FUEL INJECTOR (w/o DPF) INSTALLATION

Note

When replacing an injector (including interchanging injectors between cylinders) or common rail, replace the corresponding injection pipes with new ones.


  1. INSTALL FUEL INJECTOR LH

    Note

    Be sure to install the injector, holder clamp and bolt to their original positions.


    1. A0155RO

      Install 4 new injection nozzle seats to the cylinder head.

    2. A0158MYE04
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of clean engine oil to 4 new O-rings.

    3. Install the O-rings 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 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.

    6. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

      Note


      • A0159Q5E07

        The fork portion of the nozzle holder clamp must be set on the injector.

      • Before tightening the bolts, check that the nozzle holder clamp is set properly.

      • To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a later step.

      • When tightening the bolts, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *a Downward
    7. A01587D

      Temporarily install the common rail LH with the 2 bolts.

    8. A015DOI

      Temporarily install 4 new injection pipes to the common rail and injector.

    9. A0159P5E05
      Text in Illustration
      *1 Nozzle Leakage Pipe

      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.

    10. Set the leakage pipe and 5 new gaskets in place.

    11. A015CZW

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

      Text in Illustration
      A015CC1 Union Bolt

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

    12. Tighten the 4 holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    13. Remove the 4 injection pipes.

    14. Remove the 2 bolts and common rail LH.

    15. A015770

      Tighten the 4 hollow screws.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

    16. A0155MP

      Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

  2. INSTALL FUEL INJECTOR RH

    Note

    Be sure to install the injector, holder clamp and bolt to their original positions.


    1. A0155RO

      Install 4 new injection nozzle seats to the cylinder head.

    2. A0158MYE04
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of clean engine oil to 4 new O-rings.

    3. Install the O-rings 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 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.

    6. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

      Note


      • A0159Q5E07

        The fork portion of the nozzle holder clamp must be set on the injector.

      • Before tightening the bolts, check that the nozzle holder clamp is set properly.

      • To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a later step.

      • When tightening the bolts, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *a Downward
    7. A015DOI

      Temporarily install 4 new injection pipes to the common rail and injector.

    8. A0159P5E04
      Text in Illustration
      *1 Nozzle Leakage Pipe

      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. Set the leakage pipe and 5 new gaskets in place.

    10. A015DUS

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

      Text in Illustration
      A015CC1 Union Bolt

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

    11. Tighten the 4 holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    12. Remove the 4 injection pipes.

    13. A015DTQ

      Tighten the 4 hollow screws.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

    14. A0157TL

      Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

  3. INSTALL NOZZLE HOLDER GASKET RH


    1. A0155LDE02
      Text in Illustration
      *1 Nozzle Holder Gasket

      Press 4 new nozzle holder gaskets into the cylinder head cover RH.

      Note

      After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A015BYJ

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      A015DIT Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    2. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. A0155ERE01

      Temporarily install the cylinder head cover with the 18 bolts. Tighten the 18 bolts in the order shown in the illustration.

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

      Tech Tips

      After tightening the bolts, check that the bolts at step 11 and 20 are tightened to the specified torque.

  5. INSTALL NOZZLE HOLDER SEAL RH


    1. Press 4 new holder seals into the cylinder head cover RH.

  6. INSTALL CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)


    1. Install the cylinder head cover silencer with the 3 bolts.

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

  7. INSTALL NO. 2 VENTILATION HOSE

  8. INSTALL NOZZLE HOLDER GASKET LH


    1. A0155LDE02
      Text in Illustration
      *1 Nozzle Holder Gasket

      Press 4 new nozzle holder gaskets into the cylinder head cover LH.

      Note

      After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

  9. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A0157H8

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      A015DIT Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    2. Install a new gasket to the cylinder head cover.

      Note

      Remove any oil from the contact surface.

    3. A015CG8E01

      Temporarily install the cylinder head cover with the 17 bolts. Tighten the 17 bolts in the order shown in the illustration.

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

      Tech Tips

      After tightening the bolts, check that the bolts at step 11 and 19 are tightened to the specified torque.

