Oil Pump (W/O Dpf) Installation

Install 2 new O-rings to the cylinder block.

Install a new gasket to the groove of the timing gear case.

Remove any old seal packing (FIPG material).

Apply seal packing to the timing gear case as 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:

After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

Install the timing gear case with the union bolt and 8 bolts.

Torque:

for union bolt (A):

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

for bolt:

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

Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

Torque:

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

Remove any old seal packing (FIPG material).

Apply seal packing to the oil pan as shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

4 mm (0.157 in.)

NOTICE:

After applying seal packing, install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes.

Install the oil pan with the 22 bolts and 2 nuts.

Torque:

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

Install a new O-ring and the fuel supply pump with the 2 nuts.

Torque:

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

Temporarily install the injection gear with the nut.

HINT:

Fit the key (protrusion) of the fuel supply pump into the key slot of the injection gear.

Install a new O-ring to the injection gear.

Install the injection gear set nut.

Using SST, tighten the set nut.

SST

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

Torque:

64 N*m{650 kgf*cm, 47 ft.*lbf}

Position the crankshaft timing gear with the "1" timing marks facing forward.

Align the key groove of the crankshaft timing gear with the set key on the crankshaft.

Using SST and a hammer, tap on the timing gear to install it.

SST

09223-00010

Apply a coat of engine oil to the No. 1 idle gear shaft.

Install the gear shaft as shown in the illustration.

Align the "4" and "5" timing marks of the idle gear and crankshaft timing gear.

Using SST, turn the injection gear and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

SST

09960-10010(09962-01000,09963-00700)

Position the idle gear thrust plate with the protrusion facing forward.

Align the bolt holes and install the idle gear thrust plate with the 2 bolts.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Remove the service bolt.

Align the key groove of the No. 1 crankshaft position sensor plate with the set key.

Install the No. 1 crankshaft position sensor plate with the cupped side facing outward.

Remove any old seal packing (FIPG material).

Apply seal packing to the timing gear cover as 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:

After applying seal packing, install the timing gear cover within 3 minutes and tighten the bolts within 15 minutes.

Install a new O-ring to the timing gear case.

Install the timing gear cover with the 14 bolts and 2 nuts.

Torque:

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

Remove the screw plug and gasket.

Pour approximately 50 cc (3.05 cu. in.) of engine oil into the oil pump.

Install a new gasket and the screw plug.

Torque:

42 N*m{423 kgf*cm, 31 ft.*lbf}

Install the No. 1 vacuum transmitting pipe with the bolt.

Torque:

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

Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

Using SST, install the pulley bolt.

SST

09213-58014
09330-00021

Torque:

365 N*m{3722 kgf*cm, 269 ft.*lbf}

Install a new O-ring to the fuel supply pump.

Temporarily install the fuel supply pump with the nut.

Using SST, hold the crankshaft pulley and tighten the nut.

SST

09213-58014
09330-00021

Torque:

64 N*m{650 kgf*cm, 47 ft.*lbf}

Install the No. 2 camshaft timing pulley flange and pump drive shaft pulley with the 4 bolts.

Torque:

31 N*m{316 kgf*cm, 23 ft.*lbf}

Using a dial indicator, check the thrust clearance of the pump drive shaft while moving the pump drive shaft pulley back and forth.

Standard thrust clearance:

0.15 to 0.55 mm (0.00591 to 0.0217 in.)

HINT:

If the clearance is not within the specified range, remove and reinstall the fuel supply pump and pump drive shaft pulley. Then repeat the step above.

Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

Install the crankshaft position sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Install the 4 clips and connect the crankshaft position sensor connector.

NOTICE:

Insert the crankshaft position sensor wire harness into the protrusions of the timing gear cover.

Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

Install the camshaft position sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Connect the camshaft position sensor connector.

Install a new O-ring to the vane pump.

Install the vane pump with the 2 nuts.

Torque:

41 N*m{418 kgf*cm, 30 ft.*lbf}

Install 2 new O-rings to the vacuum pump.

Install the vacuum pump with the 2 nuts.

Torque:

21 N*m{210 kgf*cm, 15 ft.*lbf}

Install the gear cover insulator with the bolt.

Torque:

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

Install a new gasket and the water pump with the 5 bolts and 2 nuts.

Torque:

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

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}

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 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.
   

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 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}

Install the injection pipe clamp with the bolt.

Torque:

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

Install the engine oil level dipstick.

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}

Install the injection pipe clamp with the bolt.

Torque:

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

Install the engine oil level dipstick.

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 RM000004QR1006X.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 RM000004QR1006X.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 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.
   

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 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).

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.

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}

Install the injection pipe clamp with the bolt.

Torque:

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

Install the engine oil level dipstick.

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}

Install the injection pipe clamp with the bolt.

Torque:

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

Install the engine oil level dipstick.

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 the No. 1 compressor mounting bracket with the 4 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Install the V-ribbed belt tensioner with the 4 bolts.

Torque:

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

HINT:

Firmly press and hold the V-ribbed belt tensioner against the cylinder block to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

Install the generator bracket with the bolt.

Torque:

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

Install the generator with the 2 bolts.

Torque:

for bolt A:

62 N*m{632 kgf*cm, 46 ft.*lbf}

for bolt B:

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

Install the generator wire with the nut.

Torque:

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

Connect the generator connector.

Install the spacer, No. 2 idle pulley and pulley plate with the bolt.

Torque:

45 N*m{459 kgf*cm, 33 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}

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.

Check the fluid level.

Jack up the front of the vehicle and support it with stands.

Turn the steering wheel.

1. With the engine stopped, turn the steering wheel slowly from lock to lock several times.
   

Lower the vehicle.

Start the engine. Run the engine at idle for a few minutes.

Turn the steering wheel.

1. With the engine idling, turn the steering wheel to the left or right full lock position and hold it there for 2 to 3 seconds. Then turn the steering wheel to the opposite full lock position and hold it there for 2 to 3 seconds.
   

2. Repeat the step above several times.
   

Stop the engine.

Check for foaming or emulsification. If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

Check the fluid level.

Keep the vehicle level.

With the engine stopped, check the power steering fluid level in the oil reservoir. If necessary, add power steering fluid.

Power steering fluid (for TMT made):

"TEXAMATIC 1888" or equivalent

(for TASA made):

ATF "DEXRON 3" or equivalent

HINT:

If the fluid is hot, check that the fluid level is within the HOT range on the oil reservoir. If the fluid is cold, check that the fluid level is within the COLD range.

Start the engine and run it at idle.

Turn the steering wheel to the left or right full lock position, and then turn the steering wheel to the opposite full lock position. Repeat this several times to raise fluid temperature.

Standard fluid temperature:

75 to 80°C (167 to 176°F)

Check for foaming or emulsification. If foaming or emulsification is identified, bleed air from the power steering system.

With the engine idling, measure the fluid level in the oil reservoir.

Stop the engine.

Wait a few minutes and remeasure the fluid level in the oil reservoir.

Maximum fluid level increase:

5 mm (0.197 in.)

Check the fluid level.

Perform registration of the injector compensation codes (HILUX_TGN26 RM0000012XK03ZX_02_0003.html).

Perform pilot quantity learning (HILUX_TGN26 RM0000012XK03ZX_02_0009.html).

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

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.

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.