CHECK INJECTOR COMPENSATION CODE

INSTALL NO. 3 AND NO. 4 CAMSHAFTS

INSTALL NO. 1 AND NO. 2 CAMSHAFTS

CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

INSTALL FUEL INJECTOR LH

INSTALL FUEL INJECTOR RH

INSTALL NOZZLE HOLDER GASKET LH

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

INSTALL NOZZLE HOLDER SEAL LH

INSTALL OIL SEPARATOR ASSEMBLY

INSTALL NOZZLE HOLDER GASKET RH

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

INSTALL NOZZLE HOLDER SEAL RH

INSTALL CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)

INSTALL CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)

CONNECT NO. 3 VENTILATION HOSE

CONNECT NO. 2 VENTILATION HOSE

INSTALL VACUUM PUMP ASSEMBLY (w/ Intercooler)

INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ Intercooler)

INSTALL NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)

INSTALL NO. 2 IDLER PULLEY (w/ Viscous Heater)

INSTALL INJECTION PIPE RH

CONNECT NO. 2 ENGINE WIRE

INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

INSTALL COMMON RAIL ASSEMBLY LH

INSTALL INJECTION PIPE LH

INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY

INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

CONNECT ENGINE WIRE

CONNECT FUEL HOSE

INSTALL NO. 4 WATER BY-PASS PIPE

INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

INSTALL AIR TUBE SUB-ASSEMBLY LH

INSTALL CLUTCH HOSE (for Manual Transmission)

INSTALL AIR TUBE SUB-ASSEMBLY RH

INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

CONNECT WATER HOSE SUB-ASSEMBLY

INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

INSTALL NO. 4 AIR TUBE

INSTALL NO. 2 AIR HOSE

INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

INSTALL NO. 3 AIR TUBE

INSTALL NO. 1 AIR HOSE

INSTALL NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)

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

INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)

INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

INSTALL FAN SHROUD WITH FAN

INSTALL OIL COOLER TUBE (for Automatic Transmission)

INSTALL V-RIBBED BELT

INSTALL NO. 3 IDLER PULLEY (w/ Viscous Heater)

INSTALL NO. 1 IDLER PULLEY (w/ Viscous Heater)

INSTALL V-RIBBED BELT (w/ Viscous Heater)

INSTALL VANE PUMP ASSEMBLY

INSTALL RADIATOR RESERVOIR ASSEMBLY

INSTALL NO. 1 OIL RESERVOIR BRACKET

INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

INSTALL INTAKE AIR CONNECTOR

TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

INSTALL NO. 3 ENGINE ROOM WIRE

ADD ENGINE OIL

BLEED AIR FROM FUEL SYSTEM

BLEED CLUTCH LINE

INSPECT FOR CLUTCH FLUID LEAK

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

INSPECT FOR FUEL LEAK

INSPECT FOR OIL LEAK

INSPECT FOR COOLANT LEAK

WARM UP ENGINE

INSPECT FOR EXHAUST GAS LEAK

INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

INSTALL FRONT FENDER APRON SEAL REAR LH

INSTALL FRONT FENDER APRON SEAL FRONT LH

INSTALL FRONT FENDER APRON SEAL REAR RH

INSTALL FRONT FENDER APRON SEAL FRONT RH

INSTALL FRONT WHEEL

INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

INSTALL HOOD TO COWL TOP SEAL

INSTALL FRONT WIPER ARM RH

INSTALL FRONT WIPER ARM LH

INSTALL FRONT FENDER MAIN SEAL RH

INSTALL FRONT FENDER MAIN SEAL LH

INSTALL UPPER RADIATOR SUPPORT SEAL

INSPECT ENGINE IDLE SPEED

INSPECT MAXIMUM ENGINE SPEED

CHECK ENGINE OIL LEVEL

INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

After replacing fuel injector(s) with new one(s), input compensation code(s) of fuel injector(s) into ECM as follows:

• HINT:

Register compensation code.

Connect the intelligent tester to the DLC3.

Turn the ignition switch to ON.

• NOTICE:

• Do not start the engine.

Turn the tester on.

Enter the following menus: Powertrain / Engine / Utility / Injector Compensation.

Press Next.

Press Next again to proceed.

Select "Set Compensation Code".

Press Next.

Select the number of the cylinder corresponding to the fuel injector compensation code that you want to read.

