ENGINE ASSEMBLY INSTALLATION


  1. INSTALL ENGINE HANGERS


    1. A01IPKAE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips

      Part No.
      No. 1 engine hanger 12281-26040
      No. 2 engine hanger 12282-26010
      Bolt 90105-W0042

      • Insert the claw of the No. 1 engine hanger into the hole of the cylinder head sub-assembly.

      • Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head sub-assembly.

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Install a sling device and chain block to the engine and hang the engine.

    2. Remove the engine from the engine stand.

  3. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A01IPB5E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A01IP7GE01

      Using a T55 "TORX" socket wrench, install the flywheel sub-assembly with 8 new bolts and uniformly tighten the bolts in several steps in the sequence shown in the illustration.

      Torque:
      71 N*m  { 720 kgf*cm, 52 ft.*lbf }

      Note


      • Do not reuse the flywheel installation bolts.

      • Be sure to check the tightening torque within 5 minutes after tightening.

      • Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.

      • Make sure there is no oil on the bolts.

      Tech Tips

      Make sure that the seating surface of the flywheel installation bolts and installation surfaces of the crankshaft and flywheel sub-assembly are free from oil and foreign matter.

  4. INSTALL CLUTCH DISC ASSEMBLY


    1. A01IRNXE01

      Insert SST into the clutch disc, and then insert them into the flywheel.

      SST
      09301-00310

      Note

      Insert the clutch disc with the disc facing in the correct direction.

  5. INSTALL CLUTCH COVER ASSEMBLY


    1. A01ITF4E01
      Text in Illustration
      *1 Matchmark

      Align the matchmark on the clutch cover with the one on the flywheel.

    2. Install and tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Note


      • Be sure to uniformly tighten the bolts 180° at a time according to the order in the illustration.

      • Move SST up and down, right and left lightly after checking that the clutch disc assembly is in the center, and then tighten the bolts.

  6. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY


    1. A01IPWTE01

      Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.

      Maximum misalignment
      1.3 mm (0.0512 in.)

      If the misalignment is more than the maximum, using SST, adjust the diaphragm spring tip alignment.

      SST
      09333-00013

  7. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here

  8. INSTALL STIFFENER PLATE LH


    1. A01IN9CE01

      Temporarily install the stiffener plate LH with the 4 bolts.

    2. While holding the stiffener plate LH against the transaxle, tighten bolt A, and then tighten bolts B, C and D.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  9. INSTALL STIFFENER PLATE RH


    1. A01IQ9AE01

      Temporarily install the stiffener plate RH with the 4 bolts.

    2. While holding the stiffener plate RH against the transaxle, tighten bolt A, and then tighten bolts B, C and D.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  10. INSTALL OIL PAN INSULATOR


    1. Install the oil pan insulator with the 2 bolts.

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

  11. INSTALL ENGINE MOUNTING INSULATOR RH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator RH is necessary.


    1. Install the engine mounting insulator RH with the 3 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  12. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.


    1. Install the engine mounting insulator LH with the 4 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  13. INSTALL ENGINE MOUNTING BRACKET LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting bracket LH is necessary.


    1. Install the engine mounting bracket LH with the 4 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  14. INSTALL REAR ENGINE MOUNTING BRACKET


    1. Install the rear engine mounting bracket with the 5 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  15. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. Install the front engine mounting bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  16. INSTALL ENGINE WIRE


    1. Connect the connectors and attach the clamps, and install the engine wire to the engine with the bracket bolts.

  17. INSTALL STARTER ASSEMBLY


    1. Install the starter assembly with the 2 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    2. Connect the starter wire with the nut and close the terminal cap.

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

    3. Connect the starter connector.

  18. INSTALL NO. 1 AIR TUBE


    1. Install the No. 1 air tube with the 2 bolts and tighten the clamp.

      Torque:
      for bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for clamp
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

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

  19. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator with the 2 bolts and 2 nuts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  20. INSTALL ENGINE WITH TRANSAXLE


    1. Place the engine on an engine lifter, and then remove the sling device and chain block from the engine.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. Using the engine lifter, slowly raise the engine and install it to the vehicle, and then install the intermediate shaft to the pinion.

      CAUTION:

      Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • Make sure that the engine is clear of all wiring and hoses.

      • While raising the engine into the vehicle, do not allow it to contact the vehicle.

