Engine Assembly Installation

Install the No. 1 front engine mounting bracket with the 4 bolts.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Install the No. 1 front engine mounting bracket with the 4 bolts.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Install the 2 front engine mounting insulators with the 2 nuts.

Torque:

48 N*m{489 kgf*cm, 35 ft.*lbf}

Using a 19 mm deep socket wrench, install a new gasket and the engine coolant temperature sensor.

Torque:

20 N*m{200 kgf*cm, 14 ft.*lbf}

Install the camshaft position sensor with the bolt.

Torque:

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

Install the crankshaft position sensor with the bolt.

Torque:

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

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 a new gasket and the oil cooler cover with the 13 bolts and 2 nuts.

Torque:

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

Connect the oil pressure connector and install the wire harness.

Install a new gasket and the intake manifold to the cylinder head with the 4 bolts and 2 nuts in the order shown in the illustration.

Torque:

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

Apply clean engine oil to a new O-ring.

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

Install the engine oil level dipstick guide with the bolt.

Torque:

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

Check that the supply pump gear in the timing gear case moves back and forth smoothly.

Install a new O-ring to the pump.

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

Align the set key on the drive shaft with the groove of the injection gear.

Install the pump with the 2 nuts.

Torque:

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

Set a new O-ring before installing the set nut.

Using SST, hold the crankshaft pulley and install the set nut.

SST

09213-58013
09330-00021

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

Standard thrust clearance:

0.15 to 0.55 mm (0.0059 to 0.0217 in.)

Connect the 2 connectors.

Connect the 2 fuel hoses.

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
   
2. Keep the fuel inlet pipe free of foreign matter.
   

Using union nut wrench, tighten the injection pipe union nut on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Using union nut wrench, tighten the injection pipe union nut on the supply pump side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

Install the oil dipstick guide with the bolt.

Torque:

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

Install the clamp with the bolt.

Torque:

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

Install the common rail and No. 2 intake manifold insulator with the 2 bolts.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Connect the 2 connectors.

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. When replacing the common rail, it is necessary to replace the 4 injection pipes and fuel inlet pipe with new ones.
   
2. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.
   

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 (Toyota Fortuner RM000000UYX010X.html).

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the 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 (Toyota Fortuner RM000000UYX010X.html).

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

Install the engine oil level dipstick guide with the bolt.

Torque:

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

Install the 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. 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.

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 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 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 (Toyota Fortuner RM000000UYX010X.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 (Toyota Fortuner RM000000UYX010X.html).

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

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 (Toyota Fortuner RM000000UYX010X.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 (Toyota Fortuner RM000000UYX010X.html).

Check and clean the oil filter installation surface.

Apply clean engine oil to the gasket of a new oil filter.

Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.

Using SST, tighten the oil filter. Depending on the work space available, choose from the following.

SST

09228-07501

1. If enough space is available, use a torque wrench to tighten the oil filter.
   

   Torque:

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

2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 turn by hand or with a common wrench.
   

Install a new gasket and the EGR valve.

Install 2 new gaskets and the pipe with the 2 nuts and 2 bolts.

Torque:

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

HINT:

The gasket's claws should be on the pipe side.

Install a new gasket and the air connector with the 2 nuts and bolt.

Torque:

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

Install the No. 2 intake air connector bracket with the 3 bolts.

Torque:

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

Install the vacuum switching valve bracket with the 2 bolts.

Torque:

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

Connect the vacuum hose at the 3 points as shown in the illustration.

Connect the 2 connectors.

Install a new gasket and the throttle body with the 2 bolts and 2 nuts.

Torque:

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

Connect the throttle control motor connector.

Connect the throttle position sensor connector.

Install the manifold stay with the 2 bolts.

Torque:

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

HINT:

Make sure the stay's indented area (labeled A) must face the manifold.

Using a 12 mm deep socket wrench, install the 4 glow plugs.

Torque:

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

Install the glow plug connector by uniformly tightening the 4 nuts.

Torque:

2.2 N*m{22 kgf*cm, 19 in.*lbf}

Install the 4 screw grommets.

Install the wire harness with the nut.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Install a new gasket to the cylinder head, as shown in the illustration.

HINT:

Make sure the claws of the gasket face the water outlet.

Install the water outlet with the 2 bolts.

Torque:

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

Install a new gasket to the thermostat.

HINT:

When installing the thermostat to the gasket, be careful not to deform the gasket. Make sure that the thermostat is properly installed into the groove of the gasket, as shown in the illustration.

Insert the thermostat into the cylinder block with the jiggle valve facing straight upward.

HINT:

The jiggle valve may be set within 30°of either side of the prescribed position.

Install the inlet with the 3 bolts.

Torque:

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

for Automatic transmission:
Connect the clamp to the inlet with the bolt.

