CAMSHAFT (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.


  1. INSTALL CAMSHAFT


    1. A00XGBZE02
      Text in Illustration
      *1 Key

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to prevent the top of the piston from hitting against the valve head.

    2. A00XEZHE04

      Install the camshaft.


      1. Apply engine oil to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head with the key groove facing upward.

        Text in Illustration
        *1 Key Groove
        *a Upward
      3. A00XKFXE01

        Align the timing marks (1-dot marks) of the camshaft drive and driven main gears and set the No. 2 camshaft in place.

    3. Remove any old seal packing (FIPG material) from the camshaft bearing cap.

    4. A00XEIPE05
      Text in Illustration
      *1 Seal Packing
      *2 Oil Passage

      Apply seal packing to the specified areas shown in the illustration.

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

      Note


      • Do not allow seal packing to contact the oil passage of the bearing cap.

      • After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

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

    5. A00XFYXE01

      Install the 5 bearing caps to their proper locations.

    6. A00XKKZE02

      Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

    7. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    8. A00XG3WE01

      Install a new camshaft oil seal.


      1. Apply MP grease to the lip of a new oil seal.

      2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.

        SST
        09608-06041

  2. INSTALL NO. 2 TIMING BELT COVER


    1. A00XDNCE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing (FIPG) to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note

      After applying seal packing, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

    2. Install the No. 2 timing belt cover with the 4 bolts and nut.

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

  3. INSTALL CAMSHAFT TIMING PULLEY


    1. Install the camshaft timing pulley.

    2. Install the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  4. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. Using a 10 mm hexagon wrench, install a new washer and the No. 1 timing belt idler with the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    2. Check that the idler pulley moves smoothly.

      If the idler pulley does not move smoothly, check the installation condition of the idler and washer.

  5. INSTALL TIMING BELT


    1. A00983IE05
      Text in Illustration
      *1 Timing Mark

      Check that the timing marks are aligned as shown in the illustration.

      Tech Tips

      If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of crankshaft revolution.

      Note


      • Make sure that the engine is cold.

      • When turning the crankshaft, the valve heads will hit against the piston. Do not turn the crankshaft more than necessary.

    2. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

    3. A009BQYE01

      Place the tensioner upright. Then set a press on the top of the tensioner.

      Note


      • Do not scratch or deform the rod end.

      • Press in the tensioner rod.

      • Protect the tip of the push rod with a cloth in order to prevent damage.

    4. Using the press, slowly push in the push rod using 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) of force.

      Note

      Do not apply a load of over 9807 N (1000 kgf, 2205 lbf) to the push rod.

    5. Align the holes of the push rod and housing. Then pass a 1.5 mm hexagon wrench through the holes to fix the push rod in place.

    6. Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    7. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the 2 bolts.

    8. A0099WKE01

      Remove the 1.5 mm hexagon wrench from the tensioner.

    9. A0098L2E05
      Text in Illustration
      *1 Timing Mark

      Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

  6. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  7. INSTALL NO. 1 TIMING BELT COVER


    1. Install the timing belt cover and 6 washers with the 6 bolts.

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

  8. INSTALL FAN SHROUD


    1. Install the fan pulley to the water pump.

    2. Install the No. 2 water by-pass hose to the water inlet.

    3. Temporarily install the shroud together with the fan with fluid coupling to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand.

    4. A00JYTR

      Attach the claws of the shroud to the radiator as shown in the illustration.

    5. Install the fan shroud to the radiator with the 2 bolts.

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

    6. Install the fan and generator V belt Click here.

    7. Install the fan with fluid coupling to the water pump with the 4 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    8. Attach the No. 2 water by-pass hose to the clamp on the fan shroud.

    9. for Automatic Transmission:


      1. A00JZWZE02
        Text in Illustration
        *a RH Side
        *b 2.0 to 7.0 mm
        *c View A

        Connect the 2 oil cooler hoses.