Press Next.

Register compensation code.

Press Input.

Manually input the cylinder compensation code using the keyboard on the tester screen. The code is a 30 digit, alphanumeric value printed on the injector head portion.

• HINT:

• Each fuel injector compensation code is unique. The compensation code for each selected cylinder must be input into the tester correctly.

Confirm that the compensation code for the selected cylinder is correct, and then press OK.

Check that the compensation code displayed on the screen is correct by comparing it with the 30 digit alphanumeric value on the head portion of the fuel injector.

• NOTICE:

• If an incorrect fuel injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

• HINT:

If a wrong compensation code is input or read, return to the Input Value screen by pressing Input.

The saving process may fail due to a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and repeat this operation.

Press Next to register the compensation code in the ECM.

• HINT:

If the registration process fails, the compensation code may be incorrect. Check the compensation code again.

If the input compensation code fails to register even though it is input correctly, there may be a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and restart this operation.

If you want to continue with other compensation code registrations, press Next. To finish the registration, press Cancel.

Turn the ignition switch off and then turn the tester off.

Wait for at least 30 seconds.

Turn the ignition switch to ON and then turn the tester on.

Clear DTC P1601 stored in the ECM using the tester ().

w/o Intercooler:

When replacing the No. 4 camshaft with a new one, install a new hole plug ().

Add more than 19 cc (1.16 cu. in.) of engine oil into the cylinder head side oil holes.

Apply engine oil to the rollers of the valve rocker arms and the camshaft housing of the cylinder head.

Install the No. 3 and No. 4 camshafts.

Place the camshafts into the cylinder head.

• NOTICE:

• Before and after setting the camshafts, firmly set the rocker arms to the lash adjusters.

Install the No. 4 camshaft bearing cap.

Install the No. 3 camshaft bearing caps.

Temporarily install the No. 3 and No. 4 camshaft oil feed pipes with the 8 bolts by hand.

• NOTICE:

• If even one of the pipe bolt holes does not match its camshaft bearing cap bolt hole, replace the camshaft oil feed pipe.

• HINT:

• The pipe is bent on the intake side, and straight on the exhaust side.

Temporarily install the 2 union bolts by hand.

Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

• Torque:
• for 12 mm head bolt of No. 4 camshaft bearing cap:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for 10 mm head bolt of No. 3 camshaft bearing cap:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Tighten the 2 union bolts.

• Torque:
• 17 N*m{ 173 kgf*cm, 13 ft.*lbf}

Remove the service bolt from the No. 4 camshaft timing gear.

• NOTICE:

• Do not drop the bolt into the engine.

• HINT:

• If the bolt is difficult to remove, rotate the camshaft and remove the bolt. Then realign the matchmarks of the No. 3 and No. 4 camshaft timing gears.

Temporarily install the No. 2 timing chain and No. 2 camshaft timing sprocket to the No. 3 camshaft with the 2 bolts.

Using SST, hold the No. 2 camshaft timing sprocket. Tighten the 2 bolts.

• SST
• 09960-10010(09962-01000,09963-01000)

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

Rotate the crankshaft pulley clockwise so that the 2 remaining pump drive shaft gear bolts can be installed.

Temporarily install the 2 bolts to the No. 3 camshaft.

Using SST, hold the No. 2 camshaft timing sprocket. Tighten the 2 bolts.

• SST
• 09960-10010(09962-01000,09963-01000)

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

Remove the hexagon wrench from the No. 2 chain tensioner.

Remove the adhesive from the threads of the taper screw plug and the bolt hole of the timing gear case.

Apply adhesive to 3 or more threads of the taper screw plug.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a 10 mm hexagon wrench, install the taper screw plug.

• Torque:
• 15 N*m{ 153 kgf*cm, 11 ft.*lbf}

Add more than 19 cc (1.16 cu. in.) of engine oil into the cylinder head side oil holes.

Apply engine oil to the rollers of the valve rocker arms and the camshaft housing of the cylinder head.

Install the No. 1 and No. 2 camshafts.

Apply engine oil to the camshaft journals, lobes, thrust portion and gears.

Align the matchmarks of the No. 1 and No. 2 camshaft timing gears as shown in the illustration.

Place the 2 camshafts into the cylinder head.

• NOTICE:

• Before and after setting the camshafts, firmly set the rocker arms to the lash adjusters.

