INSTALL COMMON RAIL ASSEMBLY RH

INSTALL INJECTION PIPE RH

INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY

CONNECT FUEL PUMP MOTOR WIRE

INSTALL COMMON RAIL ASSEMBLY LH

INSTALL NO. 5 NOZZLE LEAKAGE PIPE

INSTALL NO. 2 FUEL PIPE (w/ DPF)

INSTALL CYLINDER HEAD COVER SILENCER RH (w/ DPF)

INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

INSTALL INJECTION PIPE LH

INSTALL NO. 6 INJECTION PIPE SUB-ASSEMBLY

INSTALL CYLINDER HEAD COVER SILENCER LH (w/ DPF)

INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

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

INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

CONNECT ENGINE WIRE

INSTALL NO. 4 WATER BY-PASS PIPE

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

CONNECT FUEL HOSE

INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

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

INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

INSTALL NO. 4 AIR TUBE

INSTALL NO. 2 AIR HOSE

INSTALL NO. 3 AIR TUBE

INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

INSTALL INTAKE AIR CONNECTOR

TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

INSTALL NO. 1 GAS FILTER

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

INSTALL AIR TUBE SUB-ASSEMBLY LH

INSTALL CLUTCH HOSE (for Manual Transmission)

INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

INSTALL AIR TUBE SUB-ASSEMBLY RH

INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

CONNECT WATER HOSE SUB-ASSEMBLY

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

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

INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

BLEED CLUTCH LINE (for Manual Transmission)

INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

INSPECT FOR FUEL LEAK

INSPECT FOR COOLANT LEAK

INSPECT FOR OIL LEAK

INSTALL UPPER RADIATOR SUPPORT SEAL

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 the common rail with the 2 bolts.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 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}

Temporarily install a new No. 5 injection pipe by hand.

• NOTICE:

• Make sure there is no damage or foreign matter on the seal surfaces.

w/ DPF:

Temporarily install the used gasket and fuel filter to injection pump fuel pipe with the nut, bolt and union bolt.

w/o DPF:

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

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

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

Using a union nut wrench, tighten the No. 5 injection pipe ends.

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

• NOTICE:

• Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench ().

Remove the bolt and No. 2 injection pipe clamp.

Remove the union bolt and gasket.

w/ DPF:

Remove the bolt, nut and fuel filter to injection pump fuel pipe.

w/o DPF:

Remove the bolt, nut and No. 2 fuel pipe.

Install the fuel pump motor wire bracket to the No. 3 intake manifold with the bolt.

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

Connect the connector to the fuel supply pump.

Install the common rail with the 2 bolts.

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

Install a new gasket and the leakage pipe with the union bolt.

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

• NOTICE:

• Make sure there is no foreign matter or damage on the seal surface.

w/ DPF:

Connect the fuel hose.

Install the No. 2 fuel pipe with the union bolt and bolt.

• Torque:
• for union bolt :
• 29 N*m{ 296 kgf*cm, 21 ft.*lbf}
• for bolt:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Install the No. 4 fuel hose.

Install the cylinder head cover silencer with the 4 bolts.

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

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:

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:

Install the cylinder head cover silencer with the 4 bolts.

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

Install the vacuum transmitting pipe with the 3 bolts.

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

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 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.

LH Side:

RH Side:

Rear Side:

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}

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}

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}

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:

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}

Install a new gasket to the intake pipe.

Install the throttle body with the 2 bolts and 2 nuts.

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

Connect the throttle position sensor connector.

Connect the throttle motor connector.

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 intercooler support bracket with the 2 bolts.

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

for Manual Transmission:

Install the No. 1 gas filter.

Connect the hose to the intake pipe.

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 a new gasket to the intake pipe.

Install the throttle body with the 2 bolts and 2 nuts.

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

Connect the throttle position sensor connector.

Connect the throttle motor connector.

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.

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:

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 the negative (-) main battery and sub-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.

Warm up the engine and check for an engine oil leak.

Install the upper radiator support seal with the 7 clips.

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.