EGR VALVE INSTALLATION

Note

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

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.

INSTALL EGR COOLER GASKET
1. Install a new gasket.
INSTALL NO. 2 EGR VALVE ASSEMBLY
INSTALL NO. 1 EGR VALVE ASSEMBLY
INSTALL NO. 9 WATER BY-PASS HOSE AND WATER HOSE
1. Connect the 2 water hoses.
2. Install the No. 9 water by-pass hose.
INSTALL NO. 3 EGR PIPE
1. w/ DPF:
  
  Install a new O-ring to the No. 3 water by-pass pipe.
2. Install 2 new gaskets.
3. Install the No. 3 EGR pipe with the 4 nuts and 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER
1. Install the EGR valve with EGR cooler with the 6 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
1. Install 2 new gaskets to the No. 2 EGR pipe.
2. Install the No. 2 EGR pipe with the 4 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  Note
  - Press down the cooler side by hand while tightening the bolts on the cylinder head side.
  - If the insulator installation stay is deformed, replace the No. 2 EGR pipe.
  - If the clearance between the head and flange is 1 mm (0.0394 in.) or more, replace the No. 2 EGR pipe.
INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
1. Install 2 new gaskets to the No. 1 EGR pipe.
2. Install the No. 1 EGR pipe with the 4 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  Note
  - Press down the cooler side by hand while tightening the bolts on the cylinder head side.
  - If the insulator installation stay is deformed, replace the No. 1 EGR pipe.
  - If the clearance between the head and flange is 1 mm (0.0394 in.) or more, replace the No. 1 EGR pipe.
CONNECT NO. 5 WATER BY-PASS PIPE
1. Connect the 2 hoses and install the bolt to connect the No. 5 water by-pass pipe.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL EGR PIPE INSULATOR
1. Install the EGR pipe insulator with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Note
  
  If the No. 1 and No. 2 EGR pipe insulator installation stay is deformed, or the bolt holes of the EGR pipe insulator do not align, replace the No. 1 and No. 2 EGR pipes as a set.
INSTALL INTAKE MANIFOLD INSULATOR

INSTALL NO. 3 INTAKE MANIFOLD

Install 2 new gaskets to the No. 1 and No. 2 intake manifolds.

Install the No. 3 intake manifold with the 16 bolts.

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

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

CONNECT NO. 2 ENGINE WIRE
1. 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.
INSTALL INTAKE PIPE
1. Install a new gasket.
2. Install the intake pipe with the 4 bolts and 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 4 EGR PIPE
1. Install 2 new gaskets to the No. 4 EGR pipe.
2. Install the No. 4 EGR pipe with the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 INTAKE MANIFOLD INSULATOR
INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)
1. Temporarily install 2 new gaskets and the No. 3 nozzle leakage pipe with the 2 injector hollow screws and 3 bolts.
2. Tighten the 2 injector hollow screws and 3 bolts.
  
  Torque:
  
  for injector hollow screw
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Tech Tips
  
  Tighten the injector hollow screws first, and then tighten the bolts.
INSTALL COMMON RAIL ASSEMBLY RH
1. Install the common rail with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
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 }
INSTALL CYLINDER HEAD COVER SILENCER RH (w/ DPF)
1. Install the cylinder head cover silencer with the 4 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY
1. Temporarily install a new No. 5 injection pipe by hand.
  
  Note
  
  Make sure there is no damage or foreign matter on the seal surfaces.
2. w/ DPF:
  
  Temporarily install the used gasket and fuel filter to injection pump fuel pipe with the nut, bolt and union bolt.
3. w/o DPF:
  
  Temporarily install the used gasket and No. 2 fuel pipe with the nut, bolt and union bolt.
4. Text in Illustration
  
  *A w/ DPF
  
  *B w/o DPF
  
  Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
5. Using a union nut wrench, tighten the No. 5 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.
6. Remove the bolt and No. 2 injection pipe clamp.
7. Remove the union bolt and gasket.
8. w/ DPF:
  
  Remove the bolt, nut and fuel filter to injection pump fuel pipe.
9. w/o DPF:
  
  Remove the bolt, nut and No. 2 fuel pipe.
CONNECT FUEL PUMP MOTOR WIRE
1. Install the fuel pump motor wire bracket to the No. 3 intake manifold with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the connector to the fuel supply pump.
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.
INSTALL COMMON RAIL ASSEMBLY LH
1. Install the common rail with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)
1. Install a new gasket and the leakage pipe with the union bolt.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  Note
  
  Make sure there is no foreign matter or damage on the seal surface.
2. w/ DPF:
  
  Connect the fuel hose.
INSTALL NO. 2 FUEL PIPE (w/ DPF)
1. Install the No. 2 fuel pipe with the union bolt and bolt.
  