      • Align the matchmarks on the intermediate shaft and pinion.

    3. Temporarily install the front suspension crossmember sub-assembly with the 2 bolts.

    4. Temporarily install the front suspension rear brace RH and front suspension rear brace LH with the 6 bolts.

    5. Connect the engine mounting insulator LH with the bolt and nut.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Tech Tips

      While holding the bolt in place, tighten the nut.

    6. A01IR8DE01

      Connect the engine mounting insulator RH with the 2 bolts and 2 nuts.

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    7. A01ISQ8E01

      Tighten the 8 front suspension crossmember sub-assembly and front suspension member rear brace bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }
    8. A01IN3ME01

      Install the front crossmember sub-assembly with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    9. A01IOT4E01
      Text in Illustration
      *1 Through Bolt
      *2 Nut

      Install the front engine mounting insulator with the through bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }
    10. A01IU3OE01
      Text in Illustration
      *1 Alignment Mark
      *2 Protrusion

      Connect the rear engine mounting insulator to the engine mounting bracket with the through bolt.

      Tech Tips

      When connecting the engine mounting insulator, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    11. Remove the 2 bolts and No. 1 engine hanger and No. 2 engine hanger.

    12. for DPF:

      Attach the 3 clamps and connect the wire harness.

    13. Connect the cable bracket with the bolt.

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

  21. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector to the cylinder head sub-assembly.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  22. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. A01INC5E01

      Install the front suspension member reinforcement RH with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

  23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01IS2KE01

      Install the front suspension member reinforcement LH with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

  24. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. Install the front lower engine mounting bracket reinforcement with the 2 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. Coat the spline of the inboard joint shaft with oil.

      Tech Tips

      Be sure to use the same type of oil that is used for the transaxle.

    2. A01ITI9

      Align the shaft splines and tap in the drive shaft with a brass bar and hammer.

      Note


      • Make sure that the snap ring opening is facing downwards when installing the drive shaft.

      • Be careful not to damage the oil seal, boot or dust cover.

  26. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH


    1. Coat the spline of the inboard joint shaft with gear oil.

    2. A01IR8P

      Align the shaft splines and securely insert the drive shaft.

    3. Install the 2 bearing bracket bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note

      Do not damage the oil seal, boot or dust cover.

  27. INSTALL FRONT AXLE ASSEMBLY LH

    Click here

  28. INSTALL FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY LH


    1. A01IQIJE03

      Connect the front stabilizer link to the front stabilizer bar with the nut.

      Torque:
      74 N*m  { 755 kgf*cm, 55 ft.*lbf }

      Tech Tips

      If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. INSTALL FRONT AXLE SHAFT NUT LH


    1. Clean the threaded parts on the drive shaft and a new axle shaft nut using a non-residue solvent.

      Note


      • Be sure to perform this work for a new drive shaft.

      • Keep the threaded parts free of oil and foreign objects.

    2. A01ITYP

      Using a 30 mm socket wrench, temporarily install the axle shaft nut.

      Torque:
      for Gasoline Engine
      216 N*m  { 2203 kgf*cm, 159 ft.*lbf }
      for Diesel Engine
      292 N*m  { 2978 kgf*cm, 215 ft.*lbf }

      Tech Tips

      Stake the nut after inspecting for looseness and runout in the following steps.

  32. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  33. STAKE FRONT AXLE SHAFT NUT LH


    1. A01IN37

      Using a chisel and a hammer, stake the front axle shaft nut.

  34. STAKE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  35. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    A01IN1RE02
    Text in Illustration
    *1 Lip
    *2 Clip B
    *3 Clip A
    *4 Lip

    1. Attach clip B to the body and install the No. 1 steering column hole cover to the body with clip A.

      Note

      Make sure that the lip of the No. 1 steering column hole cover is not damaged.

  36. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01IPG7E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft assembly.

    2. A01IQQD

      Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  37. INSTALL COLUMN HOLE COVER SILENCER SHEET


    1. A01IPW5

      Install the column hole cover silencer sheet with the 2 clips.

    2. Install the floor carpet.

  38. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01IQWPE01

      Connect the clutch release cylinder assembly and clutch flexible hose bracket with the 6 bolts.

      Torque:
      for bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  39. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the 2 transmission control cable assemblies to the transmission control cable bracket with 2 new clips.

