ENGINE ASSEMBLY INSTALLATION

Note

When replacing the injector assemblies (including shuffling the injector assemblies between the cylinders), common rail assembly or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.
When replacing the fuel supply pump assembly, common rail assembly, cylinder block sub-assembly, cylinder head sub-assembly, cylinder head gasket or timing gear case assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
After removing the injection pipe sub-assemblies, clean them with a brush and compressed air.

INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Install the No. 1 front engine mounting bracket LH with the 4 bolts.
  
  Torque:
  
  68 N*m { 693 kgf*cm, 50 ft.*lbf }
INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH
1. Install the No. 1 front engine mounting bracket RH with the 4 bolts.
  
  Torque:
  
  68 N*m { 693 kgf*cm, 50 ft.*lbf }
INSTALL FRONT ENGINE MOUNTING INSULATOR
1. Install the 2 front engine mounting insulators with the 2 nuts.
  
  Torque:
  
  48 N*m { 489 kgf*cm, 35 ft.*lbf }
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
1. Using a 19 mm deep socket wrench, install a new gasket and the engine coolant temperature sensor.
  
  Torque:
  
  20 N*m { 200 kgf*cm, 14 ft.*lbf }
INSTALL CAMSHAFT POSITION SENSOR
1. Install the camshaft position sensor with the bolt.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
INSTALL CRANKSHAFT POSITION SENSOR
1. Install the crankshaft position sensor with the bolt.
  
  Torque:
  
  8.5 N*m { 87 kgf*cm, 75 in.*lbf }
INSTALL VANE PUMP ASSEMBLY
1. Install a new O-ring to the vane pump assembly.
2. Install the vane pump assembly with the 2 nuts.
  
  Torque:
  
  41 N*m { 418 kgf*cm, 30 ft.*lbf }
INSTALL VACUUM PUMP ASSEMBLY
1. Install 2 new O-rings to the vacuum pump assembly.
2. Install the vacuum pump assembly with the 2 nuts.
  
  Torque:
  
  21 N*m { 210 kgf*cm, 15 ft.*lbf }
INSTALL TIMING GEAR COVER INSULATOR (w/ EGR Cooler)
1. Install the gear cover insulator with the bolt.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL OIL COOLER COVER SUB-ASSEMBLY
1. Install a new gasket and the oil cooler cover with the 13 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Connect the No. 2 vacuum transmitting pipe with the 2 nuts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
3. Connect the oil pressure switch connector.
INSTALL COMMON RAIL ASSEMBLY
1. Install the common rail and No. 2 intake manifold insulator with the 2 bolts.
  
  Torque:
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
2. Connect the 2 connectors.
INSTALL FUEL SUPPLY PUMP ASSEMBLY
1. Check that the injection gear in the timing gear case moves back and forth smoothly.
2. Install a new O-ring to the pump.
3. Apply a light coat of engine oil to the O-ring.
4. Align the set key on the drive shaft with the groove of the injection gear.
5. Install the pump with the 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Set a new O-ring before tightening the set nut.
7. Using SST, hold the crankshaft pulley and install the set nut.
  
  SST
  
  09213-58013
  
  09330-00021
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
8. Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.
  
  Thrust clearance
  
  0.15 to 0.55 mm (0.0059 to 0.0217 in.)
  
  If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat step above.
9. Connect the 2 connectors.
10. Connect the 2 fuel hoses.
11. Temporarily install the fuel inlet pipe with the union nuts.
  Note
  
  If the supply pump is replaced, the fuel inlet pipe must be replaced.
  
  Keep the fuel inlet pipe free of foreign matter.
12. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf, for use with union nut wrench }
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf, for use without union nut wrench }
  
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
13. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the supply pump side.
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf, for use with union nut wrench }
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf, for use without union nut wrench }
  
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
14. Install the oil level gauge guide with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
15. Install the clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
1. Temporarily install the fuel inlet pipe with the union nuts.
  Note
  
  If the supply pump is replaced, the fuel inlet pipe must be replaced.
  
  Keep the fuel inlet pipe free of foreign matter.
2. Install a new O-ring to the oil level gauge guide, and install the oil level gauge guide to the cylinder block.
  
  Note
  
  Apply a coat of engine oil to the O-ring.
3. Temporarily install the stay of the oil level gauge guide to the intake manifold with the bolt.
4. Install the clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  
  Note
  
  Install the clamp so that the fuel inlet pipe marking can be seen on both sides of the clamp.
5. Tighten the bolt of the oil level gauge guide stay.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
6. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.
  
  Torque:
  
  without union nut wrench
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  with union nut wrench
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.
  