  10. INSTALL OIL SEPARATOR ASSEMBLY


    1. Install a new gasket to the oil separator.

      Note

      Remove any oil from the contact surface.

    2. Install the oil separator with the 3 bolts.

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

  11. INSTALL NOZZLE HOLDER SEAL LH


    1. Press 4 new holder seals into the cylinder head cover LH.

  12. INSTALL CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)


    1. Install the cylinder head cover silencer with the 3 bolts.

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

  13. INSTALL NO. 3 VENTILATION HOSE

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


    1. Install the vacuum transmitting pipe with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. w/ Intercooler:

      Connect the 2 vacuum hoses.

  15. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (for Engine Mounting)


    1. Install the vacuum switching valve with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Connect the 2 vacuum hoses.

  16. INSTALL NO. 2 ENGINE WIRE


    1. A0156MME01

      Connect the No. 2 engine wire with the 3 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

    2. Attach the 2 wire harness clamps.

  17. INSTALL INJECTION PIPE RH


    1. Using a union nut wrench, install 4 new injection pipes.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

      Note


      • Make sure there is no damage or foreign matter on the seal surfaces.

      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. w/ Intercooler:

      Install the 4 injection pipe clamps with the 2 nuts.

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

  18. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


    1. w/ DPF:

      Note

      Check for damage and foreign matter on the fuel pipe installation surface of the fuel supply pump.

      If there is foreign matter, remove it from the installation surface.

      If the installation surface is damaged, replace the fuel supply pump.


      1. Temporarily install a new gasket and fuel filter to injection pump fuel pipe with the nut, bolt and union bolt.

      2. Install the No. 2 injection pipe clamp with the bolt.

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

      3. Tighten the union bolt, bolt and nut.

        Torque:
        for union bolt
        12 N*m  { 125 kgf*cm, 9 ft.*lbf }
        for bolt and nut
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      4. Connect the fuel hose.

    2. w/o DPF:


      1. Install the fuel filter to injection pump fuel pipe with the bolt.

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

      2. Connect the 2 hoses to the fuel pipe.

  19. INSTALL COMMON RAIL ASSEMBLY LH


    1. Install the common rail with the 2 bolts.

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

  20. INSTALL INJECTION PIPE LH


    1. Using a union nut wrench, install the 4 new injection pipes.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

      Note


      • Make sure there is no damage or foreign matter on the seal surfaces.

      • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. w/ Intercooler:

      Install the 4 injection pipe clamps with the 2 nuts.

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

  21. INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY


    1. w/ EGR System:


      1. Temporarily install a new No. 6 injection pipe to the common rail LH and RH.

        Note

        Make sure there is no damage or foreign matter on the seal surfaces.

      2. Install the 2 No. 2 injection pipe clamps with the 2 nuts.

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

      3. Using a union nut wrench, tighten the No. 6 injection pipe ends.

        Torque:
        34 N*m  { 347 kgf*cm, 25 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. w/o EGR System:


      1. Temporarily install a new No. 6 injection pipe to the common rail LH and RH.

        Note

        Make sure there is no damage or foreign matter on the seal surfaces.

      2. Install the bracket to the No. 3 intake manifold with the bolt.

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

      3. Install the No. 2 injection pipe clamp with the nut.

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

      4. Using a union nut wrench, tighten the No. 6 injection pipe ends.

        Torque:
        34 N*m  { 347 kgf*cm, 25 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 NO. 2 FUEL PIPE SUB-ASSEMBLY

    Note

    Check for damage and foreign matter on the fuel pipe installation surface of the supply pump.

    If there is foreign matter, remove it from the installation surface. If the installation surface is damaged, replace the fuel supply pump.


    1. A015D15E01

      Temporarily install a new gasket and the No. 2 fuel pipe with the union bolt, nut and bolt.

    2. Tighten the union bolt, nut and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for bolt and nut
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Install the No. 2 injection pipe clamp with the bolt.

