Camshaft (W/O Dpf) Installation

Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

HINT:

Set the No. 1 cylinder to 90° BTDC/compression to prevent the top of the piston from hitting against the valve head.

Install the camshafts.

1. Apply engine oil to the thrust portion of the camshaft.
   

2. Place the camshaft on the cylinder head with the key groove facing upward.
   

   Text in Illustration

   *1	Key Groove
   *a	Upward





3. Align the timing marks (1-dot marks) of the camshaft drive and driven main gears and set the No. 2 camshaft in place.
   

Remove any old seal packing (FIPG material) from the camshaft bearing cap.

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

Seal packing:

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

Standard seal diameter:

4 mm (0.157 in.)

NOTICE:

1. Do not allow seal packing to contact the oil passage of the bearing cap.
   
2. After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.
   
3. Do not start the engine for at least 2 hours after installation.
   

Install the 5 bearing caps to their proper locations.

Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Install a new camshaft oil seal.

1. Apply MP grease to the lip of a new oil seal.
   

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.
   

   SST

   09608-06041
   

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

Seal packing:

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

NOTICE:

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

Clean the bolts and their holes.

Apply adhesive to 2 or 3 threads at the end of each of the 4 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

Torque:

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

Install the camshaft timing pulley.

Tighten the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

Torque:

98 N*m{1000 kgf*cm, 72 ft.*lbf}

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}

Check that the idler pulley moves smoothly.
If the idler pulley does not move smoothly, check the installation condition of the idler and washer.

Check that the timing marks are aligned as shown in the illustration.

NOTICE:

1. Make sure that the engine is cold.
   
2. When turning the crankshaft, the valve heads will hit against the piston. Do not turn the crankshaft more than necessary.
   

HINT:

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.

Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

Place the tensioner upright. Then set a press on the top of the tensioner.

NOTICE:

1. Do not scratch or deform the rod end.
   
2. Press in the tensioner rod.
   
3. Protect the tip of the push rod with a cloth in order to prevent damage.
   

Using the press, slowly push in the push rod using 981 to 9800 N (100 to 999 kgf, 220 to 2203 lbf) of force.

NOTICE:

Do not apply a load of over 9800 N (999 kgf, 2203 lbf) to the push rod.

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.

Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

Tighten the 2 bolts.

Torque:

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

NOTICE:

Uniformly tighten the 2 bolts.

Remove the 1.5 mm hexagon wrench from the tensioner.

Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

Install the timing belt cover and 6 washers with the 6 bolts.

Torque:

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

Install 4 new injection nozzle seats to the cylinder head.

Apply a small amount of clean engine oil to 4 new O-rings.

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

Insert the 4 injectors into the cylinder head.

NOTICE:

1. Insert the injector until it touches the injection nozzle seat surface.
   
2. After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
   
3. Always return an injector to the same place it was removed from.
   

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

1. w/ EGR Cooler: (HILUX_TGN26 RM0000012XK043X_02_0003.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM0000012XK03ZX_02_0003.html)
   

Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

NOTICE:

1. The fork portion of the nozzle holder clamp must be set on the injector.
   
2. Before tightening the bolts, check that the No. 1 nozzle holder clamps are set properly.
   
3. To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in a following step.
   
4. When tightening the bolts, pay attention so as not to tilt the bolt or clamp.
   
5. Do not reuse the washer.
   
6. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.
   

HINT:

Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.

Temporarily install the 4 injection pipes with the union nuts.

HINT:

To position the injectors, loosely tighten the union nuts.

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 nozzle leakage pipe and 5 new gaskets in place.

Apply a small amount of oil to the 4 injector hollow screws and union bolt.

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

Tighten the 4 holder clamp bolts.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Remove the 4 injection pipes.

Tighten the 4 injector hollow screws in order from 1 to 4.

Torque:

16 N*m{163 kgf*cm, 12 ft.*lbf}

NOTICE:

If an injector hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

Tighten the union bolt.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

NOTICE:

If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

Check that there are no leaks from the nozzle leakage pipe connection.

1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).
   

   Part No.:

   23762-27010 (No. 2 nozzle leakage pipe)
   

   SST

   09280-00010
   

   Torque:

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

2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.
   





3. Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe and maintain 100 kPa (1.0 kgf/cm², 15 psi) of pressure for 60 seconds to check that no bubbles form.
   

   SST

   09992-00242
   

   NOTICE:

   Before checking for leakage, be sure to remove the ball and spring in the check valve.

4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.
   

5. Remove SST, the No. 2 nozzle leakage pipe and gasket.
   

   NOTICE:

   Never reinstall the disassembled check valve to the engine.

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

NOTICE:

1. Do not install the No. 3 cylinder head cover gaskets at an angle.
   
2. Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.
   

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

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

Seal packing:

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

Text in Illustration

Seal Packing

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing the seal packing.
   

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

Torque:

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

Install 4 new nozzle holder seals.

Connect the ventilation hose.

w/ EGR Cooler:
Connect the 4 injector connectors and install the 3 bolts.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

w/o EGR Cooler:
Connect the 4 injector connectors.

Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.

Temporarily install a new gasket and the union bolt.

Tighten the 3 bolts and union bolt.

Torque:

for bolt:

13 N*m{130 kgf*cm, 9 ft.*lbf}

for union bolt:

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

Connect the 3 fuel hoses.

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

w/ EGR Cooler:
Install the bolt.

Torque:

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

NOTICE:

1. If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
   
2. Make sure that the inner rubbers of the injection pipe fit inside the clamps.
   
3. When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.
   

w/o EGR Cooler:
Install the 2 bolts.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

NOTICE:

1. If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.
   
2. Make sure that the inner rubbers of the injection pipe fit inside the clamps.
   
3. When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.
   

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

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1003X.html).

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

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1003X.html).

Set a new gasket to the cylinder head.

Temporarily install the electric EGR control valve with No. 2 EGR valve and EGR cooler with the 2 nuts and bolt.

HINT:

Temporarily install the bolt so that the bolt head contacts the EGR cooler.

Connect the vacuum hose to the No. 2 EGR valve.

Set a new gasket labeled A to the No. 2 intake air connector as shown in the illustration.

Insert the No. 2 intake air connector with the gasket into the electric EGR control valve.

Install a new gasket labeled B to the electric EGR control valve side shown in the illustration.

Set a new gasket labeled C to the intake manifold.

Temporarily install the intake air connector to the intake manifold with the 3 bolts.

Temporarily install the intake air connector and electric EGR control valve with the 3 nuts shown in the illustration.

Tighten the 3 nuts labeled A shown in the illustration.

Torque:

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

Tighten the 3 bolts labeled B shown in the illustration.

Torque:

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

Tighten the bolt labeled C shown in the illustration.

Torque:

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

Tighten the 2 nuts labeled D shown in the illustration.

Torque:

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

Temporarily install the No. 2 intake air connector bracket with the 3 bolts.

Tighten the bolt labeled A.

Torque:

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

Tighten the 2 bolts labeled B.

Torque:

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

w/ EGR Cooler:

1. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.
   

   Torque:

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

2. Install the No. 1 gas filter and the gas filter bracket with the bolt.
   

   Torque:

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

3. Connect the 5 vacuum hoses.
   

   NOTICE:

   Install the vacuum hoses so that they completely cover the pipes.

4. Connect the 2 connectors.
   

w/o EGR Cooler:

1. Install the electric vacuum regulating valve together with the bracket with the 2 bolts.
   

   Torque:

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

2. Connect the 2 vacuum hoses.
   

   NOTICE:

   Install the vacuum hoses so that they completely cover the pipes.

3. Connect the connector.
   

Connect the No. 3 water by-pass pipe with wire harness with the 2 bolts.

Torque:

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

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

w/ EGR Cooler:
Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.

Torque:

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

HINT:

If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

w/o EGR Cooler:
Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts as shown in the illustration.