Torque:

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

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

Torque:

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

Install the No. 1 intercooler support bracket with the 2 bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Install the No. 2 intercooler support bracket with the 2 bolts.

Torque:

36 N*m{367 kgf*cm, 27 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:

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

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

Install the generator wire with the nut.

Torque:

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

Install the terminal cap.

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}

Install a new gasket and exhaust manifold with turbocharger to the cylinder head with the 8 collars, 8 spacers and 8 new nuts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Temporarily install a new gasket and the turbocharger with 3 new nuts.

HINT:

When installing the turbo oil pipe, loosely install the 3 nuts so that the turbocharger and cylinder head can be aligned easily.

Temporarily install the turbo oil pipe.

HINT:

Before installing the oil pipe, clean it.

1. Install a new gasket and the oil pipe with the 2 nuts, but only loosely install the nuts.
   

   NOTICE:

   The notch (narrow part) of the gasket must face the engine.

2. Install a new gasket and the oil pipe with the 2 bolts, but only loosely install the bolts.
   

   NOTICE:

   The claws of the gasket must face the pipe.





3. Install a new gasket and the oil pipe with the union bolt, but only loosely install the union bolt.
   
   

   
   
   
   




4. Temporarily install the turbocharger stay with the 3 bolts.
   

Tighten the 3 nuts of the turbocharger.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Tighten the 2 nuts and 2 bolts of the oil pipe, and the union bolt.

Torque:

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

Torque:

13 N*m{133 kgf*cm, 9 ft.*lbf} for nut

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf} for union bolt

Tighten the 3 bolts of the turbocharger stay.

Torque:

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

Install a new gasket and the outlet elbow with the 3 nuts.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Connect the 2 hoses to the 2 tubes.

Move the 2 clamps to the locations where the hoses and tubes are connected.

Temporarily install the heat insulator with the 2 bolts.

Tighten the bolt of the turbo insulator, and the 2 bolts of the heat insulator.

Torque:

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

Temporarily install the turbo insulator with the bolt.

Install a new gasket and inlet elbow with the 2 nuts.

Torque:

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

Connect the ventilation pipe to the cylinder head cover.

Move the clamp to the joint pipe of the hose.

Install the ventilation pipe with the bolt.

Torque:

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

Connect the 2 connectors to the turbocharger.

Install the harness clamp's clip to the inlet elbow.

Align the pulley set key with the key groove of the pulley and install the pulley.

Using SST, install the pulley bolt.

SST

09213-58014
09330-00021

Torque:

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

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

HINT:

If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

NOTICE:

1. The engine should be cold.
   
2. When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.
   

Using a 10 mm hexagon wrench, install the timing belt idler pulley and new washer with the bolt.

Torque:

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

Check that the idler pulley moves smoothly.
If it does not move smoothly, check the idler sub-assembly and washer.

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 to the top of the tensioner.

NOTICE:

1. Do not scratch or deform the rod end.
   
2. Press in the tensioner rod upward.
   
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 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force.

NOTICE:

Do not impose a load of over 9,807 N (100 to 1,000 kgf, 220 to 2,205 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 keep the setting position of the push rod.

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 and install the tensioner.

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 with the 6 bolts.

Torque:

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

Install the wire harness clamp.

Install the water hose clamp with the bolt.

Torque:

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

Install the engine wire to the engine.

Install a No. 1 engine hanger and No. 2 engine hanger with 2 bolts as shown in the illustration.

HINT:

Part No.

Torque:

for No. 1 engine hanger:

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

for No. 2 engine hanger:

60 N*m{612 kgf*cm, 44 ft.*lbf}

NOTICE:

Install the engine hangers with new bolts.

Attach an engine sling device and hang the engine with a chain block.

Remove the engine from the engine stand.

Slowly lower the engine into the engine compartment.

Install the engine with the 4 bolts and 4 nuts.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Remove the 2 bolts and 2 engine hangers.

Install the rear end plate with the bolt.

Torque:

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

Clean the bolts and their holes.

Apply adhesive to 2 or 3 threads of the ends of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

Install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

NOTICE:

Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer with the knock pin of the flywheel and ring gear, and then install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

HINT:

As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in the direction shown in the illustration.

Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

NOTICE:

Do not start the engine for at least an hour after installing the flywheel and ring gear.

Torque:

178 N*m{1815 kgf*cm, 131 ft.*lbf}

Clean the bolts and their holes.

Apply adhesive to 2 or 3 threads of the ends of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

Install the flywheel to the crankshaft.

Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque:

178 N*m{1815 kgf*cm, 131 ft.*lbf}

NOTICE:

Do not start the engine for at least 1 hour after installation.

Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel.

SST

09301-00110

NOTICE:

Make sure not to insert the clutch disc facing the wrong direction.

Align the matchmarks on the clutch cover and flywheel.

