ENGINE ASSEMBLY (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, clean them with a brush and compressed air.


  1. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket with the 4 bolts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket with the 4 bolts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    A01E2J8

    1. Install a new gasket to the sensor.

    2. Install the sensor.

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

    3. Connect the sensor connector.

  4. INSTALL CAMSHAFT POSITION SENSOR

    A01E329

    1. Apply a light coat of engine oil to the O-ring of the sensor.

    2. Install the sensor with the bolt.

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

    3. Connect the sensor connector.

  5. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the sensor.

    2. Install the sensor with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      A01DVCJ

    3. Install the 3 clips and connect the sensor connector.

      Note

      Insert the crankshaft position sensor wire harness into the protrusions of the timing gear cover as shown in the illustration.

  6. INSTALL VANE PUMP ASSEMBLY


    1. Install a new O-ring to the vane pump.

    2. Install the vane pump with the 2 nuts.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  7. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. Install the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

  8. 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.

  9. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

  10. INSTALL COMMON RAIL ASSEMBLY

    Click here

  11. 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. A01DY82E02

      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.

  12. INSTALL FUEL HOSE BRACKET


    1. Install the fuel hose bracket with the bolt.

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

  13. INSTALL NO. 1 FUEL PIPE


    1. Install the No. 1 fuel pipe.

  14. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector with the bolt and nut.

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

  15. INSTALL GLOW PLUG ASSEMBLY

    Click here

  16. INSTALL INTAKE MANIFOLD

    Click here

  17. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  18. INSTALL DIESEL THROTTLE BODY ASSEMBLY


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

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

    2. Connect the 2 connectors.

  19. INSTALL WATER OUTLET


    1. A01E1B7E03
      Text in Illustration
      *1 Claw

      Install a new gasket to the cylinder head 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 }

  20. INSTALL THERMOSTAT


    1. A01DVHYE08
      Text in Illustration
      *1 Gasket
      *2 Jiggle Valve
      *a CORRECT
      *b INCORRECT
      A01E2TX Upward

      Install a new gasket to the thermostat.

      Note

      When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the groove of the gasket is properly installed to the thermostat 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.

  21. INSTALL WATER INLET


    1. Install the wire harness clamp bracket to the water inlet with the bolt.

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

    2. Install the water inlet with the 3 bolts.

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

    3. Connect the wire harness clamp.

  22. INSTALL EXHAUST MANIFOLD


    1. Temporarily install a new gasket, the exhaust manifold, 8 new collars and the 8 plate washers to the cylinder head with 8 new nuts.

    2. A01DY4UE01

      Tighten the 8 nuts in the order shown in the illustration.

      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.

  23. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  24. 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 }

  25. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DYTCE05
      Text in Illustration
      *1 Cylinder Block
      *2 V-ribbed Belt Tensioner

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

  26. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolt.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  27. INSTALL GENERATOR ASSEMBLY

    A01DXLFE01

    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.

  28. INSTALL NO. 2 IDLE PULLEY ASSEMBLY


    1. Install the spacer, No. 2 idle pulley and pulley plate with the bolt.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  29. INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. Install the No. 1 viscous heater bracket with the 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  30. INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)

    Click here

  31. INSTALL NO. 1 INTERCOOLER SUPPORT BRACKET


    1. Install the No. 1 intercooler support bracket with the 2 bolts.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  32. INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET


    1. Install the No. 2 intercooler support bracket with the 2 bolts.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  33. INSTALL CRANKSHAFT PULLEY


    1. Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

    2. A01E21RE01

      Using SST, install the pulley bolt.

      SST
      09213-58014
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  34. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. Using a 10 mm hexagon wrench, install a new washer and the No. 1 timing belt idler with the bolt.

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

    2. Check that the idler pulley moves smoothly.

      If the idler pulley does not move smoothly, check the installation condition of the idler and washer.

  35. INSTALL TIMING BELT


    1. A01E2G9E05
      Text in Illustration
      *1 Timing Mark

      Check that the timing marks are aligned as shown in the illustration.

      Note


      • Make sure that the engine is cold.

      • When turning the crankshaft, the valve heads will hit against the piston. Do not turn the crankshaft more than necessary.

      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 crankshaft revolution.

    2. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

    3. A01E2YJE01

      Place the tensioner upright. Then set a press on the top of the tensioner.

      Note


      • Do not scratch or deform the rod end.

      • Press in the tensioner rod.

      • Protect the tip of the push rod with a cloth in order to prevent damage.

    4. Using the 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 apply a load of over 9800 N (999 kgf, 2203 lbf) to the push rod.

    5. Align the holes of the push rod and housing. Then pass a 1.5 mm hexagon wrench through the holes to fix the push rod in place.

    6. Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    7. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the 2 bolts.

    8. A01DZUHE01

      Remove the 1.5 mm hexagon wrench from the tensioner.

    9. A01DWQTE05
      Text in Illustration
      *1 Timing Mark

      Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

  36. INSTALL NO. 1 TIMING BELT COVER


    1. Install the timing belt cover and 6 washers with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  37. 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 }

  38. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  39. INSTALL ENGINE HANGERS


    1. A01E1IIE01
      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
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

      Tech Tips

      Part No.

      No. 1 Engine Hanger 12284-30020
      No. 2 Engine Hanger 12282-67030
      Bolt 91552-81014 and 91642-81030

      Note

      Install the engine hangers with new bolts.

