МАСЛЯНЫЙ РАДИАТОР ДВИГАТЕЛЯ УСТАНОВКА

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail assembly, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail assembly, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.


  1. INSTALL OIL COOLER ASSEMBLY


    1. A01IT2UE01

      Apply engine oil to the 2 new O-rings labeled B in the illustration.

      Note

      Do not apply engine oil to the new O-ring labeled A in the illustration.

    2. Install 3 new O-rings to the oil cooler bracket.

    3. Install the oil cooler assembly with the 5 bolts.

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

  2. INSTALL WATER BY-PASS HOSE


    1. Install the water by-pass hose to the water outlet and oil cooler assembly, and slide the 2 clamps to secure it.

      Tech Tips

      Make sure the claws of hose clamp A are positioned above the paint mark as shown in the illustration.

      A01IU9WE03
      Text in Illustration
      *1 Paint Mark
      *a Upper Side

  3. INSTALL INTAKE MANIFOLD


    1. A01IRJAE01

      Install a new gasket to the cylinder head.

      Tech Tips

      Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

    2. A01IOHHE02
      Text in Illustration
      *1 Nut

      Install the intake manifold with the 7 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      Standard Bolt
      Item Length
      Bolt A 90 mm (3.54 in.)
      Bolt B 25 mm (0.984 in.)

  4. CONNECT NO. 2 VACUUM TRANSMITTING HOSE


    1. Connect the No. 2 vacuum transmitting hose to the intake manifold.

  5. INSTALL NO. 2 INTAKE MANIFOLD


    1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  6. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the bolt.

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

  7. INSTALL GAS FILTER BRACKET


    1. Install the gas filter bracket with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  8. INSTALL NO. 1 GAS FILTER


    1. A01IOCKE01
      Text in Illustration
      *1 Protrusion
      *2 Groove

      Install the No. 1 gas filter to the gas filter bracket.

      Note

      Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.

    2. Connect the vacuum hose.

  9. INSTALL DIESEL TURBO PRESSURE SENSOR


    1. A01IOD1E01
      Text in Illustration
      *1 Protrusion

      Install the diesel turbo pressure sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

      Note

      Make sure the protrusion of the gas filter bracket is inserted into the hole of the diesel turbo pressure sensor.

    2. Connect the vacuum hose.

  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


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

    2. Install the engine oil level dipstick guide with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    3. Connect the connector and attach the wire harness clamp to the engine oil level dipstick guide.

    4. Install the engine oil level dipstick.

  11. INSTALL INTAKE MANIFOLD INSULATOR


    1. Install the intake manifold insulator to the intake manifold.

  12. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

    2. Using pliers, grip the claws of the clip and slide the clip to connect the No. 4 fuel hose to the common rail assembly.

  13. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. Using a 14 mm union nut wrench, tighten the 4 union nuts at the common rail assembly end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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.

    2. Using a 14 mm union nut wrench, tighten the 4 union nuts at the injector assembly end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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. Install the 4 No. 2 injection pipe clamps with the 2 bolts.

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

  14. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe sub-assembly with the 2 No. 2 injection pipe clamps and nut.

    2. Using a 14 mm union nut wrench, first tighten the nut at the common rail assembly end of the fuel inlet pipe sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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 14 mm union nut wrench, tighten the nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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. Tighten the No. 2 injection pipe clamp nut.

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

  15. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IN07E01
      Text in Illustration
      *1 Protrusion

      Install a new gasket.

      Note

      Make sure the protrusion of the gasket is facing upward as shown in the illustration.

    2. Install the electric EGR control valve assembly.

  16. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install 2 new gaskets to the No. 2 EGR pipe sub-assembly and electric EGR control valve assembly.

    2. A01IPRKE06
      Text in Illustration
      *1 Nut

      Temporarily install the No. 2 EGR pipe sub-assembly with the 3 bolts and 2 nuts.

      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)

    3. Tighten the 2 bolts labeled A shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    4. Tighten the bolt labeled B and 2 nuts shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Connect the electric EGR control valve connector.