Install the No. 1 camshaft bearing cap.

Install the No. 3 camshaft bearing caps.

Temporarily install the No. 1 and No. 2 camshaft oil feed pipes with the 8 bolts by hand.

• NOTICE:

• If even one of the pipe bolt holes does not match its camshaft bearing cap bolt hole, replace the camshaft oil feed pipe.

• HINT:

• The pipe is bent on the intake side, and straight on the exhaust side.

Temporarily install the 2 union bolts by hand.

Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

• Torque:
• for 12 mm head bolt of No. 1 camshaft bearing cap:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
• for 10 mm head bolt of No. 3 camshaft bearing cap:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Tighten the 2 union bolts.

• Torque:
• 17 N*m{ 173 kgf*cm, 13 ft.*lbf}

Remove the service bolt from the No. 1 camshaft timing gear.

• NOTICE:

• Do not drop the bolt into the engine.

• HINT:

• If the bolt is difficult to remove, rotate the camshaft and remove the bolt. Then realign the matchmarks of the No. 1 and No. 2 camshaft timing gears.

Temporarily install the No. 1 timing chain and No. 1 camshaft timing sprocket to the No. 2 camshaft.

Temporarily install the pump drive shaft gear with the 2 bolts.

Using SST, hold the pump drive shaft gear. Tighten the 2 bolts.

• SST
• 09960-10010(09962-01000,09963-01000)

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

Rotate the crankshaft clockwise so that the 2 remaining pump drive shaft gear bolts can be installed.

Temporarily install the 2 bolts to the pump drive shaft gear.

Using SST, hold the pump drive shaft gear. Tighten the 2 bolts.

• SST
• 09960-10010(09962-01000,09963-01000)

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

Remove the hexagon wrench.

Remove the adhesive from the threads of the taper screw plug and the bolt hole of the timing gear case.

Apply adhesive to 3 or more threads of the taper screw plug.

• Adhesive:
• Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Using a 10 mm hexagon wrench, install the taper screw plug.

• Torque:
• 15 N*m{ 153 kgf*cm, 11 ft.*lbf}

Rotate the crankshaft clockwise 3 times or more, and check that the timing marks of the camshafts (1 dot mark each) align. If the timing marks of the camshafts do not align, repeat the "Install No. 3 and No. 4 Camshafts" and "Install No. 1 and No. 2 Camshafts" procedures.

Install 4 new injection nozzle seats to the cylinder head.

Apply a light coat of clean engine oil to 4 new O-rings.

Install the O-rings to each injector as shown in the illustration.

Insert the 4 injectors into the cylinder head.

• NOTICE:

For an injector that has been replaced with a new injector, register the injector compensation code.

Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

• NOTICE:

The fork portion of the nozzle holder clamp must be set on the injector.

Before tightening the bolts, check that the nozzle holder clamp is set properly.

To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a later step.

When tightening the bolts, be careful not to tilt the bolt and clamp.

Do not reuse the washer.

Temporarily install the common rail LH with the 2 bolts.

Temporarily install 4 new injection pipes to the common rail and injector.

Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces. If scratches or dents are present, replace the nozzle leakage pipe.

Set the leakage pipe and 5 new gaskets in place.

Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

Text in Illustration

Union Bolt

• HINT:

• To position the injectors, loosely tighten the 4 hollow screws and union bolt.

Tighten the 4 holder clamp bolts.

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

Remove the 4 injection pipes.

Remove the 2 bolts and common rail LH.

Tighten the 4 hollow screws.

• Torque:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

• NOTICE:

• If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

Tighten the union bolt.

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

• NOTICE:

• If the union bolt is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

Install 4 new injection nozzle seats to the cylinder head.

Apply a light coat of clean engine oil to 4 new O-rings.

Install the O-rings to each injector as shown in the illustration.

Insert the 4 injectors into the cylinder head.

• NOTICE:

For an injector that has been replaced with a new injector, register the injector compensation code.

Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

• NOTICE:

The fork portion of the nozzle holder clamp must be set on the injector.

Before tightening the bolts, check that the nozzle holder clamp is set properly.

To tighten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a later step.

When tightening the bolts, be careful not to tilt the bolt and clamp.

Do not reuse the washer.

Temporarily install 4 new injection pipes to the common rail and injector.

Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces. If scratches or dents are present, replace the nozzle leakage pipe.

Set the leakage pipe and 5 new gaskets in place.

Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

Text in Illustration

Union Bolt

• HINT:

• To position the injectors, loosely tighten the 4 hollow screws and union bolt.

Tighten the 4 holder clamp bolts.

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

Remove the 4 injection pipes.

Tighten the 4 hollow screws.

• Torque:
• 18 N*m{ 184 kgf*cm, 13 ft.*lbf}

• NOTICE:

• If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

Tighten the union bolt.

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

• NOTICE:

• If the union bolt is accidentally tightened beyond the torque specification, it must be replaced together with the nozzle leakage pipe.

Press 4 new nozzle holder gaskets into the cylinder head cover LH.

• NOTICE:

• After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

Apply seal packing as shown in the illustration.

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

Text in Illustration

Seal Packing

• NOTICE:

Install a new gasket to the cylinder head cover.

• NOTICE:

• Remove any oil from the contact surface.

Temporarily install the cylinder head cover with the 17 bolts. Tighten the 17 bolts in the order shown in the illustration.

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

• HINT:

• After tightening the bolts, check that the bolts at step 11 and 19 are tightened to the specified torque.

Press 4 new holder seals into the cylinder head cover LH.

Install a new gasket to the oil separator.

• NOTICE:

• Remove any oil from the contact surface.

Install the oil separator with the 3 bolts.

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

Press 4 new nozzle holder gaskets into the cylinder head cover RH.

• NOTICE:

• After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

Apply seal packing as shown in the illustration.

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

Text in Illustration

Seal Packing

• NOTICE:

Install a new gasket to the cylinder head cover.

• NOTICE:

• Remove any oil from the contact surface.

Temporarily install the cylinder head cover with the 18 bolts. Tighten the 18 bolts in the order shown in the illustration.

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

• HINT:

• After tightening the bolts, check that the bolts at step 11 and 20 are tightened to the specified torque.

Press 4 new holder seals into the cylinder head cover LH.

Install the cylinder head cover silencer with the 3 bolts.

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

Install the cylinder head cover silencer with the 3 bolts.

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

Apply engine oil to 2 new O-rings.

Install the 2 O-rings to the vacuum pump.

Install the vacuum pump so that the coupling teeth of the vacuum pump (labeled A) and the groove of the camshaft (labeled B) are aligned.

• NOTICE:

• Be careful not to damage the O-ring.

Install the vacuum pump with the 3 bolts.

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

• NOTICE:

• Confirm that the vacuum pump is not at an angle, and that there is no clearance between the fitting surfaces.

Install the vacuum transmitting pipe with the 3 bolts.

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

w/ Intercooler:

Connect the 2 vacuum hoses.

Install the vacuum switching valve with the bolt.

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

Connect the 2 vacuum hoses.

Temporarily install the No. 2 idler pulley bracket with the bolt.

Temporarily install the 2 bolts to the No. 2 idler pulley bracket bolt hole.

Uniformly tighten the 3 bolts of the No. 2 idler pulley bracket in the order shown in the illustration.

• Torque:
• 49 N*m{ 495 kgf*cm, 36 ft.*lbf}

Install the collar, No. 2 idler pulley and cover with the bolt.

• Torque:
• 49 N*m{ 495 kgf*cm, 36 ft.*lbf}

Using a union nut wrench, install 4 new injection pipes.

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

• NOTICE:

w/ Intercooler:

Install the 4 injection pipe clamps with the 2 nuts.

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

Connect the No. 2 engine wire with the 3 bolts.

• Torque:
• for bolt A:
• 13 N*m{ 133 kgf*cm, 10 ft.*lbf}
• for bolt B:
• 32 N*m{ 326 kgf*cm, 24 ft.*lbf}

Attach the 2 wire harness clamps.

w/ DPF:

• NOTICE:

• Check for damage and foreign matter on the fuel pipe installation surface of the fuel supply pump.

• If there is foreign matter, remove it from the installation surface.

• If the installation surface is damaged, replace the fuel supply pump.

w/o DPF:

Install the common rail with the 2 bolts.

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

Using a union nut wrench, install the 4 new injection pipes.

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

• NOTICE:

w/ Intercooler:

Install the 4 injection pipe clamps with the 2 nuts.