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

    4. Connect the fuel hose to the No. 5 nozzle leakage pipe.

  23. CONNECT ENGINE WIRE


    1. LH Side:


      1. Install the engine wire protector with the 2 bolts.

      2. Connect the 8 connectors.

      3. Attach the wire harness clamp.

      4. Install the engine wire harness bracket with the bolt.

      5. for RHD:

        Connect the wire harness with the wire harness clamp holder.

      6. Attach the 3 wire harness clamps and connect the 2 connectors.

      7. Attach the 3 wire harness clamps and connect the 4 connectors.

    2. RH Side:


      1. Install the engine wire harness protector with the 3 bolts.

      2. Connect the 7 connectors.

      3. Attach the wire harness clamp.

      4. Install the wire harness bracket with the bolt.

      5. Install the glow plug wire harness with the nut and screw grommet.

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

      6. for RHD:

        Install the wire harness clamp holder with the bolt.

      7. for RHD:

        Connect the wire harness with the wire harness clamp holder.

    3. Rear Side:


      1. Install the glow plug wire harness with the nut and screw grommet.

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

      2. w/ DPF:

        Connect the 3 connectors.

      3. w/o DPF:

        Connect the connector.

      4. Install the engine wire harness protector with the 2 bolts.

      5. Install the 2 ground wires with the 2 bolts.

        Torque:
        8.4 N*m  { 87 kgf*cm, 74 in.*lbf }

      6. Attach the wire harness clamp.

  24. INSTALL NO. 4 WATER BY-PASS PIPE


    1. w/ EGR System:


      1. w/ DPF:

        Connect the 3 water hose ends, and temporarily install the No. 4 water by-pass pipe with the 2 bolts and nut.

      2. w/o DPF:

        Connect the 4 water hose ends, and temporarily install the No. 4 water by-pass pipe with the 2 bolts and nut.

    2. w/o EGR System:

      Connect the 3 water hose ends, and temporarily install the No. 4 water by-pass pipe with the 2 bolts and nut.

    3. First tighten the 2 bolts and then tighten the nut.

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

  25. INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)


    1. Connect the 2 water hose ends, and install the No. 3 water by-pass pipe with the 2 bolts.

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

  26. CONNECT FUEL HOSE

  27. INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    1. Connect the No. 1 air cleaner pipe to the No. 1 intake air connector pipe.

    2. Install the pipe with the bolt.

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

    3. Tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  28. INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    1. Connect the 4 water hose ends, and install the water pipe with the 4 bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  29. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


    1. Connect the No. 2 air cleaner pipe to the No. 2 intake air connector pipe.

    2. Connect the ventilation hose to the oil separator.

    3. Install the pipe with the bolt.

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

    4. Tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  30. INSTALL NO. 4 AIR TUBE


    1. A0159ZYE02
      Text in Illustration
      *1 Paint Mark
      *a Top

      Install the No. 4 air tube with the bolt.

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

    2. Tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

      Tech Tips

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

    3. Install the suction hose with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  31. INSTALL NO. 2 AIR HOSE


    1. A015DCLE02
      Text in Illustration
      *1 Protrusion
      *2 Paint Mark
      *a Top

      Connect the No. 2 air hose with the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).

      • Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).

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

  32. INSTALL NO. 3 AIR TUBE


    1. A015AOBE02
      Text in Illustration
      *1 Paint Mark
      *a Top

      Install the No. 3 air tube with the bolt.

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

    2. Tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

      Tech Tips

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

    3. Install the wire harness bracket with the bolt.

    4. Install the ground wire with the nut, and attach the wire harness clamp.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  33. INSTALL INTAKE AIR CONNECTOR


    1. Connect the intake air connector to the No. 1 and No. 2 air cleaner pipes.

    2. Install the connector with the 2 bolts.

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

    3. Tighten the 2 hose clamps.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

    4. Attach the 3 wire harness clamps.

    5. w/o Viscous Heater:

      Connect the connector to the water temperature sensor.

    6. w/ Viscous Heater:

      Connect the 2 connectors to the water temperature sensor and viscous with magnet clutch heater.

  34. TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE


    1. Temporarily install the air cleaner hose to the intake air connector.

  35. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Connect the air cleaner cap to the air cleaner hose, and install the air cleaner cap with the 4 clamps.