    2. Connect the 2 transmission control cable assemblies to the transaxle with the 2 pins.

  40. CONNECT NO. 1 WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose to the No. 4 water by-pass pipe, and slide the clamp secure it.

  41. INSTALL INTERCOOLER AIR HOSE

    Note


    • Check that the retainer is closed when the connector is inserted.

    • If replacing the hose, check for deposits in the intercooler and intercooler air hose. If necessary, wipe up deposits.

    • If replacing the hose, apply fresh oil to the O-ring.

    • Push on the connector until it makes a click sound which indicates that the connection is complete. After connecting the connector, check that the connector cannot be disconnected by pulling the connector.

    • Do not use a quick connector that has been dropped.


    1. A01ITOHE01
      Text in Illustration
      *1 Retainer

      Install the intercooler air hose to intercooler and No. 1 air tube and push in the retainer.

    2. Tighten the hose clamp.

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

  42. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose to the cylinder head sub-assembly, and slide the clamp secure it.

  43. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to the No. 3 water by-pass pipe, and slide the clamp secure it.

  44. CONNECT HOSES AND CONNECTORS


    1. Connect the vacuum pump hose to the vacuum pump assembly, and slide the clamp secure it.

    2. Connect the No. 2 fuel hose to the No. 2 nozzle leakage pipe, and slide the clamp secure it.

    3. Connect the No. 1 fuel hose to the supply pump assembly, and slide the clamp secure it.

    4. Attach the 4 clamps and connect the wire harness.

    5. Connect the ground cable with the bolt.

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

    6. Connect the 4 connectors, attach the 2 claws to install the No. 1 engine room relay block and install the 2 nuts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Connect the current sensor connector.

    8. Install the engine room No. 1 relay block cover.

  45. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  46. INSTALL FUEL FILTER SUPPORT


    1. Install the fuel filter support with the 3 bolts.

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

    2. Attach the 2 clamps and connect the wire harness.

    3. Connect the glow relay with the bolt.

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

    4. Attach the 2 clamps and connect the engine wire.

    5. Connect the connector.

    6. A01IUO2

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the connector, make sure that dirt, water and other foreign matter is not stuck between the connector and ECM.


      • Make sure that the lever is securely lowered.

  47. INSTALL FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)


    1. Install the fuel filter assembly with the 2 nuts.

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

    2. Connect the level warning switch connector.

    3. A01IQERE01

      Connect the No. 1 fuel hose, No. 2 fuel hose and No. 3 fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the claws of the clamp with the hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the hose is 1 to 5 mm (0.0394 to 0.197 in.).

    4. A01IRUSE01

      Connect the No. 4 fuel hose.

      Tech Tips

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

  48. INSTALL FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)


    1. Install the fuel filter assembly with the 2 nuts.

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

    2. Connect the level warning switch connector.

    3. A01ITKIE01

      Connect the No. 1 fuel hose, No. 2 fuel hose and No. 3 fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the claws of the clamp with the hose alignment mark as shown in the illustration.

      • Position the clamp so that the distance from the end of the hose is 1 to 5 mm (0.0394 to 0.197 in.).

    4. A01IO33E01

      Connect the No. 4 fuel hose.

      Tech Tips

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

    5. A01IN3RE01

      Connect the heater fuel hose.

      Tech Tips


      • Align the alignment marks and connect the hose.

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

  49. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  50. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  51. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Connect the air cleaner hose assembly to the turbocharger sub-assembly, and slide the clamp secure it.

    2. A01INV0E02
      Text in Illustration
      *a Upper

      Attach the 4 clamps to install the air cleaner cap sub-assembly.

    3. Connect the PCV hose to the cylinder head cover sub-assembly, and slide the clamp secure it.

    4. Attach the clamp and connect the mass air flow meter connector.

  52. INSTALL NO. 3 AIR HOSE

    Note

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


    1. A01IQDME01

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

    2. Align the paint mark of the No. 3 air hose with the embossed mark of the No. 2 air tube.

    3. A01IUFGE02

      Tighten the clamp of the No. 3 air hose on the diesel throttle body assembly 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 in 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.).

    4. A01IP6QE02

      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 in 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.).

  53. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Connect the No. 2 vacuum transmitting hose assembly to the intake manifold, and slide the clamp to secure it.

