the DLC3.

  52. 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.

  53. 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 }

  54. 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 }