    2. Connect the mass air flow meter connector and attach the wire harness clamp to the air cleaner cap.

    3. Attach the wire harness clamp.

    4. Align the protrusion of the air cleaner cap and the concave portion of the air cleaner hose.

    5. Tighten the 2 hose clamps.

      Torque:
      2.5 N*m  { 25 kgf*cm, 22 in.*lbf }

  36. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH


    1. Install a new gasket to the intake pipe.

    2. A015A91

      Install the throttle body with the 2 bolts and 2 nuts.

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

    3. Connect the throttle position sensor connector.

    4. Connect the throttle motor connector.

  37. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET


    1. Install the No. 3 intercooler support bracket with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A0159GJ

      for Manual Transmission:


      1. Connect the clutch tube to release cylinder 2 way with the bolt.

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

      2. Check that the union nut is tightened to the specified torque.

        Torque:
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }

        Tech Tips

        Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  38. INSTALL NO. 1 GAS FILTER


    1. Install the No. 1 gas filter.

    2. Connect the hose to the intake pipe.

  39. INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. A0159ZG

      Temporarily install the flare nut of the tube connector to flexible hose tube to the clutch tube to release cylinder 2 way by hand.

    2. A0155T9E01

      Temporarily install the tube connector to flexible hose tube with the 2 bolts.

    3. Tighten the bolt labeled A.

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

      Note

      Tighten the bolt labeled B after installing the clutch hose.

  40. INSTALL AIR TUBE SUB-ASSEMBLY LH

    A0156B9E01

    1. Install the air tube to the throttle body.

    2. Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

    3. A0159R6E03

      Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  41. INSTALL CLUTCH HOSE (for Manual Transmission)


    1. A015BLRE01

      Connect the clutch hose to the air tube with the bolt labeled A.

    2. Temporarily install the clutch hose to the clutch master cylinder tube to flexible hose tube and tube connector to flexible hose tube, and fix it in place with the 2 clips.

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

    3. Tighten the bolt labeled B.

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

    4. Tighten the flexible hose tube.

      Note


      • Do not bend or damage the flexible hose tube.

      • Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting points.

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.8 in.). If using a torque wrench with a length that is not 30 cm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification Click here.

      • Make sure union nut wrench and the wrench are connected in a straight line.


      1. A0155EJE01

        Using a 10 mm union nut wrench, tighten the 2 flare nuts of the flexible hose tube.

        Torque:
        without union nut wrench
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }
        with union nut wrench
        14 N*m  { 141 kgf*cm, 10 ft.*lbf }
      2. A015C6PE01

        Using a 10 mm union nut wrench, tighten the flare nut of the flexible hose tube.

        Torque:
        without union nut wrench
        15 N*m  { 154 kgf*cm, 11 ft.*lbf }
        with union nut wrench
        14 N*m  { 141 kgf*cm, 10 ft.*lbf }

  42. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH


    1. Install a new gasket to the intake pipe.

    2. A0159VX

      Install the throttle body with the 2 bolts and 2 nuts.

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

    3. Connect the throttle position sensor connector.

    4. Connect the throttle motor connector.

  43. INSTALL AIR TUBE SUB-ASSEMBLY RH

    A0156B9E01

    1. Install the air tube to the throttle body.

    2. Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

    3. A0159R6E03

      Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  44. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the No. 2 engine oil level dipstick guide.

    3. Install the No. 2 engine oil level dipstick guide with the 2 bolts.

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

    4. Connect the ventilation hose to the cylinder head cover RH.

    5. Connect the wire harness clamp to the No. 2 engine oil level dipstick guide bracket.

  45. CONNECT WATER HOSE SUB-ASSEMBLY

  46. INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)


    1. A015AQ2E02
      Text in Illustration
      *1 Protrusion
      *a Front
      *b LH Side

      Install a new gasket to the air tube LH.

      Tech Tips

      Install the gasket with the protrusion facing as shown in the illustration.

    2. Install the No. 2 cool air inlet with the 3 nuts and bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A015BUCE02
      Text in Illustration
      *1 Protrusion
      *2 Paint Mark
      *a Top

      Connect the No. 2 air hose to the No. 2 cool air inlet.