  Make sure union nut wrench and wrench are connected in a straight line.
7. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the supply pump side.
  
  Torque:
  
  without union nut wrench
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  with union nut wrench
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
  Tech Tips
  - Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.
  - Make sure union nut wrench and wrench are connected in a straight line.
INSTALL OIL FILTER SUB-ASSEMBLY
1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.
4. Using SST, tighten the oil filter. Depending on the work space available, choose from the following.
  
  SST
  
  09228-07501
  1. If enough space is available, use a torque wrench to tighten the oil filter.
    
    Torque:
    
    12 N*m { 122 kgf*cm, 9 ft.*lbf }
  2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 turn by hand or with a common wrench.
INSTALL NO. 2 EGR HOLE COVER PLATE (w/o EGR System)
1. Install the No. 2 EGR hole cover plate and gasket with the 2 nuts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL INTAKE MANIFOLD

Click here
INSTALL GLOW PLUG ASSEMBLY
- w/ EGR Cooler: Click here
- w/ EGR System without EGR Cooler: Click here
- w/o EGR System: Click here
INSTALL WATER OUTLET
1. Text in Illustration
  
  *1 Claw
  
  Install a new gasket to the cylinder head sub-assembly as shown in the illustration.
  
  Tech Tips
  
  Make sure the claws of the gasket face the water outlet.
2. Install the water outlet with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
INSTALL THERMOSTAT
1. Install a new gasket to the thermostat.
  
  Tech Tips
  
  When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.
2. Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.
  
  Tech Tips
  
  The jiggle valve may be set within 30°of either side of the prescribed position.
INSTALL WATER INLET
1. Install the water inlet with the 3 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)
1. Install the No. 1 viscous heater bracket sub-assembly with the 2 bolts.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)
1. Install the viscous with magnet clutch heater with the 2 bolt.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
2. Connect the connect.
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Install the No. 1 compressor mounting bracket with the 4 bolts.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET (w/ Intercooler)
1. Install the No. 2 intercooler support bracket with the 2 bolts.
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
INSTALL INTERCOOLER SUPPORT BRACKET (w/ Intercooler)
1. Install the intercooler support bracket with the 2 bolts.
  
  Torque:
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }

Thrust clearance
0.15 to 0.55 mm (0.0059 to 0.0217 in.)

Text in Illustration
*1	Claw

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

Text in Illustration
*1	V-ribbed Belt Tensioner Assembly
*2	Cylinder Block

Install the V-ribbed belt tensioner assembly with the 4 bolts.

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

Tech Tips

Firmly press and hold the V-ribbed belt tensioner assembly against the cylinder block to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

INSTALL GENERATOR BRACKET
1. Install the generator bracket with the bolt.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL GENERATOR ASSEMBLY
1. Install the generator with the 2 bolts.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf, for bolt A }
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf, for bolt B }
2. Install the generator wire with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
3. Connect the generator connector.
INSTALL EXHAUST MANIFOLD
1. w/ EGR Cooler:
  
  Install a new gasket, exhaust manifold, 8 new collars and 8 spacers to the cylinder head sub-assembly with 8 new nuts.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
  
  Note
  
  Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
2. w/o EGR Cooler:
  
  Install a new gasket, exhaust manifold and 8 spacers to the cylinder head sub-assembly with 8 new nuts.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL TURBOCHARGER SUB-ASSEMBLY (w/ EGR Cooler)

Click here
INSTALL TURBOCHARGER SUB-ASSEMBLY (w/o EGR Cooler)

Click here
INSTALL CRANKSHAFT PULLEY
1. Align the pulley set key with the key groove of the crankshaft pulley.
2. Using SST, install the pulley bolt.
  
  SST
  
  09213-58014
  
  09330-00021
  
  Torque:
  
  365 N*m { 3722 kgf*cm, 269 ft.*lbf }
INSTALL TIMING BELT
1. 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 engine revolution.
  Note
  
  The engine should be cold.
  
  When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.
2. Using a 10 mm hexagon wrench, install the timing belt idler pulley and new washer with the bolt.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
3. Check that the idler pulley moves smoothly.
  
  If it does not move smoothly, check the idler sub-assembly and washer.
4. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.
5. Place the tensioner upright. Then set the press to the top of the tensioner.
  Note
  
  Do not scratch or deform the rod end.
  
  Press in the tensioner rod upward.
  
  Protect the tip of the push rod with a cloth in order to prevent damage.
6. Using a press, slowly push in the push rod using 981 to 9800 N (100 to 999 kgf, 220 to 2203 lbf) of force.
  