  Torque:
  
  for union bolt
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  for bolt
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install the No. 4 fuel hose.
CONNECT CONNECTING WIRE (w/ DPF)
1. Attach the 2 clamps to install the connecting wire.
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 }
INSTALL NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)
1. Temporarily install a new gasket and No. 4 nozzle leakage pipe with the fuel check valve.
2. Tighten the fuel check valve.
  
  Torque:
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
3. Connect the fuel hose.
INSTALL CYLINDER HEAD COVER SILENCER LH (w/ DPF)
1. Install the cylinder head cover silencer with the 4 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)
1. Install the vacuum transmitting pipe with the 3 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
2. Connect the 2 vacuum hoses.
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)
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.
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.
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)
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. 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.
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.
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 }
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 }
CONNECT FUEL HOSE
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 }
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 }
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 }
INSTALL NO. 4 AIR TUBE
1. 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 }

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Text in Illustration
*1	Paint Mark
*a	Top

INSTALL NO. 2 AIR HOSE

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.

INSTALL NO. 3 AIR TUBE
1. 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 }

Text in Illustration
*1	Paint Mark
*a	Top

INSTALL NO. 1 AIR HOSE

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

Connect the No. 1 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.

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.
TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE
1. Temporarily install the air cleaner hose to the intake air connector.
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 }
INSTALL DIESEL THROTTLE BODY ASSEMBLY LH
1. Install a new gasket to the intake pipe.
2. 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.
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. 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.
INSTALL NO. 1 GAS FILTER
1. Install the No. 1 gas filter.
2. Connect the hose to the intake pipe.
INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)
1. 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. 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.
INSTALL AIR TUBE SUB-ASSEMBLY LH
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. 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 }
INSTALL CLUTCH HOSE (for Manual Transmission)
1. 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. 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. 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 }
INSTALL DIESEL THROTTLE BODY ASSEMBLY RH
1. Install a new gasket to the intake pipe.
2. 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.
INSTALL AIR TUBE SUB-ASSEMBLY RH
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. 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 }
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.
CONNECT WATER HOSE SUB-ASSEMBLY
INSTALL INTERCOOLER 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.
1. Connect the cables to the negative (-) main battery and sub-battery terminals.

ADD ENGINE COOLANT

Remove the engine air bleed cap.
Connect a clear hose to the engine air bleed pipe.
Using a wrench, remove the vent plug.

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).

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.
Disconnect the clear hose from the engine air bleed pipe.
Install the engine air bleed cap when coolant comes out.
Install the radiator reservoir cap.
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.
Maintain an engine speed of 3000 rpm for approximately 10 minutes so that the thermostat opens and air bleeding is performed.
CAUTION:
- 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.
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.
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.

ADD CLUTCH FLUID
FILL BRAKE FLUID RESERVOIR (for Manual Transmission)
1. Check the fluid level.
  
  If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.
  
  Brake fluid
  
  SAE J1703 or FMVSS No. 116 DOT 3
BLEED CLUTCH LINE (for Manual Transmission)
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.
CHECK FLUID LEVEL IN RESERVOIR (for Manual Transmission)
1. Check the fluid level.
  
  If the brake fluid level is low, check for leaks and inspect the disc brake pad. If necessary, refill the reservoir with brake fluid after repair or replacement.
  
  Brake fluid
  
  SAE J1703 or FMVSS No. 116 DOT 3
INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)
BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

Brake fluid
SAE J1703 or FMVSS No. 116 DOT 3

Brake fluid
SAE J1703 or FMVSS No. 116 DOT 3

INSPECT FOR FUEL LEAK

Perform Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Start the engine.
Turn the intelligent tester ON.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

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.

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. 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.
INSPECT FOR OIL LEAK
1. Warm up the engine and check for an engine oil leak.
INSTALL UPPER RADIATOR SUPPORT SEAL
1. Install the upper radiator support seal with the 7 clips.
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 }
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.
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.
PERFORM ELECTRIC EGR CONTROL VALVE COMPENSATION RESET

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