INTAKE MANIFOLD INSTALLATION

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Injection pipe sub-assembly or supply pump assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly
    Common rail assembly Fuel inlet pipe sub-assembly

    • Injection pipe sub-assembly or supply pump assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly or belt cover sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.


  1. INSTALL INTAKE MANIFOLD


    1. B007ON1E01

      Install a new gasket to the cylinder head sub-assembly.

      Tech Tips

      Install the gasket with the protrusion facing the rear side of the vehicle as shown in the illustration.

      Text in Illustration
      *a Protrusion
      B007USN Rear side

    2. Temporarily install the intake manifold with the 7 bolts and 2 nuts.

    3. B007WDYE01

      Tighten the 7 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      Text in Illustration
      B007USN Bolt
      B007QIC Nut

    4. Connect the wire harness bracket with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  2. INSTALL VACUUM CONTROL VALVE SET


    1. Install the vacuum control valve set to the intake manifold with the bolt.

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

    2. Connect the 2 vacuum hoses to the swirl control valve actuator and vacuum transmitting pipe sub-assembly.

    3. Connect the wire harness clamp and vacuum control valve set connector.

  3. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Install the No. 2 nozzle leakage pipe assembly with the 2 bolts.

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

    2. Connect the No. 6 fuel hose to the No. 3 nozzle leakage pipe assembly, and slide the clamp to secure the hose.

    3. Install the No. 4 fuel hose to the No. 2 nozzle leakage pipe assembly, common rail assembly and slide the 2 clamps to secure the hoses.

    4. Install the No. 5 fuel hose to the No. 2 nozzle leakage pipe assembly, No. 1 nozzle leakage pipe assembly and slide the 2clamps to secure the hoses.

  4. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note

    When replacing the fuel supply pump assembly, it is necessary to replace the fuel inlet pipe sub-assembly, No. 1 injection pipe clamp and No. 2 injection pipe clamp with a new one. Keep the fuel inlet pipe sub-assembly free of foreign matter.


    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. Install a new No. 1 injection pipe clamp and No. 2 injection pipe clamp with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. B007SYCE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using SST, tighten the fuel inlet pipe sub-assembly union nut on the common rail side sub-assembly.

      SST
      09245-11010
      Torque:
      Specified tightening torque
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)

    4. B007TNSE01
      Text in Illustration
      *a Torque Wrench Fulcrum Length

      Using a 19 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the fuel supply pump assembly side.

      Torque:
      Specified tightening torque
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

      • When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 41 N*m (418 kgf*cm, 30 ft.*lbf)

  5. INSTALL NO. 3 FUEL PIPE


    1. Temporarily install the No. 3 fuel pipe and 2 new gaskets with the union bolt and supply pump hollow screw.

    2. Tighten the union bolt and supply pump hollow screw.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
    3. B007S07E01

      Install the fuel pipe clamp to the fuel filter assembly and No. 3 fuel pipe.

      Note

      Be careful that the fuel pipe clamp and No. 4 fuel pipe sub-assembly do not interfere with each other.

      Tech Tips

      Make sure the fuel pipe clamp is oriented as shown in the illustration.

  6. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY


    1. Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.

    2. B007PG4E02
      Text in Illustration
      B007QIC Union Bolt
      B007T7S Bolt

      Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      union bolt
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
      bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe Click here.

  7. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

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

    2. Install the wiring harness clamp bracket with the bolt.

      Torque:
      13 N*m  { 128 kgf*cm, 9 ft.*lbf }

  8. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket with the bolt.

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

    2. Attach the 2 wire harness clamps.

    3. Connect the diesel throttle body assembly connector and pre-stroke control valve connector.

  9. INSTALL NO. 2 FUEL PIPE


    1. Connect the No. 2 fuel pipe with the bolt.

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

  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring and new grommet.

    2. Install the O-ring and grommet to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the bolt.

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

    4. Connect the vacuum hose to the intake manifold, and slide the clip to secure the hose.

    5. Install the engine oil level dipstick.

    6. w/ No. 2 Fuel Pipe Clamp:

      Attach the No. 2 fuel pipe clamp to the engine oil level dipstick guide.

  11. INSTALL EGR COOLER ASSEMBLY

    Click here

  12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  13. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reserve tank assembly with engine coolant to the top of the inlet.

      Standard capacity
      13.9 liters (14.6 US qts, 12.2 Imp qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    3. Loosen the bleeder plug of the water outlet sub-assembly.

    4. When air is bled and the engine coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B007OES

      Add engine coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap sub-assembly.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. B007W0B

      After the engine cools down, check that the engine coolant level is between the LOW and FULL line.

  14. BLEED AIR FROM FUEL SYSTEM


    1. B007RKZ

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

      Note


      • The maximum hand pump pumping speed is 2 strokes per second.

      • 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 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 GTS to the DLC3.

    5. Turn the ignition switch to ON and turn the GTS 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 5th time.

      B007P60E04

      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 /Trouble Codes.

    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 / Trouble Codes.

    16. Read Current DTCs.

      OK
      No DTCs are output.