OIL PUMP (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.


  1. INSTALL TIMING GEAR CASE ASSEMBLY


    1. A01DWKHE04
      Text in Illustration
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block.

    2. Remove any old seal packing (FIPG) material from the timing gear case and cylinder block.

    3. A01DYNME04
      Text in Illustration
      *1 New Gasket

      Set a new oil pump gasket to the timing gear case.

    4. A01DW8HE13
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Block, Three Bond 1207B or equivalent
      Standard seal diameter
      4.0 mm (0.157 in.)

      Note


      • After applying FIPG, install the timing gear case within 3 minutes and tighten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.

    5. A01E21QE03

      Align the "2" timing marks of the No. 1 balance shaft driven gear and oil pump drive gear, and install the timing gear case to the cylinder block.

    6. Tighten the 8 bolts and union bolt labeled A shown in the illustration.

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    7. Make sure that the oil pump drive gear rotates smoothly.

      If the gear does not rotate smoothly, remove the 8 bolts and union bolt to release the gear. Then install the bolts and gear again.

    8. Install the No. 1 vacuum transmitting pipe with the nut.

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

  2. INSTALL OIL PAN SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer with the 2 bolts and nut.

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

    2. Remove old seal packing (FIPG) from the oil pan and cylinder block.

    3. A01E0W7E03

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Block, Three Bond 1207B or equivalent
      Standard seal diameter
      4.0 mm (0.157 in.)

      Note


      • After applying FIPG, install the oil pan within 3 minutes and tighten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.

    4. Install the oil pan with the 22 bolts and 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  3. INSTALL OIL DIPSTICK GUIDE


    1. A01DZT2

      Install a new O-ring to the guide.

    2. Apply a small amount of clean engine oil to the O-ring.

    3. Install the 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 }

  4. INSTALL INJECTION GEAR


    1. A01E0IQE01

      Align the "3" timing marks of the injection gear and No. 2 balance shaft driven gear, and install the injection gear.

      Note

      Fit the key (protrusion) of the supply pump to the key slot of the injection gear.

    2. Set a new O-ring and then temporarily install the nut. Using your hand, check the thrust clearance of the supply pump drive shaft by driving the injection gear.

      Standard thrust clearance
      0.15 to 0.55 mm (0.0059 to 0.0217 in.)

      Tech Tips

      If the clearance is not within the specified range, remove the injection gear again and reinstall it.

  5. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    A01E0JEE01

    1. Check that the injection gear in the timing gear case moves back and forth smoothly.

    2. Install a new O-ring to the pump.

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

    4. A01E2NBE01

      Align the set key on the drive shaft with the groove of the injection gear.

    5. A01DXRJ

      Install the pump with the 2 nuts.

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

    6. Set a new O-ring.

    7. A01E0MBE01

      Using SST, hold the crankshaft pulley and install the set nut.

      SST
      09213-58013
      09330-00021
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    8. A01DZC9E01

      Using a dial indicator, measure the thrust clearance of the injection pump shaft by moving the pump drive shaft pulley back and forth.

      Thrust clearance
      0.15 to 0.55 mm (0.0059 to 0.0217 in.)

      If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.

    9. A01DZOI

      Connect the 2 connectors.

    10. A01DVYA

      Connect the 2 fuel hoses.

  6. INSTALL CRANKSHAFT TIMING GEAR


    1. A01E1QCE02

      Align the "1" timing marks of the oil pump drive gear and crankshaft timing gear as shown in the illustration. Using SST, install the crankshaft timing gear.

      SST
      09223-00010

  7. INSTALL NO. 1 IDLE GEAR


    1. A01DVPDE08
      Text in Illustration
      *1 Oil Hole

      Install the No. 1 idle gear shaft to the cylinder block.

    2. A01DVKIE01

      Apply light coat engine oil to the No. 1 idler gear shaft shown in the illustration.

    3. A01DY8JE03
      Text in Illustration
      *1 Service Bolt

      Align the "4" timing marks of the No. 1 idle gear and injection gear, as shown in the illustration.

    4. Align the "5" timing marks of the No. 1 idle gear and crankshaft timing gear, and install the No. 1 idle gear, as shown in the illustration.

    5. Temporarily install the No. 1 idle gear with the idle gear thrust plate and 2 bolts.

    6. Secure the idle gears to the idle gear with the service bolt.

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

    7. Tighten the No. 1 idler gear with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    8. Remove the service bolt.

    9. Install the No. 1 crankshaft position sensor plate.

  8. INSTALL TIMING GEAR COVER


    1. A01DVAGE04
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the timing gear case.

    2. Remove any old seal packing (FIPG) material from the timing gear cover.

    3. A01DYL9E06
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Block, Three Bond 1207B or equivalent
      Standard seal diameter
      4.0 mm (0.157 in.)

      Note


      • After applying FIPG, install the gear cover within 3 minutes and tighten the bolts and nuts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.

    4. Install the cover with the 14 bolts and 2 nuts.

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

  9. 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.

  10. 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.

  11. INSTALL CRANKSHAFT PULLEY


    1. A01DZE1E02

      Align the pulley set key with the key groove of the pulley.

