ENGINE ASSEMBLY (for DPF) INSTALLATION

Note

When replacing the injector assemblies (including shuffling the injector assemblies between the cylinders), common rail assembly or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.
When replacing the fuel supply pump assembly, common rail assembly, cylinder block sub-assembly, cylinder head sub-assembly, cylinder head gasket or timing gear case assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
After removing the injection pipe sub-assemblies, clean them with a brush and compressed air.

INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
1. Install the front No. 1 engine mounting bracket LH with the 4 bolts.
  
  Torque:
  
  68 N*m { 693 kgf*cm, 50 ft.*lbf }
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
1. Install the front No. 1 engine mounting bracket RH with the 4 bolts.
  
  Torque:
  
  68 N*m { 693 kgf*cm, 50 ft.*lbf }
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
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.
INSTALL CAMSHAFT 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 }
3. Connect the sensor connector.
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 }
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.
INSTALL VANE PUMP ASSEMBLY
1. Install a new O-ring to the vane pump assembly.
2. Install the vane pump assembly with the 2 nuts.
  
  Torque:
  
  41 N*m { 418 kgf*cm, 30 ft.*lbf }
INSTALL VACUUM PUMP ASSEMBLY
1. Install 2 new O-rings to the vacuum pump assembly.
2. Install the vacuum pump assembly with the 2 nuts.
  
  Torque:
  
  21 N*m { 210 kgf*cm, 15 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 FUEL SUPPLY PUMP ASSEMBLY

Click here
INSTALL COMMON RAIL ASSEMBLY

Click here
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 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.
INSTALL FUEL HOSE BRACKET
1. Install the fuel hose bracket with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 FUEL PIPE
1. Install the No. 1 fuel pipe.
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 }
INSTALL GLOW PLUG ASSEMBLY

Click here
INSTALL INTAKE MANIFOLD

Click here
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

Click here
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.
INSTALL WATER OUTLET
1. Text in Illustration
  
  *1 Claw
  
  Install a new gasket to the cylinder head sub-assembly 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 }

Text in Illustration
*1	Claw

INSTALL THERMOSTAT

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

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.

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.
INSTALL EXHAUST MANIFOLD
1. Temporarily install a new gasket, the exhaust manifold, 8 new collars and the 8 plate washers to the cylinder head sub-assembly with 8 new nuts.
2. 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.
INSTALL TURBOCHARGER SUB-ASSEMBLY

Click here
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 }

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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

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

INSTALL GENERATOR BRACKET
1. Install the generator bracket with the bolt.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL GENERATOR ASSEMBLY
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.
INSTALL NO. 2 IDLE PULLEY ASSEMBLY
1. Install the spacer, No. 2 idle pulley assembly and pulley plate with the bolt.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)
1. Install the No. 1 viscous heater bracket sub-assembly with the 4 bolts.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)

Click here
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 }
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 }
INSTALL CRANKSHAFT PULLEY
1. Align the keyway of the crankshaft pulley with the key located on the crankshaft, and then slide the crankshaft pulley into place to install it.
2. Using SST, install the pulley bolt.
  
  SST
  
  09213-58014
  
  09330-00021
  
  Torque:
  
  365 N*m { 3722 kgf*cm, 269 ft.*lbf }
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 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 }
INSTALL ENGINE WIRE
1. Install the engine wire to the engine assembly.

Text in Illustration
*1	Timing Mark

Text in Illustration
*1	Timing Mark

INSTALL ENGINE HANGERS

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.

REMOVE ENGINE FROM ENGINE STAND
1. Attach an engine sling device and hang the engine assembly with a chain block.
2. Remove the engine assembly from the engine stand.
INSTALL ENGINE ASSEMBLY
1. Slowly lower the engine assembly into the engine compartment.
2. Install the engine assembly 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.
INSTALL REAR END PLATE
1. Install the rear end plate with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL FLYWHEEL SUB-ASSEMBLY
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. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-58014
  
  09330-00021
4. Install the flywheel sub-assembly to the crankshaft.
5. 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.
INSTALL CLUTCH DISC ASSEMBLY
1. 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.
INSTALL CLUTCH COVER ASSEMBLY
1. 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.
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
1. Using a dial indicator with roller instrument, measure the diaphragm spring tip alignment.
  
  Maximum misalignment
  
  0.5 mm (0.020 in.)
  - If the alignment is not as specified, use SST to adjust the diaphragm spring tip alignment.
  SST
  
  09333-00013
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 }
INSTALL MANUAL TRANSMISSION ASSEMBLY
- for 2WD: Click here
- for 4WD: Click here
CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Connect the cooler compressor assembly with the 4 bolts.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
CONNECT WIRE HARNESS
1. Connect the 6 ECM connectors.
2. for 4WD:
  
  Connect the 4WD control ECU connector.
3. Connect the 4 injector driver connectors.
4. Connect the 4 glow plug controller connectors.
5. Attach the clamp and connect the wire harness with the 2 nuts.
  
  Torque:
  
  13 N*m { 131 kgf*cm, 9 ft.*lbf }
6. Connect the ground cable with the bolt.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
7. Connect the 2 engine room junction block connectors.
8. Connect the engine room junction block wire with the nut.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
9. Install the side engine room relay block cover.
10. Install the upper relay block cover.
INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY

Click here
CONNECT UNION TO CONNECTOR TUBE HOSE
1. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure hose.
CONNECT FUEL HOSE
1. Connect the 2 fuel hoses to the No. 2 nozzle leakage pipe assembly and fuel supply pump assembly, and slide the 2 clamps to secure hose.
CONNECT PRESSURE FEED TUBE ASSEMBLY
1. Connect the pressure feed tube assembly to the vane pump assembly.
  
  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 to the vane pump assembly, and slide the clamp to secure hose.
CONNECT HEATER HOSE
1. Connect the 2 heater hoses to the water outlet and heater pipe, and slide the 2 clamps to secure hose.
INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here
INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
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. 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 }
INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here
INSTALL STARTER ASSEMBLY
- for 2.0 kW Type: Click here
- for 2.2 kW Type: Click here
- for 2.7 kW Type: Click here
INSTALL RADIATOR ASSEMBLY

Click here
INSTALL INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR

Click here
INSTALL AIR CLEANER ASSEMBLY
1. Install the air cleaner assembly 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. Connect the mass air flow meter connector and attach the wire harness clamp.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY CLAMP SUB-ASSEMBLY
1. Install the battery clamp sub-assembly with the bolt and nut.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
ADD POWER STEERING FLUID
ADD TRANSMISSION OIL
1. Stop the vehicle on a level surface.
2. Remove the filer 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
  
  2.6 liters (2.7 US qts, 2.3 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 }

Adhesive
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Maximum misalignment
0.5 mm (0.020 in.)

Oil grade
GL-4

Viscosity
SAE 75W-90, 80W or 80W-90

Capacity
2.6 liters (2.7 US qts, 2.3 Imp.qts)

ADD ENGINE OIL

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)

Install the oil filler cap.

INSTALL HOOD SUB-ASSEMBLY
1. Install the hood sub-assembly with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Connect the washer nozzle hose.
3. Adjust the hood sub-assembly Click here.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

Text in Illustration
*a	Reference (Active Test Operation)

OK
No DTCs are output.

Standard capacity
9.8 liters (10.4 US qts, 8.6 Imp. qts)

INSPECT POWER STEERING FLUID LEVEL

Keep the vehicle level.

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.

Start the engine and run it at idle.
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)
Check for foaming or emulsification. If foaming or emulsification is identified, bleed air from the power steering system.
With the engine idling, measure the fluid level in the oil reservoir.
Stop the engine.
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.
Check the fluid level.

PERFORM REGISTRATION
1. Perform registration of the injector compensation codes Click here.
2. Perform pilot quantity learning Click here.
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.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
INSPECT FOR EXHAUST GAS LEAK
- If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

Standard fluid temperature
75 to 80°C (167 to 176°F)

Maximum fluid level increase
5 mm (0.20 in.)

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

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.

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. 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.
  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.
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.
INSTALL NO. 2 ENGINE UNDER COVER

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER

Torque:

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