  Note
  
  Do not impose a load of over 9800 N (100 to 999 kgf, 2203 lbf) to the push rod.
7. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
8. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.
9. Tighten the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Note
  
  Uniformly tighten the 2 bolts and install the tensioner.
10. Remove the 1.5 mm hexagon wrench from the tensioner.
11. Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.
INSTALL NO. 1 TIMING BELT COVER
1. Install the timing belt cover with the 6 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
2. Install the wire harness clamp.
3. Install the water hose clamp with the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL ENGINE WIRE
1. Install the engine wire.

INSTALL ENGINE HANGERS

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

Install a No. 1 engine hanger and No. 2 engine hanger with 2 bolts as shown in the illustration.

Torque:: for No. 1 engine hanger; 25 N*m { 255 kgf*cm, 18 ft.*lbf }; for No. 2 engine hanger; 60 N*m { 612 kgf*cm, 44 ft.*lbf }

Tech Tips

Part No.

No. 1 engine hanger	w/ Intercooler	12284-30060
	w/o Intercooler	12284-30020
No. 2 engine hanger		12282-67030
Bolt		90105-T0164 or 91552-81014 and 90119-T0065 or 91642-81030

Note

Install the engine hangers with new bolts.

REMOVE ENGINE STAND
1. Attach an engine sling device and hang the engine assembly with a chain block.
2. Remove the engine assembly from the engine stand.
INSTALL ENGINE ASSEMBLY
1. Slowly lower the engine assembly into the engine compartment.
2. Install the engine assembly with the 4 bolts and 4 nuts.
  
  Torque:
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
3. w/ EGR Cooler:
  
  Install the No. 2 cylinder block insulator with the bolt.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
4. Remove the 2 bolts and 2 engine hangers.
INSTALL REAR END PLATE
1. Install the rear end plate with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }

INSTALL PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)

Clean the bolts and their holes.
Using SST, hold the crankshaft pulley.

SST

09213-58014

09330-00021

Text in Illustration
*1	Flywheel Sub-assembly and Ring Gear
*2	Pump Impeller Drive Plate
*3	Rear Drive Plate Spacer
*a	Engine Side
*b	Transmission Side

Install the flywheel sub-assembly and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

Note

Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer with the knock pin of the flywheel sub-assembly and ring gear, and then install the flywheel sub-assembly and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

Tech Tips

As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in the direction shown in the illustration.

Install and uniformly tighten and tighten the 8 bolts in several steps in the sequence shown in the illustration.

Torque:

178 N*m { 1815 kgf*cm, 131 ft.*lbf }

Note

Do not start the engine for at least an hour after installing the flywheel sub-assembly and ring gear.

INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
1. Clean the bolt holes.
2. Apply adhesive to 2 or 3 threads of a new bolt end.
  
  Adhesive
  
  Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
3. Using SST, hold the crankshaft.
  
  SST
  
  09213-58014
  
  09330-00021
4. Install the flywheel sub-assembly on the crankshaft.
5. Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
  
  Torque:
  
  178 N*m { 1815 kgf*cm, 131 ft.*lbf }
  
  Note
  
  Do not start the engine for at least 1 hour after the installation.
INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
1. Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.
  
  SST
  
  09301-00110
  
  Note
  
  Take care not to insert the clutch disc facing the wrong direction.
INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)
1. Align the matchmarks on the clutch cover and flywheel.
2. Tighten the 6 bolts as described below.
  1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
  2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
    
    Torque:
    
    19 N*m { 195 kgf*cm, 14 in.*lbf }
3. Lightly move SST up and down, and right and left.
  
  SST
  
  09301-00110
4. Check that the disc is in the center, and then tighten the bolts.
INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

Click here
INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transmission)
INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)
- for R151/R156: Click here
- for R151F/R156F: Click here
- for G50: Click here
INSTALL COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Install the cooler compressor assembly with the 4 bolts.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
CONNECT WIRE HARNESS
1. Connect the 4 ECM connectors.
2. for Automatic Transmission:
  
  Connect the 3 TCM connectors.
3. w/ A.D.D.:
  
  Connect the 4WD control ECU connector.
4. for Variable Nozzle Vane Turbocharger:
  
  Connect the turbo motor driver connector.
5. Connect the 3 EDU connectors.
6. Attach the clamp and connect the wire harness with the 2 nuts.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
7. Connect the ground cable with the bolt.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
8. Connect the 2 engine room junction block connectors.
9. Connect the engine room junction block wire with the nut.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
10. Install the side engine room relay block cover.
11. Install the upper relay block cover.
INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
Text in Illustration