    2. Using SST, install the pulley bolt.

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

  12. INSTALL PUMP DRIVE SHAFT PULLEY


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

    2. Temporarily install the supply pump with the nut.

    3. A01E0MBE03

      Using SST, hold the crankshaft pulley and tighten the nut.

      SST
      09213-58013
      09330-00021
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    4. Install the No. 2 camshaft timing pulley flange and pump drive shaft pulley with the 4 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    5. A01E0PAE01

      Move the pump drive shaft pulley back and forth to check the thrust clearance of the pump drive shaft.

      Standard thrust clearance
      0.15 to 0.55 mm (0.0059 to 0.0217 in.)

      If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.

  13. 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 }

  14. 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 }

  15. INSTALL TIMING GEAR COVER INSULATOR


    1. Install the gear cover insulator with the bolt.

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

  16. INSTALL WATER PUMP ASSEMBLY


    1. A01DWA8

      Install a new gasket and the engine water pump with the 5 bolts and 2 nuts.

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

  17. INSTALL CYLINDER BLOCK INSULATOR


    1. Install the cylinder block insulator to the cylinder head.

  18. INSTALL NO. 2 TIMING BELT COVER


    1. A01E1J8E01

      Apply seal packing (FIPG) to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

    2. Install the No. 2 timing belt cover with the 4 bolts and nut.

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

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


    1. Install the timing belt idler and a new spacer with the bolt.

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

  20. INSTALL CAMSHAFT TIMING PULLEY


    1. A01DZE1E02

      Align the pulley set key with the key groove of the pulley.

    2. Using SST, install the pulley bolt.

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

  21. INSTALL TIMING BELT

    Click here

  22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DZAXE01

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

    2. Remove any old seal packing (FIPG) material from the cylinder head.

    3. A01E1YSE01

      Apply seal packing to the specific areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • Remove any oil from the contact surface.

      • Install the head cover within 3 minutes after applying seal packing.

      • Do Not start the engine for at least 2 hours after installing the seal packing.

    4. A01DZGHE01

      Install the a new gasket and cylinder head cover with the 10 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    5. Install 4 new Nozzle holder seals.

    6. Connect the ventilation hose.

    7. A01E177

      Connect the 4 connectors and install the 3 bolts.

  23. INSTALL NO. 4 INJECTION PIPE

    Note


    • When replacing the injector, also replace the injection pipe.

    • Keep the joints of the injection pipe clean.


    1. A01E10I

      Temporarily install the No. 4 injection pipe with the union nuts.

    2. Install new injection pipe clamp with the bolt.

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

      Note


      • Make sure that the inner-rubbers of the injection pipe fit inside the clamp.

      • When installing the pipe, check that the inner rubbers and the clamp are in their proper positions.

    3. A01DVF3E01

      Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

      Torque:
      without union nut wrench
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      with union nut wrench
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without SST" torque specification Click here.

      • Make sure union nut wrench and wrench are connected in a straight line.

    4. Using a union nut wrench, tighten the injection pipe union nuts on the injector side.

      Torque:
      without union nut wrench
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      with union nut wrench
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.

      • Make sure union nut wrench and wrench are connected in a straight line.

  24. INSTALL EGR COOLER WITH ELECTRIC EGR CONTROL VALVE AND NO. 2 EGR VALVE

    Click here

  25. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. A01E0JCE01

      Temporarily install the fuel inlet pipe with the union nuts.

      Note


      • If the supply pump is replaced, the fuel inlet pipe must be replaced.

      • Keep the fuel inlet pipe free of foreign matter.

    2. Install a new O-ring to the oil level gauge guide, and install the oil level gauge guide to the cylinder block.

      Note

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

    3. A01E1CP

      Temporarily install the stay of the oil level gauge guide to the intake manifold with the bolt.

    4. A01E1Y9E01

      Install the clamp with the bolt.

      Note

      Install the clamp so that the fuel inlet pipe marking can be seen on both sides of the clamp.

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

    5. Tighten the bolt of the oil level gauge guide stay.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. A01DXS1E02

      Using a 17 mm union nut wrench, tighten the injection pipe union nut on the common rail side.

      Torque:
      without union nut wrench
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      with union nut wrench
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.

      • Make sure union nut wrench and wrench are connected in a straight line.

    7. Using a 17 mm union nut wrench, tighten the injection pipe union nut on the supply pump side.

      Torque:
      without union nut wrench
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      with union nut wrench
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). If using a torque wrench with a length that is not 30 cm, calculate the torque specification for the torque wrench and union nut wrench based on the "without union nut wrench" torque specification Click here.

      • Make sure union nut wrench and wrench are connected in a straight line.

  26. INSTALL ENGINE ASSEMBLY

    Click here

  27. ADD ENGINE OIL


    1. Wipe the oil pan and drain plug.

    2. Install a new gasket and the drain plug.

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

    3. 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)

    4. Install the oil filler cap.

  28. 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. 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. A01DVKYE03

      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.

  29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  30. PERFORM REGISTRATION


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

    2. Perform pilot quantity learning Click here.

  31. 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.

  32. INSPECT FOR FUEL LEAK

    A01E2P1E01

    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.

  33. 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.

  34. INSPECT FOR OIL LEAK

  35. 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. A01E06UE01

      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.