  40. REMOVE ENGINE FROM ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

    2. Remove the engine from the engine stand.

  41. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Install the engine with the 4 bolts and 4 nuts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

    3. Remove the 2 bolts and 2 engine hangers.

  42. INSTALL REAR END PLATE


    1. Install the rear end plate with the bolt.

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

  43. INSTALL PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)


    1. Clean the bolts and their holes.

    2. A01E0WNE02

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021
    3. A01DX2GE01
      Text in Illustration
      *1 Flywheel and Ring Gear
      *2 Pump Impeller Drive Plate
      *3 Rear Drive Plate Spacer
      *a Engine Side
      *b Transmission Side

      Install the flywheel 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 and ring gear, and then install the flywheel 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.

    4. A01DZ8TE01

      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 and ring gear.

  44. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. Clean the bolts and their holes.

    2. Apply adhesive to 2 or 3 threads at the end of each bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. A01E0A8E02

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    4. Install the flywheel to the crankshaft.

    5. A01DZ7PE01

      Install and uniformly 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 installation.

  45. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)


    1. A01E2V5E01

      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.

  46. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A01E0WKE01

      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.

  47. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A01E183E01

      Using a dial indicator with roller instrument, measure the diaphragm spring tip alignment.

      Maximum misalignment
      0.5 mm (0.020 in.)

      • A01DXUQE01

        If the alignment is not as specified, use SST to adjust the diaphragm spring tip alignment.

      SST
      09333-00013

  48. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. Install the 4 bolts and rear No. 1 engine mounting insulator.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  49. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  50. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transmission)

  51. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    Click here

  52. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Connect the cooler compressor with the 4 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  53. CONNECT WIRE HARNESS


    1. Connect the 6 ECM connectors.

    2. for Automatic Transmission:

      Connect the 3 TCM connectors.

    3. Connect the 4WD control ECU connector.

    4. Connect the 4 injector driver connectors.

    5. Connect the 4 glow plug controller 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.

  54. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  55. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose.

  56. CONNECT FUEL HOSE


    1. Connect the 2 fuel hoses.

  57. CONNECT PRESSURE FEED TUBE ASSEMBLY


    1. Connect the pressure feed tube.

      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.

  58. CONNECT HEATER HOSE


    1. Connect the 2 heater hoses.

  59. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  60. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    A01DYY7E01

    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. A01DWR8E01

      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 }

  61. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  62. INSTALL STARTER ASSEMBLY


  63. INSTALL RADIATOR ASSEMBLY

    Click here

  64. INSTALL INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

    Click here

  65. INSTALL AIR CLEANER ASSEMBLY


    1. Install the air cleaner together with the No. 1 air cleaner hose with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    2. Connect the No. 1 air cleaner hose and tighten the hose clamp of the compressor inlet elbow.

    3. Install the ventilation hose and attach the ventilation hose clamp.

    4. Connect the mass air flow meter connector and attach the wire harness clamp.

  66. INSTALL BATTERY TRAY

  67. INSTALL BATTERY

  68. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the battery clamp with the bolt and nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  69. ADD POWER STEERING FLUID

  70. ADD TRANSMISSION FLUID (for Automatic Transmission)


    1. Add automatic transmission fluid Click here.

  71. ADD TRANSMISSION OIL (for Manual Transmission)

    A01E16LE07

    1. Stop the vehicle on a level surface.

    2. Remove the filler plug and gasket.

    3. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.

      If the result is not as specified, add transmission oil.

      Oil grade
      GL-4
      Viscosity
      SAE 75W-90, 80W or 80W-90
      Capacity
      2.2 liters (2.3 US qts, 1.9 Imp. qts)

      Note


      • Too much or too little oil will lead to transmission problems.

      • After adjusting the oil level, drive the vehicle and check the oil level again.

    4. Check for oil leakage when the oil level is low. If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.

    5. Install a new gasket and the filler plug.

      Torque
      37 N*m (377 kgf*cm, 27 ft.*lbf)

  72. ADD ENGINE OIL


    1. 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)

    2. Install the oil filler cap.

  73. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood with the 4 bolts.

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

    2. Connect the washer nozzle hose.

    3. Adjust the hood Click here.

  74. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  75. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      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. A01DVKYE05
      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.

      A01DYT1E05

      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.

  76. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

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

    2. Tighten the radiator drain cock plug by hand.

    3. A01DYVNE01

      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.

    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. A01DY58E01

      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. A01E2D9E01

      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.

  77. 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. A01DX57E01

      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.

  78. INSPECT POWER STEERING FLUID LEVEL


    1. A01DV6BE01

      Keep the vehicle level.

    2. 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.

    3. Start the engine and run it at idle.

    4. 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)
    5. A01DX57E02

      Check for foaming or emulsification. If foaming or emulsification is identified, bleed air from the power steering system.

    6. A01DW3UE01

      With the engine idling, measure the fluid level in the oil reservoir.

    7. Stop the engine.

    8. 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.

    9. Check the fluid level.

  79. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes Click here.

    2. Perform pilot quantity learning Click here.

  80. INSPECT FOR COOLANT LEAK

    Check for engine coolant leaks Click here.

  81. INSPECT FOR OIL LEAK


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

  82. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  83. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. 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.

  84. CHECK ENGINE IDLE SPEED AND MAXIMUM SPEED

    Tech Tips


    • For more information about the intelligent tester, refer to its operator's manual.

    • If an intelligent tester is not available, use a tachometer's tester probe as a substitute.


    1. Connect the intelligent tester to the DLC3.

    2. A01DW1ME07
      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.

      • Make sure that PM regeneration is not being performed.

      • for Automatic Transmission:

        Make sure that the transfer shift lever is not in the L4 position.


      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.

  85. INSPECT ENGINE OIL LEVEL


    1. Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.

      If low, check for leakage and add oil up to the full level mark.

      Note

      Do not fill engine oil above the full level mark.

  86. INSTALL NO. 2 ENGINE UNDER COVER

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

  87. INSTALL NO. 1 ENGINE UNDER COVER

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