INTAKE MANIFOLD (w/ DPF) INSTALLATION

Note

When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

INSTALL INTAKE MANIFOLD
1. Temporarily install a new gasket and the intake manifold with the 2 nuts and 4 bolts.
2. Tighten the 2 nuts and 4 bolts in the order shown in the illustration.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  Note
  
  Make sure that the swirl control valve actuator is not damaged by the surrounding parts.
3. Attach the sensor wire connector clamp to the intake manifold.
INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
INSTALL NO. 1 GLOW PLUG CONNECTOR
1. Temporarily install the No. 1 glow plug connector with the 4 nuts.
2. Tighten the 4 nuts.
  
  Torque:
  
  2.2 N*m { 22 kgf*cm, 19 in.*lbf }
3. Install the 4 screw grommets.
4. Connect the No. 1 glow plug connector to the wire harness.
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL INTAKE MANIFOLD INSULATOR
1. Install the intake manifold insulator.

INSTALL VACUUM CONTROL VALVE SET

Install the vacuum control valve set with the 2 bolts.

Torque:

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

Text in Illustration
*1	White Paint Mark
*2	Green Paint Mark
*3	Swirl Control Valve Actuator

Connect the 3 vacuum hoses and 2 vacuum switching valve connectors.

Note

When connecting the hoses, match the colors of the paint marks on the hoses to the colors of the paint marks on the swirl control valve as shown in the illustration.

INSTALL INTAKE PIPE STAY
1. Install the intake pipe stay with the bolt.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.
  
  Text in Illustration
  
  Union Bolt
2. Temporarily install a new gasket and the union bolt.
3. Tighten the 3 bolts and union bolt.
  
  Torque:
  
  for bolt A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt B
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  
  for union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 3 NOZZLE LEAKAGE PIPE
1. Text in Illustration
  
  *1 O-Ring
  
  Apply a light coat of fuel to the O-ring of the fuel check valve.
2. Text in Illustration
  
  *1 Gasket
  
  Fuel Check Valve
  
  Temporarily install the No. 3 nozzle leakage pipe with the 2 bolts.
3. Temporarily install a new gasket and fuel check valve.
4. Tighten the 2 bolts and fuel check valve.
  
  Torque:
  
  for bolt
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  
  for fuel check valve
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
  
  Note
  
  Make sure the gasket of fuel check valve A contacts the No. 3 nozzle leakage pipe as shown in the illustration when tightening the fuel check valve.
5. Connect the 2 fuel hoses.

Text in Illustration
	Union Bolt

Text in Illustration
*1	O-Ring

INSTALL NO. 2 FUEL PIPE

Text in Illustration

*1 O-Ring

Apply a light coat of fuel to the O-ring of the fuel check valve.

Text in Illustration
*1	O-Ring

Text in Illustration
*1	Gasket
	Union Bolt
	Fuel Check Valve

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

Temporarily install a new gasket and the fuel check valve.
Using a 6 mm hexagon wrench, tighten the union bolt.

Torque:

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

Note

Make sure the gasket of union bolt A contacts the No. 2 fuel pipe as shown in the illustration when tightening the union bolt.
Tighten the fuel check valve.

Torque:

32 N*m { 321 kgf*cm, 23 ft.*lbf }

INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY
Note
- When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
- Keep the joints of the injection pipe clean.
1. Temporarily install the No. 4 injection pipe with the union nuts.
2. Install the 2 No. 2 injection pipe clamps with the bolt and nut.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
3. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

INSTALL NO. 1 FUEL PIPE

Temporarily install the No. 1 fuel pipe with the 4 bolts.
Temporarily install a new gasket with the union bolt.
Tighten the union bolt and 4 bolts in the order shown in the illustration.

Torque:

for union bolt

30 N*m { 306 kgf*cm, 22 ft.*lbf }

for bolt

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

Connect the No. 2 fuel pipe Click here.

Text in Illustration
*1	No. 2 Fuel Pipe	-	-
	Union Bolt	-	-

INSTALL INTAKE AIR CONNECTOR
1. Text in Illustration
  
  *1 Claw
  
  Set a new gasket on the intake manifold.
  
  Note
  
  Make sure the claw of the gasket faces the intake manifold as shown in the illustration.
2. Install the intake air connector with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
CONNECT WIRE HARNESS
1. Attach the 5 clamps and connect the wire harness to the cowl top panel.
2. for LHD:
  
  Connect the wire harness with the bolt.
  
  Torque:
  
  22 N*m { 219 kgf*cm, 16 ft.*lbf }
3. Connect the wire harness with the bolt.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
INSTALL GAS FILTER BRACKET
1. Install the gas filter bracket with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Attach the clamp and connect the wire harness.
INSTALL NO. 1 GAS FILTER
1. Install the No. 1gas filter to the gas filter bracket.
2. Connect the vacuum hose.
INSTALL THROTTLE BODY BRACKET
1. Temporarily install the throttle body bracket with the 3 bolts.
2. Tighten the 3 bolts of the throttle body bracket in the order shown in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL EMISSION CONTROL VALVE BRACKET
1. Install the emission control valve bracket with the bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
1. Install the manifold absolute pressure sensor with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the vacuum hose and manifold absolute pressure sensor connector.
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

Click here
INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Text in Illustration
*1	Claw

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
for Automatic Transmission	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
for Manual Transmission	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

Tech Tips

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
Please contact your TOYOTA dealer for further details.
for Cold Area Specification Vehicles:

Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

Note

Never use water as a substitute for engine coolant.

Press the No. 1 and No. 2 inlet and No. 1 and No. 2 outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
Bleed air from the cooling system.
1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
2. Maintain the engine speed at a speed between 2500 and 3000 rpm.
3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
  CAUTION:
  
  When pressing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
4. Stop the engine and wait until the coolant cools down to ambient temperature.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
After the coolant cools down, check that the coolant level is at the FULL line.

If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

BLEED AIR FROM FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.
  Note
  
  The maximum hand pump pumping speed is 2 strokes per second.
  
  The hand pump must be pushed with a full stroke during pumping.
  
  When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
  
  If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
  
  If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
  
  If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.
2. Check if the engine starts.
  Note
  - Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
  - Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
  - Use a fully-charged battery.
  1. When the engine can be started, proceed to the next step.
  2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
3. Turn the engine switch off.
4. Connect the intelligent tester to the DLC3.
5. Turn the engine switch on (IG) and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. Text in Illustration
  
  *a
  Reference
  
  (Active Test Operation)
  
  Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.
  
  Tech Tips
  
  When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.
11. Enter the following menus: Powertrain / Engine and ECT / DTC.
12. Read Current DTCs.
13. Clear the DTCs Click here.
  
  Tech Tips
  
  It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.
14. Repeat steps *1 to *3.
15. Enter the following menus: Powertrain / Engine and ECT / DTC.
16. Read Current DTCs.
  
  OK
  
  No DTCs are output.
INSPECT FOR COOLANT LEAK

Note

Before each inspection, turn the A/C switch off.

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

Text in Illustration
*a	Reference (Active Test Operation)

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Perform the Active Test.

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

Perform the Active Test.

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