ENGINE OIL COOLER (w/ 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.
After removing the injection pipes, clean them with a brush and compressed air.

INSTALL OIL COOLER ASSEMBLY
1. Install 2 new gaskets to the oil cooler.
2. Install the oil cooler to the oil cooler cover with the 4 nuts.
  
  Torque:
  
  16 N*m { 163 kgf*cm, 12 ft.*lbf }
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.
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 work 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 turn by hand or with a common wrench.
INSTALL STARTER ASSEMBLY
- for 2.2 kW Type Bosch Made: Click here
- for 2.2 kW Type Denso Made: Click here
- for 2.7 kW Type: Click here
INSTALL FUEL SUPPLY PUMP ASSEMBLY

Click here
INSTALL COMMON RAIL ASSEMBLY

Click here

ADD ENGINE OIL

Wipe the oil pan and drain plug.
Install a new gasket and the drain plug.

Torque:

34 N*m { 347 kgf*cm, 25 ft.*lbf }

Add new oil.

Standard oil capacity

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

Install the oil filler cap.

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. Start the engine.
  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 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.

OK
No DTCs are output.

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.

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.
INSPECT FOR FUEL LEAK
CAUTION:
- During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.
- During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped 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 push 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.
INSTALL NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Torque:

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