EGR COOLER (for DPF) INSTALLATION

Note

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

INSTALL EGR COOLER INSULATOR

Text in Illustration
*1	No. 2 EGR Cooler Insulator
*2	No. 1 EGR Cooler Insulator

Install the 2 EGR cooler insulators to the EGR cooler.

Tech Tips

Install the EGR cooler insulators so that they are positioned as shown in the illustration.
Install the No. 2 EGR cooler insulator within the range labeled "A" in the illustration.

INSTALL NO. 2 EGR VALVE ASSEMBLY
1. Using a 6 mm hexagon wrench, install 2 new gaskets, the EGR valve adapter, No. 2 EGR valve, EGR cooler and 3 plate washers with the 3 hexagon socket head cap bolts.
  
  Torque:
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
2. Install the bolt labeled A.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }

TEMPORARILY INSTALL INTAKE AIR CONNECTOR WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY

Install 2 new gaskets and the electric EGR control valve to the stud bolts of the intake air connector.

Temporarily install the intake air connector with electric EGR control valve to the EGR valve adapter with the 3 nuts.

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

TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

Install a new gasket to the intake manifold.
Install a new gasket to the stud bolts of the cylinder head.
Set the electric EGR control valve with No. 2 EGR valve and EGR cooler on the intake manifold and cylinder head.
Temporarily install the intake air connector to the intake manifold with the 3 bolts labeled A.
Temporarily install the EGR cooler to the intake manifold with the 2 bolts labeled B.

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

Text in Illustration
*1	New Gasket	*2	Intake Manifold
*3	Intake Air Connector	*4	EGR Cooler

TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER
1. Tighten the 3 bolts labeled A in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 bolts labeled B in the illustration.
  
  Torque:
  
  22 N*m { 224 kgf*cm, 16 ft.*lbf }
3. Tighten the 2 nuts labeled C in the illustration.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
4. Temporarily install the EGR valve bracket with the 3 bolts.
5. Tighten the bolt labeled D in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
6. Tighten the 2 bolts labeled E in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
7. Tighten the 3 nuts labeled F in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Text in Illustration
  
  *1 EGR Valve Bracket - -
8. Connect the fuel pressure sensor connector to the common rail.
CONNECT NO. 3 WATER BY-PASS PIPE
1. Connect the No. 3 water by-pass pipe with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
CONNECT ENGINE WIRE
1. Connect the engine wire with the bolt.
  
  Torque:
  
  13 N*m { 128 kgf*cm, 9 ft.*lbf }
2. Attach the 2 wire harness clamps.
INSTALL THROTTLE BODY BRACKET
1. Install the throttle body bracket with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL WIRING HARNESS CLAMP BRACKET
1. Install the wiring harness clamp bracket with the bolt.
  
  Torque:
  
  13 N*m { 128 kgf*cm, 9 ft.*lbf }
INSTALL GAS FILTER BRACKET WITH GAS FILTER
1. Install the gas filter bracket with gas filter with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the vacuum hose.
INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR
1. Install the manifold absolute pressure sensor with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the vacuum hose and manifold absolute pressure sensor connector.
INSTALL NO. 5 WATER BY-PASS PIPE
1. Text in Illustration
  
  *a Upper Side
  
  Install the No. 5 water by-pass pipe with the 2 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Connect the 2 water hoses to the electric EGR control valve.
  Tech Tips
  - Push the water hoses on until they contact the body of the electric EGR control valve.
  - The direction of the hose clamps is indicated in the illustration.
3. Attach the 2 wire harness clamps.
INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY
Note
- When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.
- Keep the joints of the injection pipe clean.
1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.
2. Install the 2 No. 3 injection pipe clamps with the 4 nuts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
3. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
4. Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

Text in Illustration
*1	EGR Valve Bracket	-	-

Text in Illustration
*a	Upper Side

INSTALL FUEL INLET PIPE SUB-ASSEMBLY

Temporarily install the fuel inlet pipe with the union nuts.
Note
- When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.
- Keep the fuel inlet pipe free of foreign matter.

Text in Illustration
*1	Fuel Inlet Pipe
*2	Paint Mark
*3	No. 2 Fuel Pipe

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

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

Tech Tips

When installing the No. 2 injection pipe clamp, align it with the paint mark of the fuel inlet pipe shown in the illustration.

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

Torque:

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

Note

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.

Torque:

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

Note

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

INSTALL NO. 3 CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the No. 3 cylinder head cover with the 3 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE
1. Install the manifold stay with vacuum switching valve with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
2. Connect the 2 vacuum transmitting hoses.
3. Connect the vacuum switching valve connector.

CONNECT WATER BY-PASS HOSE

Connect the 6 water by-pass hoses.

Tech Tips

When connecting the hoses, make sure the paint marks and clamps are as shown in the illustration.
The direction of each hose clamp is indicated in the illustration.

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

INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Install a new O-ring to the engine oil level dipstick guide.
2. Apply a small amount of clean engine oil to the O-ring.
3. Install the engine oil level dipstick guide with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
4. Attach the wire harness clamp.
5. Install the engine oil level dipstick.
INSTALL FRONT FENDER SEAL
1. Install the front fender seal with the 5 clips.
INSTALL FRONT FENDER APRON SEAL UPPER
1. Install the front fender apron seal upper with the 5 clips.
INSTALL FRONT WHEEL LH
INSTALL DIESEL THROTTLE BODY 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 ENGINE COOLANT

Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Tighten the radiator drain cock plug by hand.

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

Standard capacity

Item	Specified Condition
A/T	11.1 liters (11.7 US qts, 9.8 Imp. qts)
M/T	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.

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.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
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.
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. Check if the engine starts.
  Note
  - Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
  - Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
  - Use a fully-charged battery.
  1. When the engine can be started, proceed to the next step.
  2. If the engine cannot be started, bleed 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. Text in Illustration
  
  *a
  Reference
  
  (Active Test Operation)
  
  Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 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.
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 a 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.

Text in Illustration
*a	Reference (Active Test Operation)

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Part	Control Range	Diagnostic Note
Test the Fuel Leak	Pressurize common rail interior and check for fuel leaks	Stop/Start	The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed. The above conditions are maintained while the Active Test is being performed.

INSTALL NO. 1 ENGINE UNDER COVER

Torque:

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