*1 Hinge
1. Attach the 2 hinges to install the glove compartment door.
2. Text in Illustration
  
  *1 Stopper
  
  While pushing in the sides of the glove compartment door as indicated by the arrows in the illustration, close the door to engage it to the 2 stoppers.
CONNECT UNION TO CONNECTOR TUBE HOSE
1. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure hose.
CONNECT FUEL HOSE
1. Connect the 2 fuel hoses to the No. 2 nozzle leakage pipe assembly and fuel supply pump assembly, and slide the 2 clamps to secure hose.
CONNECT PRESSURE FEED TUBE ASSEMBLY
1. Connect the pressure feed tube assembly to the vane pump assembly.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 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. Connect the oil reservoir to pump hose to the vane pump assembly, and slide the clamp to secure hose.
CONNECT HEATER HOSE
1. Connect the 2 heater hoses to the water outlet and heater pipe, and slide the 2 clamps to secure hose.
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here
INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
1. Align the matchmarks on the propeller shaft flange and transfer flange.
2. Install the propeller shaft with the 4 nuts and 4 washers.
  
  Torque:
  
  88 N*m { 897 kgf*cm, 65 ft.*lbf }
3. Align the matchmarks on the propeller shaft flange and differential flange.
4. Connect the propeller shaft with the 4 bolts, 4 nuts and 4 washers.
  
  Torque:
  
  88 N*m { 897 kgf*cm, 65 ft.*lbf }
INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here
INSTALL STARTER ASSEMBLY
- for 2.0 kW Type: Click here
- for 2.2 kW Type: Click here
- for 2.7 kW Type: Click here
INSTALL RADIATOR ASSEMBLY

Click here
INSTALL INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ Intercooler)
1. Install the intake air connector to the air hoses.
2. Install the intercooler with the 4 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
3. Install a new No. 2 air hose and then tighten the 2 hose clamps.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
4. Tighten the 2 hose clamps of the No. 1 air hose.
  
  Torque:
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
5. Connect the IAT sensor connector and manifold absolute diesel pressure sensor connector.
6. Connect the vacuum hose to the manifold absolute pressure sensor.
7. Attach the 2 clamps.
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)
1. Install the engine cover with the 3 bolts and 2 nuts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o Intercooler)
1. Connect the pipe (with the 2 air hoses) and install the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 clamps.
3. Connect the vacuum hose to the gas filter.
4. Connect the manifold absolute pressure sensor connector.
5. w/ No. 1 Engine Cover
  1. Install the engine cover bracket with the 2 bolts.
    
    Torque:
    
    18 N*m { 184 kgf*cm, 13 ft.*lbf }
  2. Attach the 4 claws to the pins of the engine cover bracket and install the No. 1 engine cover sub-assembly.
INSTALL AIR CLEANER ASSEMBLY
1. Install the air cleaner assembly with the 2 bolts.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
2. w/ Intake Air Temperature Sensor:
  
  Connect the intake air temperature sensor.
3. w/ Mass Air Flow Meter:
  
  Connect the mass air flow meter.
4. Tighten the hose clamp.
5. w/o EGR Cooler:
  
  Connect the ventilation hose.
INSTALL BATTERY AND BATTERY TRAY
INSTALL BATTERY BRACKET

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Text in Illustration
*1	Hinge

Text in Illustration
*1	Stopper

ADD ENGINE OIL

Wipe the oil pan and drain plug before installing the plug.
Install a new gasket and the drain plug.

Torque:

34 N*m { 347 kgf*cm, 25 ft.*lbf }

Add new oil.

Oil capacity

Item	Capacity
Drain and refill with oil filter change	6.9 liters (7.3 US qts, 6.1 Imp. qts)
Drain and refill without oil filter change	6.6 liters (7.0 US qts, 5.8 Imp. qts)
Dry fill	7.4 liters (7.8 US qts, 6.5 Imp. qts)

Install the oil filler cap.

ADD MANUAL TRANSMISSION OIL (for Manual Transmission)
ADD POWER STEERING FLUID
INSTALL HOOD SUB-ASSEMBLY
1. Install the hood sub-assembly with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Connect the washer nozzle hose.
3. Adjust the hood sub-assembly Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)
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 reservoir tank's B line.
  
  Standard capacity
  
  9.8 liters (10.4 US qts, 8.6 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).
  
  Note
  
  Never use water as a substitute for engine coolant.
4. Press the inlet and 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.
    
    Tech Tips
    
    The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
  2. Maintain the engine speed at 2500 to 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 F line.
  
