ENGINE OIL COOLER INSTALLATION

Note


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

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL OIL COOLER ASSEMBLY


    1. for CCo:


      1. A01IT2UE01

        Apply engine oil to the 2 new O-rings labeled B in the illustration.

        Note

        Do not apply engine oil to the new O-ring labeled A in the illustration.

      2. Install 3 new O-rings to the No. 1 oil cooler bracket.

    2. for DPF:


      1. A01IOY3E01

        Apply engine oil to the 2 new gaskets labeled B in the illustration.

        Note

        Do not apply engine oil to the new gasket labeled A in the illustration.

      2. Install 3 new gaskets to the No. 1 oil cooler bracket.

    3. Install the oil cooler assembly with the 5 bolts.

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

  2. INSTALL WATER BY-PASS HOSE


    1. Install the water by-pass hose to the water outlet and oil cooler assembly, and slide the 2 clamps to secure it.

      Tech Tips

      Make sure the claws of hose clamp A are positioned above the paint mark as shown in the illustration.

      A01IU9WE03
      Text in Illustration
      *1 Paint Mark
      *a Upper Side

  3. INSTALL INTAKE MANIFOLD


    1. A01IRJAE01

      Install a new gasket to the cylinder head.

      Tech Tips

      Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

    2. A01IOHHE02
      Text in Illustration
      *1 Nut

      Install the intake manifold with the 7 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 90 mm (3.54 in.)
      Bolt B 25 mm (0.984 in.)

  4. CONNECT NO. 2 VACUUM TRANSMITTING HOSE


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

  5. INSTALL NO. 2 INTAKE MANIFOLD


    1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  6. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the bolt.

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

  7. INSTALL GAS FILTER BRACKET


    1. Install the gas filter bracket with the 2 bolts.

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

  8. INSTALL NO. 1 GAS FILTER


    1. A01IOCKE01
      Text in Illustration
      *1 Protrusion
      *2 Groove

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

      Note

      Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.

    2. Connect the vacuum hose.

  9. INSTALL DIESEL TURBO PRESSURE SENSOR


    1. A01IQUFE04
      Text in Illustration
      *1 Protrusion

      Install the sensor with the bolt.

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

      Note

      Make sure the protrusion of the gas filter bracket is inserted into the hole of the sensor.

    2. Connect the sensor connector.

    3. Connect the vacuum hose.

  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    3. Connect the connector and attach the wire harness clamp to the engine oil level dipstick guide.

    4. Install the engine oil level dipstick.

  11. INSTALL INTAKE MANIFOLD INSULATOR


    1. Install the intake manifold insulator to the intake manifold.

  12. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

    2. Using pliers, grip the claws of the clip and slide the clip to connect the No. 4 fuel hose to the common rail assembly.

  13. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. Using a 14 mm union nut wrench, tighten the 4 union nuts at the common rail end of the injection pipes.

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

      Note

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

    2. Using a 14 mm union nut wrench, tighten the 4 union nuts at the injector end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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.

    3. Install the 4 No. 2 injection pipe clamps with the 2 bolts.

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

  14. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe sub-assembly with the 2 No. 2 injection pipe clamps and nut.

    2. Using a 14 mm union nut wrench, first tighten the nut at the common rail assembly end of the fuel inlet pipe sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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.

    3. Using a 14 mm union nut wrench, tighten the nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 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. Tighten the No. 2 injection pipe clamp nut.

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

  15. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IN07E01
      Text in Illustration
      *1 Protrusion

      Install a new gasket.

      Tech Tips

      Make sure the protrusion of the gasket is facing upward as shown in the illustration.

    2. Install the electric EGR control valve assembly.

  16. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install 2 new gaskets to the No. 2 EGR pipe sub-assembly and electric EGR control valve assembly.

    2. A01IPRKE06
      Text in Illustration
      *1 Nut

      Temporarily install the No. 2 EGR pipe sub-assembly with the 3 bolts and 2 nuts.

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

    3. Tighten the 2 bolts labeled A shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    4. Tighten the bolt labeled B and 2 nuts shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Connect the electric EGR control valve connector.

  17. CONNECT NO. 8 WATER BY-PASS HOSE


    1. Connect the No. 8 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure it.

  18. INSTALL NO. 7 WATER BY-PASS HOSE


    1. Install the No. 7 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure it.

  19. INSTALL EGR VALVE BRACKET


    1. Install the 2 EGR valve brackets with the 3 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    2. Connect the 2 connectors and attach the 2 wire harness clamps.

  20. CONNECT ENGINE WIRE


    1. for DPF:

      Connect the engine wire with the 2 bolts and 5 nuts.


      1. Connect the engine wire with the 2 bolts and 5 nuts.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      2. Connect the glow plug connector.

      3. Install the bolt and attach the clamp.

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

      4. Connect the 3 connectors.

    2. for CCo:


      1. Connect the engine wire with the 2 bolts and 3 nuts.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      2. Connect the glow plug wire harness with the nut and grommet.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Install the wire harness bracket with the bolt.

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

    4. Attach the 2 wire harness clamps.

    5. Connect the fuel pressure sensor connector and the pressure discharge valve connector.

  21. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. A01IS0N

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

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    2. A01IS7W

      Connect the throttle position sensor and throttle motor connector.

    3. Connect the No. 6 water by-pass hose to the diesel throttle body assembly.

    4. Connect the No. 7 water by-pass hose to the diesel throttle body assembly.

  22. 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.).

  23. 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)

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  25. BLEED AIR FROM 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.

  26. 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.

  27. 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.

  28. INSPECT FOR OIL LEAK


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

  29. 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.

  30. INSPECT ENGINE OIL LEVEL


  31. INSTALL NO. 1 ENGINE UNDER COVER


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

  32. INSTALL RADIATOR SUPPORT OPENING COVER


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

    2. Install the 3 clips.

  33. INSTALL NO. 1 ENGINE COVER


    1. A01INMI

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