        Tech Tips


        • Position the hose clamps as shown in the illustration.

        • Position the clips so that the distance from the end of the hose is 2.0 to 7.0 mm (0.0787 to 0.275 in.).

      2. Attach the 2 oil cooler hoses to the clamp on the fan shroud.

    10. Connect the No. 2 water by-pass hose to the radiator reservoir.

    11. Connect the No. 1 water by-pass hose to the fan shroud and attach the 2 clamps.

    12. Install the radiator reservoir with the 3 bolts.

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

  9. INSTALL NO. 1 RADIATOR HOSE

    A00K088E01
    Text in Illustration
    *1 Protrusion
    *2 Paint Mark
    *a Top
    *b LH Side

    1. Install the radiator hose and attach the clamp.

      Tech Tips

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

  10. INSTALL INJECTOR ASSEMBLY

    Note

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


    1. A00XKL6

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a small amount of clean engine oil to 4 new O-rings.

    3. A00XII7E01
      Text in Illustration
      *1 New O-Ring

      Install one of 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 injection nozzle seat surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from being fully seated. If so, pull out the injector and reinstall it.

      • Always reinstall an injector to the same place it was removed from.

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A00XCQKE02
      Text in Illustration
      *1 Washer
      *a Downward

      Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

      Tech Tips

      Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.

    7. Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A00XJOYE01

      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. A00XELGE02

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

    10. Apply a small amount of oil to the 4 injector hollow screws and union bolt.

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

    12. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A00XFVDE05
      Text in Illustration
      *1 Union Bolt

      Tighten the 4 injector hollow screws in order from 1 to 4.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      If an injector hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

    14. Tighten the union bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

    15. Remove the 4 injection pipes.

  11. INSPECT FOR FUEL LEAK


    1. A00XIKLE01

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


      1. Install a new gasket and the and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        SST
        09280-00010
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

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

      3. A00XJ22E01

        Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe, maintain 100 kPa (1.0 kgf/cm2, 15 psi) of pressure for 60 seconds and check that no bubbles form.

        SST
        09992-00242

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

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

        Note

        Never reinstall the disassembled union bolt to the engine.

  12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A00XDKAE01
      Text in Illustration
      *1 No. 3 Cylinder Head Cover Gasket
      *2 Cylinder Head Cover

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

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

    3. A00XK1ZE06

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      A00XC0D Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover.

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

    5. A00XH2EE01

      Temporarily install the cover with the 10 bolts and 2 nuts in the order shown in the illustration. Then, tighten the 10 bolts and 2 nuts in the order shown in the illustration in 2 progressive steps.

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

    6. Install 4 new nozzle holder seals.

  13. INSTALL VENTILATION PIPE


    1. Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover with the bolt.

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

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


    1. A00XEDIE01

      Install the No. 2 cylinder head cover with the 4 bolts.

      Torque:
      for bolt A
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  15. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A00XET4E01

      Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.

      Text in Illustration
      A00XFQT 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 }

  16. INSTALL NO. 3 NOZZLE LEAKAGE PIPE


    1. A00XFIEE01
      Text in Illustration
      *1 O-Ring

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

    2. A00XH2SE01
      Text in Illustration
      *1 Gasket
      A00XFQT 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.

  17. INSTALL NO. 2 FUEL PIPE


    1. A00XD3QE01
      Text in Illustration
      *1 O-Ring

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

    2. A00XIKVE01
      Text in Illustration
      *1 Gasket
      A00XHOQ Union Bolt
      A00XFQT Fuel Check Valve

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

    3. Temporarily install a new gasket and the fuel check valve.

    4. 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.

    5. Tighten the fuel check valve.

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

  18. 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.

  19. INSTALL NO. 1 FUEL PIPE


    1. Temporarily install the No. 1 fuel pipe with the 4 bolts.

    2. Temporarily install a new gasket with the union bolt.

    3. 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 }

    4. Connect the No. 2 fuel pipe Click here.

      A00XH74E02
      Text in Illustration
      *1 No. 2 Fuel Pipe - -
      A00XFQT Union Bolt - -

  20. INSTALL INTAKE AIR CONNECTOR


    1. A00JVG7E01
      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 }

  21. 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.

  22. INSTALL NO. 1 GAS FILTER


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

    2. Connect the vacuum hose.

  23. INSTALL THROTTLE BODY BRACKET


    1. A00K044E01

      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 }

  24. 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 }

  25. 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.

  26. 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 }

  27. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Install a new gasket and the electric EGR control valve to the intake air connector.

    2. Connect the electric EGR control valve connector.

  28. TEMPORARILY INSTALL EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY


    1. Install a new gasket to the stud bolts of the intake air connector.

    2. Install a new gasket to the stud bolts of the cylinder head.

    3. Install the EGR valve adapter to the electric EGR control valve and intake air connector with the 2 nuts and bolt labeled A.

    4. Temporarily install the EGR cooler to the intake manifold with the 2 bolts labeled B in the illustration.

    5. Temporarily install the EGR cooler to the cylinder head with the 2 nuts labeled C in the illustration.

      A00XF0FE02
      Text in Illustration
      *1 New Gasket *2 EGR Valve Adapter
      *3 EGR Cooler *4 Electric EGR Control Valve
      *5 Intake Air Connector - -

  29. TIGHTEN EGR COOLER WITH NO. 2 EGR VALVE ASSEMBLY


    1. Tighten the 2 bolts labeled A in the illustration.

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

    2. Tighten the 2 nuts labeled B in the illustration.

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

    3. Install the air connector stay with the 3 bolts labeled C in the illustration.

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

    4. Tighten the 2 nuts and bolt labeled D in the illustration.

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

    5. Install the No. 1 fuel pipe to the air connector stay with the bolt labeled E.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      A00XHUOE01
      Text in Illustration
      *1 Air Connector Stay *2 No. 1 Fuel Pipe

    6. Connect the fuel pressure sensor connector to the common rail.

    7. Connect the 4 injector connectors and attach the 3 wire harness clamps.

  30. INSTALL NO. 4 ENGINE COVER BRACKET


    1. Install the No. 4 engine cover bracket with the bolt.

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

  31. INSTALL ENGINE COVER BRACKET INSULATOR


    1. A00XFEIE01
      Text in Illustration
      *1 Claw

      Install the 2 engine cover bracket insulators with the 2 nuts.

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

      Tech Tips

      Make sure that the claws of the engine cover bracket insulators contact the engine cover brackets.

  32. INSTALL NO. 3 ENGINE COVER BRACKET


    1. Install the No. 3 engine cover bracket with the 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  33. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket.

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

    2. Attach the 2 wire harness clamps and connect the glow plug connector to the wiring harness clamp bracket.

    3. Connect the glow plug connector.

  34. INSTALL NO. 1 VACUUM TRANSMITTING PIPE


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

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

    2. Connect the vacuum hose to the intake manifold.

  35. INSTALL WATER BY-PASS HOSE

    Tech Tips


    • When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.

    • The direction of each hose clamp is indicated in the illustration.


    1. Connect the No. 5 water by-pass hose labeled A in the illustration.

    2. Connect the No. 6 water by-pass hose labeled B in the illustration.

    3. Connect the No. 8 water by-pass hose labeled C in the illustration.

    4. Connect the No. 3 water by-pass hose labeled D in the illustration.

    5. Connect the No. 4 water by-pass hose labeled E in the illustration.

    6. Connect the No. 7 water by-pass hose labeled F in the illustration.

    7. Attach the 4 water by-pass hose clamps.

      A00XJACE01
      Text in Illustration
      *1 Paint Mark - -
      *a Upper Side *b LH Side

  36. CONNECT HEATER WATER PIPE SUB-ASSEMBLY


    1. Install the heater water pipe with the bolt.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

    2. Attach the water by-pass hose clamp.

  37. INSTALL NO. 1, NO. 2 AND NO. 3 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. 1, No. 2 and No. 3 injection pipes with the union nuts.