  If the coolant level is below the F line, add TOYOTA SLLC to the F line.
BLEED AIR FROM FUEL SYSTEM
1. 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 Click here.
7. Start the engine.*1
8. 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.
  
  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.
BLEED AIR FROM POWER STEERING SYSTEM
1. Check the fluid level.
2. Jack up the front of the vehicle and support it with stands.
3. Turn the steering wheel.
  1. With the engine stopped, turn the steering wheel slowly from lock to lock several times.
4. Lower the vehicle.
5. Start the engine. Run the engine at idle for a few minutes.
6. Turn the steering wheel.
  1. With the engine idling, turn the steering wheel to the left or right full lock position and hold it there for 2 to 3 seconds. Then turn the steering wheel to the opposite full lock position and hold it there for 2 to 3 seconds.
  2. Repeat the step above several times.
7. Stop the engine.
8. Check for foaming or emulsification. If the system has to be bled twice because of forming or emulsification, check for fluid leaks in the system.
9. Check the fluid level.

Standard capacity
9.8 liters (10.4 US qts, 8.6 Imp. qts)

OK
No DTCs are output.

INSPECT POWER STEERING FLUID LEVEL

Keep the vehicle level.

With the engine stopped, check the power steering fluid level in the oil reservoir. If necessary, add power steering fluid.

Power steering fluid (for TMT made)
"TEXAMATIC 1888" or equivalent
(for TSAM made)
"TEXAMATIC 1322S" or equivalent

Tech Tips

If the fluid is hot, check that the fluid level is within the HOT range on the oil reservoir. If the fluid is cold, check that the fluid level is within the COLD range.

Start the engine and run it at idle.
Turn the steering wheel to the left or right full lock position, and then the wheel to the opposite full lock position. Repeat several times to raise fluid temperature.

Standard fluid temperature

75 to 80°C (167 to 176°F)
Check for foaming or emulsification. If foaming or emulsification is identified, bleed air from the power steering system.
With the engine idling, measure the fluid level in the oil reservoir.
Stop the engine.
Wait a few minutes and remeasure the fluid level in the oil reservoir.

Maximum fluid level increase

5 mm (0.20 in.)

If a problem is found, bleed air from the power steering system.
Check the fluid level.

PERFORM REGISTRATION
1. Perform registration of the injector compensation codes.
  - w/ EGR Cooler: Click here
  - w/o EGR Cooler: Click here
2. Perform pilot quantity learning.
  - w/ EGR Cooler: Click here
  - w/o EGR Cooler: Click here
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
Note

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 to the radiator reservoir.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm²,17.1 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 cylinder block and head.
INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the problem areas to stop the leak. Replace damaged parts as necessary.
INSPECT FOR FUEL LEAK
CAUTION:
- During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
- During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.
1. Check that there are no leaks from any part of the fuel system when the engine is stopped.
  
  If there is fuel leakage, repair or replace parts as necessary.
2. Start the engine and check that there are no leaks from any part of the fuel system.
  
  If there is fuel leakage, repair or replace parts as necessary.
3. Disconnect the return hose from the common rail.
4. Start the engine and check for fuel leaks from the return pipe.
  
  If there is fuel leakage, replace the common rail.
5. Connect the intelligent tester to the DLC3.
6. Start the engine and push the intelligent tester main switch ON.
7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.
8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.
9. Check that there are no leaks from any part of the fuel system.
  
  Note
  
  A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.
  
  If there is fuel leakage, repair or replace parts as necessary.
10. Reconnect the return hose to the common rail.
INSPECT ENGINE IDLE SPEED AND MAXIMUM SPEED
Tech Tips
- For more information about the intelligent tester, refer to its operator's manual.
- If a intelligent tester is not available, use a tachometer's tester probe as a substitute.
1. Connect the intelligent tester to the DLC3.
2. Text in Illustration
  
  *a Front view of DLC3
  
  If a tester is not available, connect the tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.
  
  SST
  
  09843-18040
3. Inspect the idle speed.
  Tech Tips
  - Make sure that the engine is warmed up.
  - Make sure that the A/C switch is off.
  1. Start the engine and measure the idle speed.
    
    Standard idle speed
    
    700 to 800 rpm
4. Inspect the maximum speed.
  1. Start the engine.
  2. Fully depress the accelerator pedal.
  3. Measure the maximum speed.
    
    Maximum Speed
    
    4450 to 4750 rpm
5. If the tester probe of a tachometer is connected to the DLC3, disconnect the tester probe together with SST from terminal 9 of the DLC3.
6. Disconnect the intelligent tester from the DLC3.
INSPECT ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low and full level marks.
  
  If the oil level is low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.
INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }