Egr Cooler (W/ Glow Plug Controller) Installation

Install the 2 EGR cooler insulators to the EGR cooler.

HINT:

1. Install the EGR cooler insulators so that they are positioned as shown in the illustration.
   
2. Install the No. 2 EGR cooler insulator within the range labeled "A" in the illustration.
   

Using a 6 mm hexagon wrench, install 2 new gaskets, the EGR valve adapter, No. 2 EGR valve, EGR cooler and 3 plate washers with the 3 hexagon socket head cap bolts.

Torque:

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

Install the bolt labeled A.

Torque:

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

Install 2 new gaskets and the electric EGR control valve to the stud bolts of the intake air connector.

Temporarily install the intake air connector with electric EGR control valve to the EGR valve adapter with the 3 nuts.

Install a new gasket to the intake manifold.

Install a new gasket to the stud bolts of the cylinder head.

Set the electric EGR control valve with No. 2 EGR valve and EGR cooler on the intake manifold and cylinder head.

Temporarily install the intake air connector to the intake manifold with the 3 bolts labeled A in the illustration.

Temporarily install the EGR cooler to the intake manifold with the 2 bolts labeled B in the illustration.

Temporarily install the EGR cooler to the cylinder head with the 2 nuts labeled C in the illustration.

Tighten the 3 bolts labeled A in the illustration.

Torque:

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

Tighten the 2 bolts labeled B in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Tighten the 2 nuts labeled C in the illustration.

Torque:

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

Temporarily install the EGR valve bracket with the 3 bolts.

Tighten the bolt labeled D in the illustration.

Torque:

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

Tighten the 2 bolts labeled E in the illustration.

Torque:

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

Tighten the 3 nuts labeled F in the illustration.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

for DPF:
Connect the fuel pressure sensor connector to the common rail.

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

Torque:

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

Connect the engine wire with the bolt.

Torque:

13 N*m{128 kgf*cm, 9 ft.*lbf}

Attach the 2 wire harness clamps.

Install the throttle body bracket with the 3 bolts.

Torque:

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

Install the wiring harness clamp bracket with the bolt.

Torque:

13 N*m{128 kgf*cm, 9 ft.*lbf}

Install the gas filter bracket with gas filter with the bolt.

Torque:

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

Connect the vacuum hose.

Install the manifold absolute pressure sensor with the bolt.

Torque:

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

Connect the vacuum hose and manifold absolute pressure sensor connector.

Install the No. 5 water by-pass pipe with the 2 bolts.

Torque:

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

Connect the 2 water hoses to the electric EGR control valve.

HINT:

1. Push the water hoses on until they contact the body of the electric EGR control valve.
   
2. The direction of the hose clamps is indicated in the illustration.
   

Attach the 2 wire harness clamps.

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

Install the 2 No. 3 injection pipe clamps with the 4 nuts.

Torque:

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

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 RM000004QR1006X.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 RM000004QR1006X.html).

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.
   
2. Keep the fuel inlet pipe free of foreign matter.
   

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

Torque:

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

HINT:

When installing the No. 2 injection pipe clamp, align it with the paint mark of the fuel inlet pipe shown in the illustration.

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut 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 RM000004QR1006X.html).

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump 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 RM000004QR1006X.html).

Install the No. 3 cylinder head cover with the 3 bolts.

Torque:

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

Install the fuel pipe insulator to the fuel pipes.

Install the vacuum switching valve to the manifold stay with the screw.

Connect the 2 vacuum hoses to the vacuum switching valve.

Install the manifold stay with vacuum switching valve with the 2 bolts.

Torque:

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

Connect the 2 vacuum hoses.

Connect the vacuum switching valve connector.

Connect the 6 water by-pass hoses.

HINT:

1. When connecting the hoses, make sure the paint marks and clamps are as shown in the illustration.
   
2. The direction of each hose clamp is indicated in the illustration.
   

Install a new O-ring to the engine oil level dipstick guide.

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

Install the engine oil level dipstick guide with the bolt.

Torque:

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

Attach the wire harness clamp.

for DPF:
Install the engine oil level dipstick.

for i-ART:
Install the engine oil level dipstick and gasket.

Install the front fender seal with the 5 clips.

Install the front fender apron seal upper with the 5 clips.

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:

Item	Specified Condition
for Automatic Transmission	11.1 liters (11.7 US qts, 9.8 Imp. qts)
for Manual Transmission	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.

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. for DPF: (HILUX_TGN26 RM000000PDK0X2X.html)
   
2. for i-ART: (HILUX_TGN26 RM000000PDK0X4X.html)
   

Start the engine.*1

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

Read Current DTCs.

Clear the DTCs.

1. for DPF: (HILUX_TGN26 RM000000PDK0X2X.html)
   
2. for i-ART: (HILUX_TGN26 RM000000PDK0X4X.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 / DTC.

Read Current DTCs.

OK:

No DTCs are output.

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.

Perform the Active Test.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Turn the intelligent tester on.
   

4. Enter the following menus: Powertrain / Engine / Active Test.
   

5. 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.