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

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

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

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

    4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

    5. 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.

  38. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe with the union nuts.

      Note


      • When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.

      • Keep the fuel inlet pipe free of foreign matter.

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

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

    3. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

    4. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

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

  39. INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE


    1. A00XIAXE02
      Text in Illustration
      *1 White Mark
      *2 Blue Mark

      Install the manifold stay with vacuum switching valve with the 2 bolts and connect the No. 4 vacuum transmitting hose and No. 1 vacuum transmitting hose.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Note

      Make sure the vacuum transmitting hose color matches the connection area color.

    2. A00XJ44E02
      Text in Illustration
      *1 Yellow Mark
      *2 No. 2 EGR Valve

      Connect the 2 No. 2 vacuum transmitting hoses shown in the illustration.

      Tech Tips


      • Make sure that the vacuum transmitting hose with the yellow mark is connected to the side of the No. 2 EGR valve that has a yellow mark as shown in the illustration.

      • Push on the vacuum transmitting hose until it reaches the bent part of the pipe.

    3. Connect the No. 1 vacuum transmitting hose.

    4. Connect the 3 vacuum switching valve connectors.

  40. CONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A00XFW0E01

      Temporarily install the vane pump oil reservoir with the 3 bolts.

    2. Tighten the 3 bolts of the vane pump oil reservoir in the order shown in the illustration.

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

  41. INSTALL INJECTOR DRIVER


    1. Install the injector driver assembly with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Connect the 4 connectors.

  42. INSTALL DIESEL THROTTLE BODY ASSEMBLY


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

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

    2. Connect the throttle control motor connector.

  43. INSTALL NO. 1 INTAKE PIPE


    1. Connect the No. 1 intake pipe with the No. 1 air hose and install the 2 bolts.

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

    2. Tighten the 2 hose clamps of the No. 1 air hose.

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

    3. Connect the 2 connectors to the intake air temperature sensor and throttle position sensor.

    4. Attach the 2 wire harness clamps.

  44. CONNECT INTERCOOLER AIR HOSE


    1. A00JW0GE01
      Text in Illustration
      *a Front Side of Vehicle
      *b RH Side

      Connect the intercooler air hose and tighten the hose clamp.

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

      Tech Tips

      Install the hose clamp so that it is facing the direction shown in the illustration.

  45. CONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Connect the No. 4 vacuum transmitting pipe with the bolt.

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

  46. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal LH with the 5 clips.

  47. INSTALL FRONT WHEEL LH

    Torque:
    112 N*m  { 1137 kgf*cm, 82 ft.*lbf }

  48. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  50. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

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

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

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

      Tech Tips


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

      • Please contact your TOYOTA dealer for further details.

      • for Cold Area Specification Vehicles:

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

      Note

      Never use water as a substitute for engine coolant.

    4. Press the 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.

    5. Install the radiator reservoir cap.

    6. Using a wrench, install the vent plug.

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

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at 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.

    8. After the coolant cools down, check that the coolant level is at the FULL line.

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

  51. BLEED AIR FROM FUEL SYSTEM


    1. A00JTRJ

      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. A00JX9YE05
      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.

      A00JUDPE04

      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.

  52. 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.

  53. INSPECT FOR OIL LEAK


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

  54. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG).

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. 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.

  55. 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.

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


    1. Install the No. 1 engine under cover with the 4 bolts.

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

  57. INSTALL FRONT BUMPER LOWER COVER


    1. Install the front bumper lower cover with the clip and 5 bolts.

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

  58. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  59. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A00K0KKE01
      Text in Illustration
      *1 No. 1 Engine Cover Hook
      *2 No. 3 Engine Cover Bracket

      Attach the 2 No. 1 engine cover hooks to the No. 3 engine cover bracket.

    2. Install the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }