OIL PUMP > INSTALLATION

for Preparation Click here



1. INSTALL TIMING GEAR CASE ASSEMBLY


A071169E01

  1. Install 2 new O-rings to the cylinder block.

  1. Remove any old seal packing (FIPG) material from the timing gear case and cylinder block.

  1. Set a new oil pump gasket to the timing gear case.



    A075511E03

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

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    4 mm (0.15 in.)

    NOTICE:
    1. After applying FIPG, install the timing gear case within 3 minutes and tighten the bolts within 15 minutes.
    2. Do not start the engine for at least 2 hours after the installation.



    A038758E01

  1. Align the "2" timing marks of the No. 1 balance shaft driven gear and oil pump drive gear, and install the timing gear case to the cylinder block.

  1. Tighten the 8 bolts and union bolt.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf } for bolt
    16 N*m{ 163 kgf*cm , 12 ft.*lbf } for union nut

  1. Make sure that the oil pump drive gear rotates smoothly.

    NOTICE:
    If the gear does not rotate smoothly, remove the 8 bolts and union bolt to release the gear. Then install the bolts and gear again.

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

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



2. INSTALL OIL PAN SUB-ASSEMBLY

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

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

  1. Remove old seal packing (FIPG) from the oil pan and cylinder block.



    A074129E04

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

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    4 mm (0.15 in.)

    NOTICE:
    1. After applying FIPG, install the oil pan within 3 minutes and tighten the bolts within 15 minutes.
    2. Do not start the engine for at least 2 hours after the installation.

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

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



3. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

  1. Apply clean engine oil to a new O-ring.

  1. Install the O-ring to the level gauge.

  1. Install the level gauge with the bolt.

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



4. INSTALL INJECTION GEAR


A038760E01

  1. Align the "3" timing marks of the injection gear and balance No. 2 shaft driven gear, and install the injection gear.

    NOTICE:
    Fit the key (protrusion) of the supply pump to the key slot of the injection gear.

  1. Set a new O-ring and then temporarily install the nut. Using your hand, check the thrust clearance of the supply pump drive shaft by driving the injection gear.

    Thrust clearance:
    0.15 to 0.55 mm (0.0059 to 0.0217 in.)

    HINT:
    If the clearance is not within the specified range, remove the injection gear again and reinstall it.



5. INSTALL FUEL SUPPLY PUMP ASSEMBLY


6. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


A072407E01

  1. Align the "1" timing marks of the oil pump drive gear and crankshaft timing gear as shown in the illustration. Using SST, install the crankshaft timing gear.

    SST
    09223-00010  



7. INSTALL NO. 1 IDLE GEAR


    A060159E02

  1. Install the No. 1 idle gear shaft to the cylinder block.



    A038762E01

  1. Align the "4" timing marks of the No. 1 idle gear and injection gear, as shown in the illustration.

  1. Align the "5" timing marks of the No. 1 idle gear and crankshaft timing gear, and install the idle gear No. 1, as shown in the illustration.

  1. Install the idle gear No. 1 with the idle gear thrust plate and 2 bolts.

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

  1. Remove the service bolt.

  1. Install the No. 1 crankshaft angle sensor plate.



8. INSTALL TIMING GEAR COVER


A072411E01

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

  1. Remove any old seal packing (FIPG) material from the timing gear cover.



    A075513E02

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

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    4 mm (0.15 in.)

    NOTICE:
    1. After applying FIPG, install the gear cover within 3 minutes and tighten the bolts and nuts within 15 minutes.
    2. Do not start the engine for at least 2 hours after the installation.

  1. Install the cover with the 14 bolts and 2 nuts.

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



9. INSTALL CRANKSHAFT POSITION SENSOR

  1. Apply clean engine oil to a new O-ring.

  1. Install the O-ring to the sensor.

  1. Install the sensor with the bolt.

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



10. INSTALL CAMSHAFT POSITION SENSOR

  1. Apply clean engine oil to a new O-ring.

  1. Install the O-ring to the sensor.

  1. Install the sensor with the bolt.

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



11. INSTALL CRANKSHAFT PULLEY


A072417E02

  1. Align the pulley set key with the key groove of the pulley.

  1. Using SST, install the pulley bolt.

    SST
    09213-58013  

    Torque:
    365 N*m{ 3,722 kgf*cm , 270 ft.*lbf }



12. INSTALL PUMP DRIVE SHAFT PULLEY

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

  1. Partially install the supply pump with the nut.



    A070711E01

  1. Using SST, hold the crankshaft pulley to tighten the nut.

    SST
    09213-58013  
    09330-00021  

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



    A038747E01

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

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



    A036609E01

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

    Thrust clearance:
    0.15 to 0.55 mm (0.0059 to 0.0217 in.)

    HINT:
    If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat step above.



13. INSTALL VANE PUMP ASSEMBLY

  1. Install a new O-ring to the vane pump.

  1. Install the vane pump with the 2 nuts.

    Torque:
    39 N*m{ 398 kgf*cm , 29 ft.*lbf }



14. INSTALL VACUUM PUMP ASSEMBLY

  1. Install a new O-ring to the vacuum pump.

  1. Install the vacuum pump with the 2 nuts.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf }



15. INSTALL WATER PUMP ASSEMBLY


    A112074E01

  1. Install a new gasket and the water pump with the 6 bolts and 2 nuts.

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



16. INSTALL NO. 2 TIMING BELT COVER


A060279E01

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

    Seal packing:
    Part No. 08826-00080 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.

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

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



17. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


18. INSTALL CAMSHAFT TIMING PULLEY


A060182E01

  1. Install the camshaft timing pulley.

  1. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

    Torque:
    98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }



19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


A060179E02

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

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

    Seal packing:
    Part No. 08826-00080 or equivalent

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



    G034877E01

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

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

  1. Install 4 new nozzle holder seals.



20. INSTALL INJECTION PIPE


G038585E02

NOTICE:
  1. When replacing the injector, also replace the injection pipe.
  2. Keep the joints of the injection pipe clean.

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

  1. 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.



    A098972E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

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

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

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



    A098893E01

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

  1. Install 2 new injection pipe clamps with the 2 bolts.

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

    NOTICE:
    1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
    2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.



    A098973E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

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

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

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



21. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


A098974E01

  1. 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. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.

  1. Using SST, tighten the inlet pipe union nut on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

  1. Using SST, tighten the inlet pipe union nut on the supply pump side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

  1. Install the oil level gauge guide with the 2 bolts.

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



    G036615E01

  1. Install the clamp with the bolt.

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



22. INSTALL MANIFOLD STAY


G037596E01

  1. Install the stay with the 2 bolts.

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



23. INSTALL NO.1 COMPRESSOR MOUNTING BRACKET

  1. Install the bracket with the 4 bolts.

    Torque:
    47 N*m{ 479 kgf*cm , 35 ft.*lbf }



24. INSTALL GENERATOR ASSEMBLY


A111821E01

  1. Install the generator and adjusting bar with the 2 bolts.

    Torque:
    62 N*m{ 630 kgf*cm , 46 ft.*lbf } for bolt A
    25 N*m{ 254 kgf*cm , 19 ft.*lbf } for bolt B

  1. Install the generator wire with the nut.

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

  1. Connect the generator connector.



25. INSTALL GENERATOR BRACKET


26. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


A097638E01

  1. Install the tensioner with the 4 bolts.

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

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



27. INSTALL TIMING BELT


A070691E02

  1. 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.

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

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

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

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



    A070548E01

  1. Place the tensioner upright. Then set the 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.

  1. Using a 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.

  1. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

  1. Tighten the 2 bolts.

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

    NOTICE:
    Uniformly tighten the 2 bolts and install the tensioner.



    A059983E01

  1. Remove the 1.5 mm hexagon wrench from the tensioner.



    A070549E02

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



28. INSTALL NO. 1 TIMING BELT TENSIONER ASSEMBLY


29. INSTALL NO. 1 TIMING BELT COVER

  1. Install the timing belt cover with the 6 bolts.

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

  1. Install the wire harness clamp.

  1. Install the water hose clamp with the bolt.

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



30. REMOVE ENGINE FROM ENGINE STAND


31. INSTALL ENGINE ASSEMBLY


A098988E01

  1. Attach the chain block and engine sling device to the engine hangers.

  1. Slowly lower the engine into the engine compartment.

  1. Install the engine mounting bracket with the 4 bolts and 4 nuts.

    Torque:
    38 N*m{ 388 kgf*cm , 28 ft.*lbf }

  1. Remove the 2 engine hangers.



32. INSTALL REAR END PLATE

  1. Install the end plate with the bolt.

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



33. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


A054047E01

  1. Clean the bolt and its hole.

  1. Apply adhesive to 2 or 3 threads of the bolt end.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



    A072424E02

  1. Using SST, hold the crankshaft.

    SST
    09213-58013  
    09330-00021  

    Torque:
    365 N*m{ 3,722 kgf*cm , 270 ft.*lbf }

  1. Install the flywheel, drive plate and drive plate spacer on the crankshaft.



    A114804E01

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

    Torque:
    178 N*m{ 1,815 kgf*cm , 132 ft.*lbf }

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



34. INSTALL FLY WHEEL SUB-ASSEMBLY (for Manual Transmission)


A054047E01

  1. Clean the bolt and its hole.

  1. Apply adhesive to 2 or 3 threads of the bolt end.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



    A072424E02

  1. Using SST, hold the crankshaft.

    SST
    09213-58013  
    09330-00021  

    Torque:
    365 N*m{ 3,722 kgf*cm , 270 ft.*lbf }

  1. Install the flywheel on the crankshaft.



    A114803E01

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

    Torque:
    178 N*m{ 1,815 kgf*cm , 132 ft.*lbf }

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



35. INSTALL PROPELLER SHAFT ASSEMBLY

  1. Front Side:
    Install the propeller shaft assembly (Click here).

  1. Rear Side:
    Install the propeller shaft assembly (Click here).



36. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    A111834

  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum length:
    40 mm (1.57 in.)
    If the free length is less than the minimum, replace the compression spring.

  1. Install the front pipe to the pipe support.



    A111803E01

  1. Install a new gasket to the outlet pipe.

    NOTICE:
    1. Be careful with the installation direction of the gasket.
    1. Do not reuse the gasket.
    1. To ensure a proper seal, do not use the front pipe to force the gasket onto the outlet pipe.

    HINT:
    1. Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.

  1. Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

    CAUTION:
    Do not reuse the gasket.



37. INSTALL STARTER ASSEMBLY


    A111844E01

  1. A/T:
    Install the starter and ground cable with the 2 nuts and bolt.

  1. M/T:
    Install the starter and ground cable with the nut and bolt.

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

  1. Install the starter wire to terminal 30 with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 7 ft.*lbf }

  1. Connect the starter connector.

  1. A/T:
    Install the A/T oil dipstick with the 2 bolts.

  1. M/T:
    Install the clutch release cylinder.



38. INSTALL COOLER COMPRESSOR ASSEMBLY

  1. Install the compressor with the 4 bolts.

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



39. CONNECT HOSES AND CONNECTORS


G034367E01

  1. Using SST, install the pressure feed tube.

    SST
    09023-12701  

    Torque:
    51 N*m{ 520 kgf*cm , 38 ft.*lbf }



    G035298E01

  1. Connect the 2 fuel hoses.

  1. Connect the vacuum pump hose.

  1. Connect the oil reservoir to pump hose.



    G035297E03

  1. Connect the 4WD control ECU connector.

  1. Connect the turbo motor driver connector.

  1. Connect the 3 TCM connectors.

  1. Connect the 4 ECM connectors.



    G035296E01

  1. Connect the 2 injector driver connectors.



    G035294E01

  1. Install the ground cable with the bolt.

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

  1. Connect the 2 engine room junction block connectors.

  1. Install the engine room J/B wire with the nut.

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

  1. Install the engine room relay block cover (side).

  1. Install the engine room relay block cover (upper).



40. INSTALL CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    A112150

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

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



    A112149

  1. Using a 22 mm deep socket wrench, install a new gasket and the IAT sensor.

    Torque:
    29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }



    A110367E01

  1. Install the CAC with the 4 bolts.

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

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

  1. Tighten the 4 hose clamps of the No. 1 and No. 2 air hose.

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

  1. Connect the diesel turbo IAT sensor connector.



41. INSTALL NO. 1 COVER SUB-ASSEMBLY


    A110362

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

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



42. INSTALL RADIATOR ASSEMBLY

  1. Install the radiator assembly (Click here).



43. INSTALL AIR CLEANER ASSEMBLY


A099628E02

  1. Connect the air cleaner hose.

  1. Install the cleaner with the 2 bolts.

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

  1. Tighten the hose clamp of the compressor inlet elbow.

  1. Connect the MAF meter connector and install the clamp.



44. INSTALL BATTERY AND BATTERY TRAY


45. INSTALL BATTERY BRACKET


46. INSTALL RADIATOR GRILLE


B108604E01

  1. Push the radiator grille in the direction indicated by the arrow in the illustration. Attach the 5 claws to install the radiator grille.

  1. Install the 2 screws and 2 clips.



47. INSTALL HOOD SUB-ASSEMBLY

  1. Install the hood with the 4 bolts.

    Torque:
    13 N*m{ 134 kgf*cm , 10 ft.*lbf }

  1. Connect the washer nozzle hose to the washer nozzle.

  1. Adjust the hood.



48. ADD FUEL


49. TIGHTEN FUEL TANK CAP ASSEMBLY


50. ADD ENGINE COOLANT

  1. Tighten the radiator drain cock plug by hand.

  1. Tighten the cylinder block drain cock plug.

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



    A098989E01

  1. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

    Standard capacity:
    Item
    		Specified Condition
    A/T
    		11.1 liters (11.7 US qts, 9.8 lmp. qts)
    M/T
    		9.8 liters (10.4 US qts, 8.6 lmp. 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 consists of a combination of low phosphates and organic acids).
    1. Please contact your TOYOTA dealer for further details.

    NOTICE:
    Never use water as a substitute for engine coolant.

  1. 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.

  1. Install the radiator reservoir cap.



    A099591E01

  1. Using a wrench, install the vent plug.

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

  1. 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 2,000 to 2,500 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.
      1. Be careful as the radiator hoses are hot.
      1. 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.



    G036768E01

  1. 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.



51. ADD TRANSMISSION OIL (for Manual Transmission)


D025304E13

  1. Stop the vehicle on a level surface.

  1. Remove the filer plug and gasket.

  1. Check that the oil level is between 0 to 5 mm (0 to 0.20 in.) from the bottom lip of the filler plug opening.
    If the result is not as specified, add transmission oil.

    Oil grade:
    GL-4 or GL-5

    Viscosity:
    SAE 75W-90

    Capacity:
    2.6 liters (2.7 US qts, 2.3 lmp.qts)

    NOTICE:
    1. Too much or too little oil will lead to transmission problems.
    2. After adjusting the oil level, drive the vehicle and check the oil level again.

  1. Check for oil leakage when the oil level is low.
    If leakage is found, repair the area necessary to stop the leak. Replace damaged parts as necessary.

  1. Install a new gasket and the filler plug.

    Torque:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



52. ADD TRANSMISSION FLUID (for Automatic Transmission)

HINT:
Drive the vehicle so that the engine and transmission are at normal operating temperature.

ATF temperature:
70 to 80° C (158 to 176° F)



    G036408E01

  1. Park the vehicle on a level surface and set the parking brake.

  1. With the engine idling and the brake pedal depressed, move the shift lever into all positions from P to L. Then return it to P.

  1. Pull out the dipstick and wipe it clean.

  1. Push it back fully into the pipe.

  1. Pull it out and check that the fluid level is in the HOT range.
    If there are leaks, it is necessary to repair or replace O-rings, FIPG, oil seals, plugs or other parts.



53. ADD ENGINE OIL


54. BLEED AIR FROM FUEL SYSTEM


A098962E01

  1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.



55. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


56. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.



57. CHECK FOR ENGINE OIL LEAKS


58. CHECK FOR ENGINE COOLANT LEAKS


59. CHECK FOR FUEL LEAKS


60. CHECK ENGINE OIL LEVEL


61. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 2 bolts.

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



62. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

  1. Install the under cover with the 4 bolts.

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