DIESEL THROTTLE BODY INSTALLATION

INSTALL DIESEL THROTTLE BODY ASSEMBLY
1. Install a new gasket and the diesel throttle body with the 2 nuts and 2 bolts.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
2. Connect the throttle position sensor and throttle motor connector.
3. Connect the No. 6 water by-pass hose to the throttle body.
4. Connect the No. 7 water by-pass hose to the throttle body.

INSTALL NO. 3 AIR HOSE

Note

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

Text in Illustration
*1	Embossed Mark
*2	Paint Mark
*a	Rear
*b	RH Side

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

Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.
Tighten the clamp of the No. 3 air hose on the diesel throttle body side.

Torque:

6.5 N*m { 66 kgf*cm, 58 in.*lbf }
Tech Tips
- Align the paint mark of the air hose with the embossed mark and push on the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).
- Position the clamp so that distance A is 4 to 9 mm (0.157 to 0.354 in.).
Tighten the clamp of the No. 3 air hose on the No. 2 air tube side.

Torque:

6.5 N*m { 66 kgf*cm, 58 in.*lbf }
Tech Tips
- Align the paint mark of the air hose with the embossed mark and push on the air hose so that distance B is 0 to 2 mm (0 to 0.0787 in.).
- Position the clamp so that distance A is 9 to 15 mm (0.354 to 0.591 in.).

ADD ENGINE COOLANT

Tighten the radiator drain cock plug by hand.

Add TOYOTA Super Long Life Coolant (SLLC) to the radiator reservoir filler opening.

Standard Capacity

Item	Specified Condition
w/o Power Heater	7.4 liters (7.8 US qts, 6.5 Imp. qts)
w/ Power Heater	7.8 liters (8.2 US qts, 6.9 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 is a combination of low phosphates and organic acids).

Note

Never use water as a substitute for engine coolant.

Text in Illustration

*1 Air Release Plug

Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.
Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.
Install the cap and air release plug, and warm up the engine sufficiently.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
Bleed air from the cooling system.
Note
- Before starting the engine, turn the A/C switch off.
- Adjust the air conditioning temperature setting to MAX (HOT).
- Adjust the air conditioning blower setting to Lo.
1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.
  
  Tech Tips
  
  The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand and sensing vibrations when the engine coolant starts to flow inside the hose.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
2. After the engine has warmed up, run the engine according to the following pattern for at least 7 minutes: 3000 rpm for 5 seconds, and then idle speed for 45 seconds (repeat this pattern at least 8 times).
3. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.
  CAUTION:
  When squeezing the radiator hoses:
  - Wear protective gloves.
  - Be careful as the radiator hoses are hot.
  - Keep your hands away from the radiator fan.
After the engine has cooled down, check that the coolant level is between FULL and LOW.

If the coolant level is low, add coolant until the coolant level leaks the reservoir tank FULL line.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSPECT FOR COOLANT LEAK
1. Remove the radiator reservoir cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
2. Fill the radiator with coolant, and then attach a radiator cap tester.
3. Warm up the engine.
4. Pump the radiator cap tester to 118 kPa (1.2 kgf/cm², 17 psi), and then check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leakage.
  
  If there are no signs of external coolant leaks, check the heater core, cylinder block and head.
5. Reinstall the radiator reservoir cap.
INSTALL ENGINE UNDER COVER
1. Install the engine under cover with the 11 clips.
INSTALL FRONT LOWER BUMPER ABSORBER
1. Insert the 2 hooks of the front lower bumper absorber into the installation holes on the body to install the front lower bumper absorber.
2. Install the 8 bolts and 3 screws.
3. Install the 4 screws and 2 bolts.
INSTALL RADIATOR SUPPORT OPENING COVER
1. Install the radiator support opening cover with the 7 clips.
INSTALL NO. 1 ENGINE COVER
1. Attach the 4 clips to install the No. 1 engine cover.
PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING

Tech Tips

Be sure to turn off the ignition switch before performing this procedure.
1. Turn the ignition switch to ON.
2. Turn the ignition switch off and wait 10 seconds.
  
  Tech Tips
  
  The fully closed position of the diesel throttle valve is learned when the ignition switch is turned off.