  17. CONNECT NO. 8 WATER BY-PASS HOSE


    1. Connect the No. 8 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure it.

  18. INSTALL NO. 7 WATER BY-PASS HOSE


    1. Install the No. 7 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure it.

  19. INSTALL EGR VALVE BRACKET


    1. Install the 2 EGR valve brackets with the 3 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    2. Connect the 2 connectors and attach the 2 wire harness clamps.

  20. CONNECT ENGINE WIRE


    1. Connect the engine wire with the bolt and 3 nuts.

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

    2. Install the wire harness bracket with the bolt.

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

    3. Attach the 2 wire harness clamps.

    4. Connect the glow plug wire harness with the nut and grommet.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    5. Connect the pressure discharge valve connector.

    6. Connect the fuel pressure sensor connector.

  21. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. A01IS0N

      Install a new gasket and the diesel throttle body assembly with the 2 nuts and 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    2. A01IS7W

      Connect the throttle position sensor and throttle motor connector.

    3. Connect the No. 6 water by-pass hose to the diesel throttle body assembly.

    4. Connect the No. 7 water by-pass hose to the diesel throttle body assembly.

  22. INSTALL NO. 3 AIR HOSE

    Note

    Before installation, remove any oil residue from the inside of pipe and hose.


    1. A01IQDME01

      Align the paint mark of the No. 3 air hose with the embossed mark of the diesel throttle body assembly.

    2. Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.

    3. A01IUFGE02

      Tighten the clamp of the No. 3 air hose on the diesel throttle body assembly side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).

    4. A01IP6QE02

      Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the embossed mark and push in the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).

      • Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).

  23. ADD ENGINE OIL


    1. Add new engine oil.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)
      ACEA C2

      - 0W-30

      - 5W-30
      Standard Capacity
      Item Specified Condition
      Drain and refill without oil filter change 5.5 liters (5.8 US qts, 4.8 Imp. qts)
      Drain and refill with oil filter change 5.9 liters (6.2 US qts, 5.2 Imp. qts)
      Dry fill 6.3 liters (6.7 US qts, 5.5 Imp. qts)

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  25. BLEED AIR FROM FUEL SYSTEM


    1. A01IQ0Q

      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


      • 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. 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 to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01IRMJE03

      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.

      A01IRYOE04

      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.


      1. When no DTCs are output, the air bleeding is completed.

      2. If any DTCs are output, proceed to the next step.

    13. Clear the DTCs Click here.

    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.

  26. ADD ENGINE COOLANT


    1. Затяните пробку сливного крана радиатора вручную.

    2. Долейте в наливную горловину радиатора фирменную жидкость с увеличенным сроком замены (SLLC) от компании Тойота.

      Номинальный объем
      Параметр / Устройство Заданные условия
      Для моделей без подогревателя 7,4 литра (7,8 кварты США, 6,5 английской кварты)
      Для моделей с подогревателем 7,8 литра (8,2 кварты США, 6,9 английской кварты)

      Tech Tips

      Автомобили Toyota первоначально заправляются охлаждающей жидкостью TOYOTA SLLC на заводе. Во избежание повреждения системы охлаждения двигателя или других технических проблем разрешается использовать только охлаждающую жидкость "TOYOTA Super Long Life Coolant" или аналогичную высококачественную охлаждающую жидкость на основе этиленгликоля (а не на силикатной, аминовой, нитритной или борнокислой основе), изготовленную по гибридной технологии органических кислот с длительным сроком годности (охлаждающая жидкость, изготовленная по гибридной технологии органических кислот, состоит из низкофосфатных соединений и органических кислот).

      Note

      Никогда не используйте воду вместо охлаждающей жидкости.

    3. A01IQ5WE05
      Обозначения на рисунке
      *1 Пробка выпуска воздуха
      A01ISM9 Линия B

      Снимите пробку радиатора и пробку выпуска воздуха, и долейте охлаждающую жидкость до отметки B на расширительном бачке.

    4. Несколько раз сожмите рукой входной и выходной патрубки радиатора, а затем проверьте уровень охлаждающей жидкости.

      Если уровень охлаждающей жидкости недостаточен, добавьте жидкость.

    5. Установите пробку радиатора и пробку выпуска воздуха, а затем надлежащим образом прогрейте двигатель.

      Torque:
      2,0 Н*м  { 20 кгс*см, 18 фунт-сила-дюймов }

    6. Выпустите воздух из системы охлаждения.

      Note


      • Перед запуском двигателя установите выключатель системы кондиционирования в положение OFF (ВЫКЛ).

      • Установите температуру кондиционера на уровень MAX (HOT).

      • Установите вентилятор кондиционера в режим Lo.


      1. Прогревайте двигатель, пока не откроется термостат. Когда термостат откроется, обеспечьте циркуляцию охлаждающей жидкости в течение нескольких минут.

        CAUTION:

        При сжатии патрубка радиатора:

        • Работайте в защитных перчатках.

        • Будьте осторожны: патрубки радиатора горячие.

        • Не прикасайтесь к вентилятору радиатора.

        Tech Tips

        Момент открывания термостата можно определить, сжав входной патрубок радиатора рукой и отметив вибрации, когда охлаждающая жидкость двигателя начнет поступать в шланг.

      2. После прогрева двигателя дайте ему поработать не менее 7 мин в следующем цикле: на частоте 3000 об/мин в течение 5 с, а затем на частоте вращения холостого хода в течение 45 с (этот цикл следует повторить, по крайней мере, 8 раз).

      3. Несколько раз сожмите рукой входной и выходной патрубки радиатора, чтобы удалить воздух из системы.

        CAUTION:

        При сжатии патрубка радиатора:

        • Работайте в защитных перчатках.

        • Будьте осторожны: патрубки радиатора горячие.

        • Не прикасайтесь к вентилятору радиатора.

    7. A01IQM4

      После охлаждения двигателя убедитесь, что уровень охлаждающей жидкости находится между отметками "LOW" и "FULL".

      Если уровень охлаждающей жидкости мал, долейте жидкость до отметки FULL на расширительном бачке.

  27. INSPECT FOR COOLANT LEAK


    1. Снимите пробку расширительного бачка радиатора.

      CAUTION:

      Во избежание ожогов не снимайте пробку расширительного бачка радиатора, пока двигатель и радиатор не остынут. Тепловое расширение вызывает выброс из радиатора горячей охлаждающей жидкости и пара.

    2. A01IU3X

      Заполните радиатор охлаждающей жидкостью, а затем подсоедините приспособление для опрессовки системы охлаждения и проверки пробки радиатора.

    3. Прогрейте двигатель.

    4. С помощью этого приспособления создайте давление 118 кПа (1,2 кгс/см2, 17 фунта на кв. дюйм) и убедитесь, что давление не падает.

      Если давление снижается, проверьте на наличие утечек шланги, радиатор и насос системы охлаждения.

      Если нет признаков наружной утечки охлаждающей жидкости, проверьте сердцевину отопителя, блок цилиндров и головку блока цилиндров.

    5. Установите пробку расширительного бачка радиатора.

  28. INSPECT FOR OIL LEAK


    1. Warm up the engine and check for an engine oil leak.

  29. INSPECT FOR FUEL LEAK

    Tech Tips

    Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.


    1. Perform Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Start the engine.

      4. Turn the intelligent tester on.

      5. Enter the following menus: Powertrain / Engine / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        Performs inspection of the high pressure fuel system.


        • Engine Speed: 2050 rpm

        • Fuel Pressure: 172000 kPa

        • Target Common Rail Pressure: 176000 kPa

        • Target Pump SCV Current: 1.4 A

        • MAP: 176 kPa

        • MAF: 39 g/sec.

  30. 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.

  31. INSTALL NO. 1 ENGINE UNDER COVER


    1. A01IUIX

      Install the No. 1 engine under cover with the 10 clips and 6 bolts.

  32. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Attach the 4 hooks to install the radiator support opening cover.

    2. Install the 3 clips.

  33. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.