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

w/ EGR System:

w/o EGR System:

Temporarily install a new gasket and the No. 2 fuel pipe with the union bolt, nut and bolt.

Tighten the union bolt, nut and bolt in the order shown in the illustration.

• Torque:
• for union bolt:
• 25 N*m{ 255 kgf*cm, 18 ft.*lbf}
• for bolt and nut:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Install the No. 2 injection pipe clamp with the bolt.

• Torque:
• 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}

Connect the fuel hose to the No. 5 nozzle leakage pipe.

RH side:

Install the engine wire harness protector with the 3 bolts labeled A.

Connect the 7 connectors.

Attach the wire harness clamp.

Install the wire harness bracket with the bolt labeled B.

Install the glow plug wire harness with the nut labeled C.

• Torque:
• 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}

Attach the 5 wire harness clamps and connect the 4 connectors.

LH side:

Install the engine wire harness protector with the 2 bolts labeled A.

Connect the 8 connectors.

Install the wire harness bracket with the bolt labeled B.

for RHD:

Connect the wire harness with the wire harness clamp holder labeled C.

Attach the 3 wire harness clamps and connect the 2 connectors.

Attach the 3 wire harness clamps and connect the 4 connectors.

Connect the wire harness with the wire harness clamp holder labeled B.

Attach the ground wire clamp labeled A to the relay block side.

Install the ground wire to the body panel with the bolt.

• Torque:
• 8.4 N*m{ 87 kgf*cm, 74 in.*lbf}

Connect the 4 connectors to the injector driver.

Install the ground wire with the bolt.

• Torque:
• 8.4 N*m{ 86 kgf*cm, 74 in.*lbf}

Connect the wire harness holder to the relay block.

Connect the 4 connectors to the relay block.

Connect the wire harness with the wire harness clamp holder.

for RHD:

Connect the wire harness with the wire harness clamp holder.

Connect the ECM connector to the ECM.

Connect the wire harness with the wire harness clamp holder.

Attach the wire harness tab labeled A to the relay block.

Connect the 4 connectors to the relay block.

for LHD:

w/ EGR System:

w/o EGR System:

Connect the 3 water hose ends, and temporarily install the No. 4 water by-pass pipe with the 2 bolts and nut.

First tighten the 2 bolts and then tighten the nut.

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

Connect the 2 water hose ends, and install the No. 3 water by-pass pipe with the 2 bolts.

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

Temporarily install the flare nut of the tube connector to flexible hose tube to the clutch tube to release cylinder 2 way by hand.

Temporarily install the tube connector to flexible hose tube with the 2 bolts.

Tighten the bolt labeled A.

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

• NOTICE:

• Tighten the bolt labeled B after installing the clutch hose.

Install the air tube to the throttle body.

Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

Connect the clutch hose to the air tube with the bolt labeled A.

Temporarily install the clutch hose to the clutch master cylinder tube to flexible hose tube and tube connector to flexible hose tube, and fix it in place with the 2 clips.

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

Tighten the bolt labeled B.

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

Tighten the flexible hose tube.

• NOTICE:

• HINT:

Using a 10 mm union nut wrench, tighten the 2 flare nuts of the flexible hose tube.

• Torque:
• without union nut wrench:
• 15 N*m{ 154 kgf*cm, 11 ft.*lbf}
• with union nut wrench:
• 14 N*m{ 141 kgf*cm, 10 ft.*lbf}

Using a 10 mm union nut wrench, tighten the flare nut of the flexible hose tube.

• Torque:
• without union nut wrench:
• 15 N*m{ 154 kgf*cm, 11 ft.*lbf}
• with union nut wrench:
• 14 N*m{ 141 kgf*cm, 10 ft.*lbf}

Install the air tube to the throttle body.

Align the embossed mark of the throttle body with the paint mark of the No. 4 air hose.

Tighten the hose clamp so that it is 7 to 11 mm (0.276 to 0.433 in.) from the end of the hose as shown in the illustration.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

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

Install the O-ring to the No. 2 engine oil level dipstick guide.

Install the No. 2 engine oil level dipstick guide with the 2 bolts.

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

Connect the ventilation hose to the cylinder head cover RH.

Connect the wire harness clamp to the No. 2 engine oil level dipstick guide bracket.

Connect the No. 2 air cleaner pipe to the No. 2 intake air connector pipe.

Connect the ventilation hose to the oil separator.

Install the pipe with the bolt.

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

Tighten the hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

Install the No. 4 air tube with the bolt.

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

Tighten the hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

• Make sure the direction of the hose clamp is as shown in the illustration.

Install the suction hose with the bolt.

• Torque:
• 9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Connect the No. 2 air hose with the hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

Connect the No. 1 air cleaner pipe to the No. 1 intake air connector pipe.

Install the pipe with the bolt.

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

Tighten the hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

Install the No. 3 air tube with the bolt.

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

Tighten the hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

• Make sure the direction of the hose clamp is as shown in the illustration.

Install the wire harness bracket with the bolt.

Install the ground wire with the nut, and attach the wire harness clamp.

• Torque:
• 8.4 N*m{ 85 kgf*cm, 74 in.*lbf}

Connect the No. 1 air hose with the hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

Install the No. 1 idler pulley bracket with the bolt.

• Torque:
• 49 N*m{ 495 kgf*cm, 36 ft.*lbf}

Install the heater assembly with the 2 bolts.

• Torque:
• 48.5 N*m{ 495 kgf*cm, 36 ft.*lbf}

Connect the 2 heater hoses.

Using pliers, grip the claws of the clips and slide the 2 clips.

Connect the connector and attach the clamp.

Connect the 4 water hose ends, and install the water pipe with the 4 bolts.

• Torque:
• 9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Install a new gasket to the air tube LH.

• HINT:

• Install the gasket with the protrusion facing as shown in the illustration.

Install the No. 2 cool air inlet with the 3 nuts and bolt.

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

Connect the No. 2 air hose to the No. 2 cool air inlet.

Tighten the No. 2 air hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

Install a new gasket to the air tube RH.

• HINT:

• Install the gasket with the protrusion facing as shown in the illustration.

Install the No. 1 cool air inlet with the 3 nuts and bolt.

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

Connect the vacuum hose, intake air temperature sensor connector and turbo pressure sensor connector.

Connect the No. 1 air hose to the No. 1 cool air inlet.

Tighten the No. 1 air hose clamp.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

Install a new gasket to the air tube RH.

• HINT:

• Install the gasket with the protrusion facing as shown in the illustration.

Install a new gasket to the air tube LH.

• HINT:

• Install the gasket with the protrusion facing as shown in the illustration.

Align the No. 1 and No. 2 air hoses and intercooler pipes and connect them, and install the intercooler with the 2 bolts and 2 nuts labeled A in the illustration.

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

Temporarily install the 4 nuts labeled B in the illustration.

Tighten the air tube LH and RH with the 4 nuts labeled B shown in the illustration.

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

Connect the vacuum hose, intake air temperature sensor connector and turbo pressure sensor connector.

Tighten the clamp of the No. 2 air hose.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

Tighten the clamp of the No. 1 air hose.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

• HINT:

Install the shroud together with the fluid coupling fan between the radiator and engine components.

• NOTICE:

• Be careful not to damage the radiator core.

Temporarily install the fluid coupling fan to the fan bracket with the 4 nuts.

• HINT:

• Tighten the nuts as much as possible by hand.

Attach the shroud claws to the radiator.

Install the shroud with the 2 bolts.

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

Tighten the 4 nuts of the fluid coupling fan.

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

Temporarily install the oil cooler tube to the fan shroud with the bolt labeled A. Install the bolt labeled B. Then tighten the bolt labeled A to the specified torque.

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

Connect the inlet No. 4 oil cooler hose as shown in the illustration.

• NOTICE:

• Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Connect the inlet No. 2 and No. 3 oil cooler hoses as shown in the illustration.

• NOTICE:

• Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Connect the inlet and outlet No. 1 oil cooler hoses as shown in the illustration.

• NOTICE:

• Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Pass the hose through the flexible hose clamp and close the clamp shown in the illustration.

Attach a wrench to the V-ribbed belt tensioner bracket and turn the wrench clockwise.

Install the V-ribbed belt as shown in the illustration.

Check that the belt fits properly in the ribbed grooves.

• HINT:

• Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

• If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt.

Align the No. 3 idler pulley bracket knock pin and No. 1 idler pulley bracket knock pin hole and install the No. 3 idler pulley with the nut.

• Torque:
• 88 N*m{ 898 kgf*cm, 64 ft.*lbf}

Install the collar, No. 1 idler pulley and cover with the bolt.