  54. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Remove the attached vinyl tape from the hose and compressor.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.

    4. A01IPZC

      Connect the suction hose sub-assembly to the compressor assembly with pulley with the bolt.

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

  55. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. Remove the attached vinyl tape from the hose and compressor.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor assembly with pulley.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.

    4. A01IQA7

      Connect the discharge hose sub-assembly to the compressor assembly with pulley with the bolt.

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

  56. INSTALL RADIATOR ASSEMBLY

    Click here

  57. INSTALL BATTERY CARRIER


    1. Install the battery carrier with the 4 bolts.

      Torque:
      19 N*m  { 189 kgf*cm, 14 ft.*lbf }

    2. Attach the 2 clamps to connect the wire harness.

  58. INSTALL BATTERY TRAY

  59. INSTALL BATTERY

  60. INSTALL BATTERY INSULATOR

  61. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Attach the hook of the battery clamp sub-assembly to the battery carrier.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Adjust the battery clamp sub-assembly position.

    4. Tighten the nut and bolt.

      Torque:
      for bolt
      17 N*m  { 168 kgf*cm, 12 ft.*lbf }
      for nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

  62. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  63. ADD MANUAL TRANSAXLE OIL


    1. A01IQEZE41

      Add oil until the oil level is within 5 mm (0.197 in.) from the bottom of the transmission filler plug opening.

      Manual Transaxle Oil:
      "Toyota Genuine Manual Transmission Gear Oil LV" or "API GL-4 and SAE 75W"
      Standard Capacity:
      2.3 liters (2.4 US qts, 2.0 Imp. qts)

    2. Install a new gasket and the transmission filler plug.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note


      • When adding transaxle oil, make sure the vehicle is level.

      • An excessively large or small amount of oil may cause problems.

      • After adding oil, drive the vehicle and recheck the oil level.

  64. ADD ENGINE OIL


    1. Add new engine oil.

      Standard Oil Grade
      Item Oil Grade Oil Viscosity (SAE)

      for CCo:

      Diesel fuel that contains between 50 ppm and 500 ppm of sulfur

      G-DLD1, ACEA B1, API CF-4 or CF

      (You may also use API CE or CD)

      - 5W-30

      - 10W-30

      - 15W-40

      - 20W-50

      for CCo:

      Diesel fuel that contains 50 ppm or less of sulfur

      		 ACEA C2, ACEA B1, API CF-4 or CF

      - 0W-30

      - 5W-30

      - 10W-30

      - 15W-40

      - 20W-50
      for DPF ACEA C2

      - 0W-30

      - 5W-30
      Standard Capacity (for CCo)
      Item Specified Condition
      Drain and refill without oil filter change 5.9 liters (6.2 US qts, 5.2 Imp. qts)
      Drain and refill with oil filter change 6.3 liters (6.7 US qts, 5.5 Imp. qts)
      Dry fill 7.1 liters (7.5 US qts, 6.2 Imp. qts)
      Standard Capacity (for DPF)
      Item Specified Condition
      Drain and refill without oil filter change 5.5 liters (5.8 US qts, 4.8 Imp. qts)
      Drain and refill with oil filter change 5.9 liters (6.2 US qts, 5.2 Imp. qts)
      Dry fill 6.7 liters (7.1 US qts, 5.9 Imp. qts)

  65. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. 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)

      Note

      Never use water as a substitute 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 is a combination of low phosphates and organic acids).

    3. A01IQ5WE05
      Text in Illustration
      *1 Air Release Plug
      A01ISM9 B Line

      Remove the radiator cap and air release plug and add coolant to the B line of the reservoir tank.

    4. 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.

    5. Install the cap and air release plug, and warm up the engine sufficiently.

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

    6. 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.

        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.

        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.

      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.

    7. A01IQM4

      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.

  66. INSTALL FRONT BUMPER COVER

    Click here

  67. INSTALL OUTER COWL TOP PANEL


    1. Install the cowl top panel with the 9 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  68. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (for DPF)


    1. A01INRQE02

      Connect the 2 vacuum hoses.

      Note

      Connect the vacuum hoses so that the painted marks of the 2 vacuum hoses are as shown in the illustration.

    2. A01IT6Y

      Install the sensor with the bolt.

