Throttle Body Installation

Install a new gasket to the intake manifold.

HINT:

Align the protrusion of the gasket with the groove of the intake manifold.

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

Torque:

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

Connect the 2 water by-pass hoses to the throttle body with motor assembly.

Connect the throttle position sensor and control motor connector.

Install the intake air connector with the 2 bolts, and then tighten the 2 hose clamps.

Torque:

for bolt:

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

for hose clamp on throttle body side:

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

for hose clamp on air cleaner side:

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

Connect the No. 2 PCV hose.

Connect the vacuum hose.

Tighten the cylinder block water drain cock plug.

Torque:

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

Tighten the radiator drain cock plug by hand.

Add engine coolant.

Standard capacity:

Item	Specified Condition
for Automatic Transmission	8.1 liters (8.6 US qts, 7.1 Imp. qts)
for Manual Transmission	7.8 liters (8.2 US qts, 6.9 Imp. qts)

NOTICE:

Do not substitute plain water 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. Press the radiator hose inlet and radiator hose outlet several times by hand, and then check the coolant level. If the coolant level is low, add coolant.
   

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the radiator hose inlet will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. 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 F line.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

1. Press the radiator hose inlet and radiator hose outlet several times by hand to bleed air while warming up the engine.
   
2. The thermostat opening timing can be confirmed by pressing the radiator hose outlet 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. Then remove the radiator cap and check the coolant level.*7

CAUTION:

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

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.
If the coolant level is below the F line, repeat steps *4 through *8.
If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

Disconnect the EFI and ETCS fuses at the same time. Wait at least 60 seconds and reconnect the fuses.

Turn the ignition switch to ON without operating the accelerator pedal.

NOTICE:

If the accelerator pedal is operated, perform the above steps again.

Connect the tester to the DLC3 and clear the DTCs (HILUX_TGN26 RM000000PDK0SXX.html).

Start the engine and check that the MIL is not illuminated and that the idle speed is within the specified range when the cooler is switched off after the engine is warmed up.

Engine Idle Speed:

Condition	Specified Condition
Air conditioning switched off	600 to 700 rpm

NOTICE:

1. Be sure to perform this step with all accessories off.
   
2. Make sure that the shift lever is in neutral.
   

Enter the following menus: Powertrain / Engine and ECT / Data List / Throttle Sensor Position. Fully depress the accelerator pedal and check that the value is 60% or more.

Perform a road test and confirm that there are no abnormalities.

Remove the radiator cap.

CAUTION:

To avoid being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.

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 then check that the pressure does not drop.
If the pressure drops, check the hose, radiator and water pump for leakage. If no external leakage is found, check the heater core, cylinder block and cylinder head.

Install the radiator cap.