Torque:

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

HINT:

If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

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

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1003X.html).

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

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1003X.html).

Connect the No. 4 water by-pass hose to the EGR cooler.

HINT:

1. The direction of the hose clamp is indicated in the illustration.
   
2. Insert the outlet hose into the stopper.
   

Connect the No. 3 water by-pass hose to the EGR cooler.

HINT:

1. The direction of the hose clamp is indicated in the illustration.
   
2. Insert the outlet hose into the stopper.
   

Install the clamp.

Connect the pipe (with the 2 air hoses) and install the bolt.

Torque:

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

Tighten the 2 clamps.

Connect the vacuum hose to the gas filter.

Connect the manifold absolute pressure sensor connector.

Install the engine cover bracket with the 2 bolts.

Torque:

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

Attach the 4 claws to the pins of the cover bracket to install the engine cover.

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}

Connect the 2 connectors.

Install a new gasket and the intake air connector with the 4 bolts.

Torque:

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

Install the intercooler with the 4 bolts.

Torque:

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

Install a new No. 2 air hose and then tighten the 2 hose clamps.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Tighten the 2 hose clamps of the No. 1 air hose.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

w/o Mass Air Flow Meter:
Install the intake air temperature sensor.

w/ Mass Air Flow Meter:
Using a 22 mm deep socket wrench, install a new gasket and the intake air temperature sensor.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Connect the intake air temperature sensor connector.

w/o EGR Cooler:

1. Install the manifold absolute pressure sensor with the 2 bolts.
   

   Torque:

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

2. Connect the manifold absolute pressure sensor connector and vacuum hose.
   

w/ EGR Cooler:

1. Install the manifold absolute pressure sensor with the 2 bolts.
   

   Torque:

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

2. Connect the vacuum hose and attach the 2 clamps.
   

3. Connect the manifold absolute pressure sensor connector.
   

Install the engine cover with the 3 bolts and 2 cap nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Install the fan pulley to the water pump.

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

NOTICE:

Be careful not to damage the radiator core.

Install the fluid coupling with fan to the fan pulley with the 4 nuts.
Tighten the nuts as much as possible by hand.

Attach the claws of the fan shroud to the radiator.

Install the fan shroud with the 2 bolts.

Torque:

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

Install the fan and generator V belt (HILUX_TGN26 RM000001474016X_01_0001.html).

Tighten the 4 nuts of the fluid coupling with fan.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Install the radiator reservoir with the 2 bolts.

Torque:

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

Connect the No. 1 and No. 2 water by-pass hoses to the radiator.

Install the oil reservoir with the 3 bolts.

Torque:

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

Add new engine oil.

Standard Oil Grade:

Oil Grade	Oil Viscosity (SAE)
G-DLD1, API CF-4, CF or ACEA B1	- 5W-30 - 10W-30 - 15W-40 - 20W-50

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.

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

NOTICE:

1. Hand pump pumping speed: Max. 2 strokes/ sec.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. 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.
   
5. 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.
   
6. 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.
   

Check if the engine starts.

NOTICE:

1. 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.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. 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.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

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

Clear the DTCs.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0TAX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0SWX.html)
   

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 fifth 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.

1. w/ EGR Cooler: (HILUX_TGN26 RM000000PDK0TAX.html)
   
2. w/o EGR Cooler: (HILUX_TGN26 RM000000PDK0SWX.html)
   

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.

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the radiator reservoir.

Standard capacity:

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

NOTICE:

Never use water as a substitute for engine coolant.

HINT:

1. 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).
   
2. Please contact your TOYOTA dealer for further details.
   

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 17 in.*lbf}

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

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:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

4. Stop the engine and wait until the coolant cools down to ambient temperature.
   

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

After the coolant cools down, check that the coolant level is at the F line.
If the coolant level is below the F line, add TOYOTA SLLC to the F line.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 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 heater core, cylinder block and head.

Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

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.

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.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and push the intelligent tester main switch on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

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.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.

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.