COMMON RAIL (w/o EGR Cooler) 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.
When replacing the common rail, do not remove the foreign object mixing prevention caps of the common rail until just before the fuel inlet pipe and injection pipe are connected to the common rail.
After removing the injection pipes, clean them with a brush and compressed air.

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 INLET PIPE SUB-ASSEMBLY
1. 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.
2. 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.
3. 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 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. Install the injection pipe clamp with the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
1. w/ Intercooler:
  1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.
  2. Temporarily install a new gasket and the union bolt.
  3. Tighten the 3 bolts and union bolt.
    
    Torque:
    
    for bolt
    
    13 N*m { 130 kgf*cm, 9 ft.*lbf }
    
    for union bolt
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. w/o Intercooler:
  1. Temporarily install the No. 2 nozzle leakage pipe with the 2 bolts.
  2. Temporarily install a new gasket and the union bolt.
  3. Tighten the 2 bolts and union bolt.
    
    Torque:
    
    for bolt
    
    13 N*m { 130 kgf*cm, 9 ft.*lbf }
    
    for union bolt
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Connect the 3 fuel hoses.
INSTALL NO. 4 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. 4 injection pipe with the union nuts.
2. w/ Intercooler:
  
  Install the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  Note
  - If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
  - Make sure that the inner rubbers of the injection pipe fit inside the clamps.
  - When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.
3. w/o Intercooler:
  
  Install the 2 bolts.
  
  Torque:
  
  13 N*m { 130 kgf*cm, 9 ft.*lbf }
  Note
  - If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
  - Make sure that the inner rubbers of the injection pipe fit inside the clamps.
  - When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.
4. Using a 17 mm union nut wrench, tighten the injection 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.
5. 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.

TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ Intercooler)

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts labeled A in the illustration.

Note

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.
Install a new gasket and the EGR valve adapter to the electric EGR control valve with the 2 bolts labeled B in the illustration.

Torque:

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

Note

Make sure the claws of the gasket face the electric EGR control valve as shown in the illustration.
Set a new gasket on the intake manifold.

Note

Make sure the claws of the gasket face the intake manifold as shown in the illustration.

Temporarily install the intake air connector to the intake manifold with the 3 bolts labeled C in the illustration.

Text in Illustration
*1	No. 2 Intake Air Connector	*2	Electric EGR Control Valve
*3	Intake Air Connector	*4	EGR Valve Adapter
*5	New Gasket	*6	Claw
*7	Intake Manifold	-	-
*a	0 to 2 threads	-	-

INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)
1. w/ Intercooler:
  1. Temporarily install the No. 1 EGR pipe and 2 new gaskets to the cylinder head and EGR valve adapter with the 2 nuts and 2 bolts.
    
    Note
    
    Make sure the claws of the gasket face the No. 1 EGR pipe as shown in the illustration.
  2. Tighten the 2 nuts labeled A.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
  3. Tighten the 2 bolts labeled B.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
    
    Text in Illustration
    
    *1 New Gasket *2 Claw
2. Text in Illustration
  
  *1 Claw
  
  w/o Intercooler:
  
  Install 2 new gaskets and the No. 1 EGR pipe with the 2 nuts and 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Tech Tips
  
  Make sure the claws of the gasket face the No. 1 EGR pipe.
TIGHTEN INTAKE AIR CONNECTOR (w/ Intercooler)
1. Tighten the 3 nuts labeled A in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 3 bolts labeled B in the illustration.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  Tighten the bolts in the order shown in the illustration.
  
  Text in Illustration
  
  *a Front Side of Vehicle - -
INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)
1. w/ Intercooler:
  1. Temporarily install the No. 2 intake air connector bracket with the 3 bolts.
  2. Tighten the bolt labeled A.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  3. Tighten the 2 bolts labeled B.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. w/o Intercooler:
  
  Install the No. 2 intake air connector bracket with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)
1. w/ Intercooler:
  1. Install the electric vacuum regulating valve bracket with the 2 bolts.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  2. Install the No. 1 gas filter with gas filter bracket with the bolt.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  3. Connect the 6 vacuum hoses.
    
    Note
    
    Be sure to securely connect the vacuum hoses.
  4. Connect the 2 connectors.
2. w/o Intercooler:
  1. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.
    
    Torque:
    
    20 N*m { 204 kgf*cm, 15 ft.*lbf }
  2. Connect the 2 vacuum hoses.
  3. Connect the connector.
CONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)
1. Connect the No. 3 water by-pass pipe with wire harness with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }

Text in Illustration
*1	New Gasket	*2	Claw

Text in Illustration
*1	Claw

Text in Illustration
*a	Front Side of Vehicle	-	-

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 pipes clean.

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

Text in Illustration
*1	No. 2 Injection Pipe
*2	No. 2 Injection Pipe Clamp
*3	No. 3 Injection Pipe Clamp
*4	Painted Mark

w/ Intercooler:

Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.

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

Tech Tips

If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Text in Illustration
*1	No. 1 Injection Pipe
*2	No. 2 Injection Pipe Clamp
*3	No. 3 Injection Pipe Clamp
*4	Painted Mark

w/o Intercooler:

Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts as shown in the illustration.

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

Tech Tips

If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

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.
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.

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 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 of a turn by hand or with a common wrench.
INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ Intercooler)
1. Install the manifold stay with vacuum switching valve with the 2 bolts and connect the vacuum transmitting hose.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
  
  Note
  
  Be sure to securely connect the vacuum transmitting hose.
2. Text in Illustration
  
  *1 Yellow Paint
  
  *2 Pink Paint
  
  Connect the 2 vacuum transmitting hoses.
  Note
  
  Be sure to securely connect the vacuum transmitting hoses.
  
  Make sure the vacuum transmitting hoses' color matches the connection areas' color.
3. Connect the vacuum switching valve connector.
INSTALL MANIFOLD STAY (w/o Intercooler)
1. Install the manifold stay with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
  
  Tech Tips
  
  The manifold stay indented area (labeled A) must face the manifold.
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.
INSTALL DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)

Click here

Text in Illustration
*1	Yellow Paint
*2	Pink Paint

ADD ENGINE OIL

Add new engine oil.

Standard Oil Grade

Oil Grade

Oil Viscosity (SAE)

ACEA C2

- 0W-30

- 5W-30

Standard Capacity

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

Install the oil filler cap.

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
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. Enter the following menus: Powertrain / Engine / 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 / 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 / DTC.
16. Read Current DTCs.
  
  OK
  
  No DTCs are output.
INSPECT FOR FUEL LEAK
CAUTION:
- During Active Test mode, the engine speed becomes high and the combustion noise becomes loud, so pay attention.
- During Active Test mode, the fuel pressure becomes high. Be extremely careful not to expose your eyes, hands, or body to escaping 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 turn 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 FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
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 }