    4. Tighten the No. 2 air hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).

      • Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).

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

  47. INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)


    1. A015BE4E02
      Text in Illustration
      *1 Protrusion
      *a Front
      *b RH Side

      Install a new gasket to the air tube RH.

      Tech Tips

      Install the gasket with the protrusion facing as shown in the illustration.

    2. Install the No. 1 cool air inlet with the 3 nuts and bolt.

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

    3. Connect the vacuum hose, intake air temperature sensor connector and turbo pressure sensor connector.

    4. A0159LAE02
      Text in Illustration
      *1 Protrusion
      *2 Paint Mark
      *a Top

      Connect the No. 1 air hose to the No. 1 cool air inlet.

    5. Tighten the No. 1 air hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

      Tech Tips


      • Align the paint mark of the air hose with the protrusion and push on the air hose so that distance B is 0 to 3 mm (0 to 0.118 in.).

      • Position the clamp so that distance A is 2 to 6 mm (0.0787 to 0.236 in.).

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

  48. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  49. BLEED CLUTCH LINE (for Manual Transmission)

    A015C3Z

    1. Remove the release cylinder bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      11 N*m  { 110 kgf*cm, 8 ft.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  50. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)

  51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  52. REGISTER INJECTOR COMPENSATION CODE

    Click here

  53. ADD ENGINE COOLANT


    1. A0155B5

      Remove the engine air bleed cap.

    2. A015CT0

      Connect a clear hose to the engine air bleed pipe.

    3. A0155YY

      Using a wrench, remove the vent plug.

    4. A015DA3

      Fill the radiator with TOYOTA SLLC to the radiator reservoir filler neck.

      Tech Tips

      Pour TOYOTA SLLC until it spills out of the engine air bleed pipe.

      Standard Capacity (for Automatic Transmission)
      Item Specified Condition
      Front heater only 14.8 liters (15.6 US qts, 13.0 Imp. qts)
      Front heater and rear heater 17.6 liters (18.6 US qts, 15.5 Imp. qts)
      Front heater with viscous heater 15.2 liters (16.1 US qts, 13.4 Imp. qts)
      Front heater and rear heater with viscous heater 18.0 liters (19.0 US qts, 15.4 Imp. qts)
      Standard capacity (for Manual Transmission)
      15.4 liters (16.3 US qts, 13.5 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      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).

    5. A0155YY

      Install the vent plug.

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

      Note

      Do not tighten the plug to 5.0 N*m (51 kgf*cm, 44 in.*lbf) or more, as the plug will be damaged.

    6. A015CT0

      Disconnect the clear hose from the engine air bleed pipe.

    7. A0155B5

      Install the engine air bleed cap when coolant comes out.

    8. Install the radiator reservoir cap.

    9. Start the engine.

      Note

      Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the FULL line.

    10. Maintain an engine speed of 3000 rpm for approximately 10 minutes so that the thermostat opens and air bleeding is performed.

      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

      Note


      • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      Tech Tips

      The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    11. Stop the engine, and wait until the engine 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.

    12. A0156WQ

      Check that the coolant level is between the FULL and LOW lines.

      If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines.

  54. INSPECT FOR COOLANT LEAK

    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. A015DVY

      Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 17.8 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 cylinder block and cylinder head.

  55. INSPECT FOR FUEL LEAK


    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 and ECT / Active Test.

      6. Perform the Active Test.

        Tester Display Test Detail Control Range Diagnostic Note
        Test the Fuel Leak Pressurizes fuel inside common rail and checks for fuel leaks Stop/Start

        • The fuel inside the common rail is pressurized to the specified value and the engine speed increases to 2000 rpm when Start is selected.

        • The above conditions are preserved while Start is selected.

  56. INSPECT FOR OIL LEAK


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

  57. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 7 clips.

  58. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 10 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  59. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Install the front fender splash shield RH with the clip, and then install the 3 bolts and 2 screws.

  60. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Install the front fender splash shield LH with the clip, and then install the 3 bolts and screw.