• Torque:
• 49 N*m{ 495 kgf*cm, 36 ft.*lbf}

Install the V-ribbed belt as shown in the illustration.

Temporarily install the lock nut, and turn the bolt clockwise.

Using a belt tension gauge, inspect the belt tension.

• Standard Belt Tension:

• Item	Condition	Specified Condition
  New belt	5 to 35°C (41 to 95°F)	550 to 800 N (56 to 82 kgf, 123.6 to 179.8 lbf)
  Used belt	5 to 35°C (41 to 95°F)	300 to 500 N (31 to 51 kgf, 67.4 to 112.4 lbf)

• HINT:

Tighten the nut.

• Torque:
• 40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Check that the belt fits properly in the ribbed grooves.

• HINT:

• Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

• If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt.

Apply a light coat of engine oil to a new O-ring, and install it to the vane pump.

Install the vane pump with 2 new nuts.

• Torque:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Install the radiator reservoir with the 3 bolts.

Connect the 2 hoses to the upper radiator tank and water inlet.

• HINT:

• Make sure the directions of the hose clamps are as shown in the illustration.

Install a new bracket with the 2 bolts.

• Torque:
• 4.5 N*m{ 46 kgf*cm, 40 in.*lbf}

Install the vane pump oil reservoir to the bracket.

Connect the intake air connector to the No. 1 and No. 2 air cleaner pipes.

Install the connector with the 2 bolts.

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

Tighten the 2 hose clamps.

• Torque:
• 6.3 N*m{ 64 kgf*cm, 56 in.*lbf}

Attach the 3 wire harness clamps.

w/o Viscous Heater:

Connect the connector to the water temperature sensor.

w/ Viscous Heater:

Connect the 2 connectors to the water temperature sensor and viscous with magnet clutch heater.

Temporarily install the air cleaner hose to the intake air connector.

Connect the air cleaner cap to the air cleaner hose, and install the air cleaner cap with the 4 clamps.

Connect the mass air flow meter connector and attach the wire harness clamp to the air cleaner cap.

Attach the wire harness clamp.

Align the protrusion of the air cleaner cap and the concave portion of the air cleaner hose.

Tighten the 2 hose clamps.

• Torque:
• 2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Install the No. 3 engine room wire to the main battery and sub-battery positive terminals with the 2 nuts.

• Torque:
• 7.6 N*m{ 77 kgf*cm, 67 in.*lbf}

Connect the No. 3 engine room wire with the 4 clamps.

Add fresh oil.

• Standard Engine Oil:

• Item	Oil Grade	Oil Viscosity (SAE)
  w/ DPF	ACEA C2 (Using engine oil other than ACEA C2 may damage catalytic converter)	- 0W-30 - 5W-30 (0W-30 is best choice for fuel economy and good starting in cold weather)
  w/o DPF	G-DLD-1, API CF-4, API CF or ACEA B1 (You may also use API CE or CD)	- 5W-30 - 10W-30 - 15W-40 - 20W-50 (5W-30 is best choice for fuel economy and good starting in cold weather).

• Standard Capacity:

• Item	Specified Condition
  Drain and refill with oil filter change	9.2 liters (9.7 US qts, 8.1 Imp. qts)
  Drain and refill without oil filter change	8.2 liters (8.7 US qts, 7.2 Imp. qts)
  Dry fill	9.9 liters (10.5 US qts, 8.7 Imp. qts)

Install the oil filler cap.

Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

• NOTICE:

Check if the engine starts.

• NOTICE:

Turn the engine switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch ON (IG) and turn the intelligent tester on.

Clear the DTCs ().

Start the engine.*1

Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

• HINT:

• 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.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

Clear the DTCs ().

• HINT:

• 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.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine and ECT / DTC.

Read Current DTCs.

• OK:
• No DTCs are output.

Remove the release cylinder bleeder plug cap.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled.

Tighten the bleeder plug.

• Torque:
• 11 N*m{ 110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.

Connect the cables to negative (-) main battery and sub-battery battery terminals.

Remove the engine air bleed cap.

Connect a clear hose to the engine air bleed pipe.

Using a wrench, remove the vent plug.

Fill the radiator with TOYOTA SLLC to the radiator reservoir filler neck.

• HINT:

• Pour TOYOTA SLLC until it spills out of the engine air bleed pipe.

