TIMING BELT (for DPF) INSTALLATION

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.
INSTALL TIMING BELT
1. 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. 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. Remove the 1.5 mm hexagon wrench from the tensioner.
9. Text in Illustration
  
  *1 Timing Mark
  
  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 and 6 washers with the 6 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
INSTALL FAN SHROUD
1. Install the fan pulley to the water pump.
2. Install the fan shroud together with the fluid coupling with fan between the radiator and engine component.
  
  Note
  
  Be careful not to damage the radiator core.
3. Install the fluid coupling with fan to the fan pulley with the 4 nuts.
  
  Tighten the nuts as much as possible by hand.
4. Attach the claws of the fan shroud to the radiator.
5. Install the fan shroud with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
6. Install the fan and generator V belt Click here.
7. Tighten the 4 nuts of the fluid coupling with fan.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
8. Install the radiator reservoir with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
9. Connect the No. 1 and No. 2 water by-pass hoses to the radiator.
10. Install the oil reservoir with the 3 bolts.
  
  Torque:
  
  4.5 N*m { 46 kgf*cm, 40 in.*lbf }
INSTALL RADIATOR HOSE INLET
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.
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.
INSTALL NO. 1 ENGINE UNDER COVER

Torque:

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