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

    3. Connect the sensor connector and attach the wire harness clamp.

  69. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  70. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  72. BLEED FUEL SYSTEM


    1. A01IQ0Q

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • 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. Start the engine.

      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 the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs.


    7. Start the engine.*1

    8. A01IRMJE03

      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 fifth time.

      A01IRYOE04

      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.


      1. When no DTCs are output, the air bleeding is completed.

      2. If any DTCs are output, proceed to the next step.

    13. Clear the DTCs.


    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.

  73. CHARGE REFRIGERANT

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Perform vacuum purging using a vacuum pump.

    2. Charge refrigerant HFC-134a (R134a).

      Standard
      440 +/-30 g (15.5 +/-1.1 oz)
      A01IS7RE26

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.

      • Approximately 100 g (3.53 oz) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.

  74. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes Click here.

    2. Perform registration of the pilot quantity learning Click here.

  75. PERFORM INITIALIZATION


    1. Perform initialization of the crank time compensation reset function Click here.

  76. PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING

    Tech Tips

    Be sure to turn off the ignition switch before performing this inspection.


    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.

  77. INSPECT FOR REFRIGERANT LEAK


    1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

    2. Perform the operation observing the following instructions:


      • Stop the engine.

      • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that some refrigerant remains in the refrigeration system.

        Tech Tips

        When the compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm2, 57 to 85 psi).

    3. A01IPCYE30
      Text in Illustration
      *1 Check for Leakage
      *2 Halogen Leak Detector

      Using a halogen leak detector, check the refrigerant line for leakage.

    4. If a gas leak is not detected from the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and check for gas leakage.

    5. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and check for gas leakage.

  78. INSPECT FOR OIL LEAK


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

  79. 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. A01IU3X

      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.

  80. INSPECT FOR FUEL LEAK

    Tech Tips

    Using the intelligent tester to perform Active Tests allow relays, VSVs, actuators and other items to be operated without removing any parts. This non-intrusive functional inspection can be very useful because intermittent operation may be discovered before parts or wiring is disturbed. Performing Active Tests early in troubleshooting is one way to save diagnostic time. Data List information can be displayed while performing Active Tests.


    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 / Active Test.

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        Performs inspection of the high pressure fuel system.


        • Engine Speed: 2050 rpm

        • Fuel Pressure: 172000 kPa

        • Target Common Rail Pressure: 176000 kPa

        • Target Pump SCV Current: 1400 mA

        • MAP: 176 kPa

        • MAF: 39 g/sec.

  81. INSPECT FOR EXHAUST GAS LEAK


    1. Check that there are no exhaust gas leaks from the points (connection areas of the exhaust pipes and installation areas of each sensor) shown in the illustration.

      A01IN0ZE01

  82. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 5 clips.

  83. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 5 clips.

  84. INSTALL NO. 2 ENGINE UNDER COVER


    1. A01IOL8

      Install the No. 2 engine under cover with the 4 clips.

  85. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 10 clips and 6 bolts.

  86. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Insert the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.

    2. Install the 4 bolts.

    3. Install the 2 clips.

  87. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

      Attach the 4 clips to install the No. 1 engine cover.

  88. CHECK IDLE SPEED

    Note


    • Turn all the electrical systems and A/C off.

    • Inspect the engine idle speed with the cooling fan off.

    • When checking the idle speed, move the shift lever to neutral.

    Tech Tips


    • For more information about the intelligent tester, refer to its operator's manual.

    • If an intelligent tester is not available, use a tachometer as a substitute.


    1. Warm up and stop the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine and idle it.

      3. Enter the following menus: Powertrain / Engine / Data List / Engine SPD.

    3. When not using the intelligent tester:


      1. A01IUGRE32

        Connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

        SST
        09843-18040

      2. Start the engine and idle it.

    4. Inspect the engine idle speed.

      Standard idle speed
      720 to 820 rpm

    5. Turn the ignition switch off.

    6. Disconnect the intelligent tester or tachometer tester probe from the DLC3.

  89. CHECK MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Check the maximum engine speed.

      Maximum engine speed
      5100 to 5250 rpm

  90. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Attach the 4 hooks to install the radiator support opening cover.

    2. Install the 3 clips.

  91. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  92. CHECK ABS SPEED SENSOR SIGNAL


    1. Check the speed sensor signal Click here.