• Standard Capacity (for Automatic Transmission):

• Item	Specified Condition
  Front heater only	14.8 liters (15.6 US qts, 13.0 Imp. qts)
  Front heater and rear heater	17.6 liters (18.6 US qts, 15.5 Imp. qts)
  Front heater with viscous heater	15.2 liters (16.1 US qts, 13.4 Imp. qts)
  Front heater and rear heater with viscous heater	18.0 liters (19.0 US qts, 15.4 Imp. qts)

• Standard capacity (for Manual Transmission):
• 15.4 liters (16.3 US qts, 13.5 Imp. qts)

• NOTICE:

• Do not substitute plain water for engine coolant.

• HINT:

• 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).

Install the vent plug.

• Torque:
• 2.0 N*m{ 20 kgf*cm, 18 in.*lbf}

• NOTICE:

• Do not tighten the plug to 5.0 N*m (51 kgf*cm, 44 in.*lbf) or more, as the plug will be damaged.

Disconnect the clear hose from the engine air bleed pipe.

Install the engine air bleed cap when coolant comes out.

Install the radiator reservoir cap.

Start the engine.

• NOTICE:

• Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the FULL line.

Maintain an engine speed of 3000 rpm for approximately 10 minutes so that the thermostat opens and air bleeding is performed.

• CAUTION:

• NOTICE:

• HINT:

• The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

Stop the engine, and wait until the engine 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.

Check that the coolant level is between the FULL and LOW lines.

If the coolant level is above the FULL line, drain coolant so that the coolant level is between the FULL and LOW lines.

Perform Active Test.

Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 17.8 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 cylinder head.

Install the No. 1 engine under cover with the 10 bolts.

• Torque:
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}

Install the front fender splash shield RH with the clip, and then install the 3 bolts and 2 screws.

Install the front fender splash shield LH with the clip, and then install the 3 bolts and screw.

Install the front fender apron seal rear LH with the 4 clips.

w/o KDSS:

Install the front fender apron seal front LH with the 4 clips.

w/ KDSS:

Install the front fender apron seal front LH with the 3 clips.

Install the front fender apron seal rear RH with the 4 clips.

Install the front fender apron seal front RH with the 3 clips.

Install the engine cover with the 2 nuts.

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

Push the ventilator louver in the direction indicated by the arrow in the illustration to attach the 17 claws and 2 clips and install the ventilator louver.

Attach the 12 clips and 4 clamps to install the hood to cowl top seal.

Install the washer hose.

Stop the wiper motor at the automatic stop position.

Clean the wiper pivot serration with a wire brush.

Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade comes to the position shown in the illustration.

• Standard Measurement:

• Position	Specified Condition
  B	20.0 to 40.0 mm (0.787 to 1.57 in.)

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

• HINT:

• Hold down the wiper arm hinge with your hand while tightening the nut.

Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

Stop the wiper motor at the automatic stop position.

Clean the wiper pivot serration with a wire brush.

Install the wiper arm and blade with the nut. Make sure that the wiper arm and blade comes to the position shown in the illustration.

• Standard Measurement:

• Position	Specified Condition
  A	16.8 to 36.8 mm (0.661 to 1.45 in.)

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

• HINT:

• Hold down the wiper arm hinge with your hand while tightening the nut.

Attach the 3 clips to install the fender main seal.

Install the upper radiator support seal with the 7 clips.

When using the GTS:

When not using the GTS:

Warm up and stop the engine.

Connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

• SST
• 09843-18040

Text in Illustration

*a	Front view of DLC3

Inspect the engine idle speed.

• Standard Idle Speed:

• Item	Specified Condition
  for Automatic Transmission	550 to 750 rpm
  for Manual Transmission	500 to 600 rpm

Disconnect the tester probe from terminal 9 (TAC) of the DLC3.

Start the engine.

Fully depress the accelerator pedal.

Check the maximum engine speed.

• Maximum engine speed:
• 4700 to 4900 rpm

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.

• NOTICE:

• Do not fill engine oil above the full level mark.

• HINT:

• A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.

• When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.

Check that the engine coolant level is between the LOW and FULL lines when the engine is cold.

If the engine coolant is low, check for leaks and add "TOYOTA Super Long Life Coolant (SLLC)" or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the FULL line.

• NOTICE:

• Do not substitute plain water for engine coolant.