Loosely install the 6 bolts.

Tighten the 6 bolts as described below.

1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
   

2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
   

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

Lightly move SST up and down, and right and left.

SST

09301-00110

Check that the disc is in the center, and then tighten the bolts.

Using a dial indicator with roller instrument, measure the diaphragm spring tip alignment.

Maximum misalignment:

0.5 mm (0.020 in.)

1. If the misalignment is greater than the maximum, use SST to adjust the diaphragm spring tip alignment.
   

SST

09333-00013

Connect the cooler compressor with the 4 bolts.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the 2 heater hoses.

Using a union nut wrench, connect the pressure feed tube.

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (Toyota Fortuner RM000000UYX010X.html).

Connect the 2 fuel hoses.

Connect the vacuum pump hose.

Connect the oil reservoir to pump hose.

Connect the turbo motor driver connector.

Connect the 3 TCM connectors.

Connect the 4 ECM connectors.

Connect the 3 EDU connectors.

Connect the ground cable with the bolt.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Connect the 2 engine room junction block connectors.

Connect the engine room junction block wire with the nut.

Torque:

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

Install the side relay block cover.

Install the upper relay block cover.

Attach the 2 hinges to install the door.

While pushing in the sides of the glove compartment door as indicated by the arrows in the illustration, close the door to engage the 2 stoppers.

Align the matchmarks on the yoke and transfer flange.

Connect the propeller shaft with the 4 washers and 4 nuts.

Torque:

88 N*m{897 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the yoke and differential flange.

Install the front propeller shaft with the 4 bolts, 4 washers and 4 nuts.

Torque:

88 N*m{897 kgf*cm, 65 ft.*lbf}

Install the intake air connector to the air hoses.

Install the CAC with the 4 bolts.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf}for bolt labeled A

12 N*m{125 kgf*cm, 9 ft.*lbf}for bolts labeled B, C and D

Tighten the 2 clamps.

Connect the vacuum hose to the manifold absolute pressure sensor.

Connect the IAT sensor connector.

Connect the manifold absolute diesel pressure sensor connector.

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

Torque:

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

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Connect the connector to the MAF meter.

Connect the hose and tighten the hose clamp.

Install the battery clamp with the bolt and nut.

Torque:

5.4 N*m{55 kgf*cm, 48 in.*lbf}

Wipe the oil pan and drain plug.

Install a new gasket and the drain plug.

Torque:

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

Add new oil.

Standard oil capacity:

Item	Specified Condition
Drain and refill with oil filter change	6.9 liters (7.3 US qts, 6.1 Imp. qts)
Drain and refill without oil filter change	6.6 liters (7.0 US qts, 5.8 Imp. qts)
Dry fill	7.4 liters (7.8 US qts, 6.5 Imp. qts)

Install the oil filler cap.

Install the hood with the 4 bolts.

Torque:

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

Connect the washer nozzle hose.

Adjust the hood (Toyota Fortuner RM00000138K003X.html).

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 reservoir tank's B line.

Standard Capacity:

Item	Specified Condition
Manual transmission	9.8 liters (10.4 US qts, 8.6 Imp. qts)
Automatic transmission	11.1 liters (11.7 US qts, 9.8 Imp. qts)

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 is a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

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, 18 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 2,500 to 3,000 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.
   

Start the engine.

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 (Toyota Fortuner RM0000012WY005X.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 (Toyota Fortuner RM0000012WY005X.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.

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:

ATF "DEXRON'' II or III

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 (0.20 in.)

Check the fluid level.

Perform registration of the injector compensation codes (Toyota Fortuner RM0000012XK030X_02_0003.html).

Perform pilot quantity learning (Toyota Fortuner RM0000012XK030X_02_0009.html).

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.

Connect the intelligent tester to the DLC3.

If an intelligent tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

SST

09843-18030

Check the idle speed.

HINT:

1. The engine is warmed up.
   
2. The A/C switch is OFF.
   

1. Start the engine and measure the idle speed.
   

   Standard idle speed:

   700 to 800 rpm
   

   If the idle speed is not as specified, perform the troubleshooting procedures in the Diagnostics section.
   

Check the maximum speed.

1. Start the engine.
   

2. Fully depress the accelerator pedal.
   

3. Measure the maximum speed.
   

   Standard maximum speed:

   4,450 to 4,750 rpm
   

   If the maximum speed is not as specified, perform the troubleshooting in the Diagnostics section.
   

If the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe with SST from terminal 9 of the DLC3.

Disconnect the intelligent tester from the DLC3.

Warm up the engine, stop the engine and wait for 5 minutes. The oil level should be between the dipstick's low and full level marks.
If the oil level is low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not add engine oil above the full level mark.

Install the under cover with the 4 bolts.

Torque:

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

Install the under cover with the 8 bolts.

Torque:

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