ENGINE UNIT REASSEMBLY

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL TURBO WATER HOSE UNION (w/ EGR Cooler)

    Note

    If coolant leaks from a turbo water hose union or a turbo water hose union is corroded, replace the turbo water hose union.


    1. Clean the cylinder block side hole and new turbo water hose union with non-residue solvent.

    2. A01DY19E01

      Apply adhesive onto the shaded area of a turbo water hose union as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the turbo water hose union within 3 minutes after applying adhesive.

    3. Set the turbo water hose union and tap it until the edge of the turbo water hose union fits against the chamfered part of the cylinder block as shown in the illustration.

  2. INSTALL CYLINDER BLOCK WATER DRAIN COCK PLUG (w/o EGR Cooler)


    1. Clean the cylinder block side hole and new cylinder block water drain plug with non-residue solvent.

    2. A01DWH5E01

      Apply adhesive onto the shaded area of a cylinder block water drain plug as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the cylinder block water drain plug within 3 minutes after applying adhesive.

    3. Set the cylinder block water drain plug and tap it until the edge of the cylinder block water drain plug fits against the chamfered part of the cylinder block as shown in the illustration.

  3. INSTALL TIGHT PLUG

    A01DYSYE03

    1. Apply adhesive to the end of a new tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    2. Position A:

      Using a 14 mm steel bar and hammer, tap in the tight plug as shown in the illustration.

    3. Other Positions:

      Using SST and a hammer, tap in a new tight plug as shown in the illustration.

      Position B

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )

      Position C

      SST
      09950-60010   ( 09951-00190 )
      09950-70010   ( 09951-07100 )

      Position D

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

      Position E

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )

      Position F

      SST
      09950-60010   ( 09951-00400, 09951-00450 )
      09950-70010   ( 09951-07100 )

      Position G

      SST
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100 )
      A01DVSKE01

  4. INSTALL STUD BOLT

    A01DYHSE01

  5. INSTALL STRAIGHT PIN

    A01E208E01

  6. INSTALL RING PIN

    A01DZDWE01

  7. INSTALL NO. 1 STRAIGHT SCREW PLUG


    1. Install a new gasket and the screw plug.

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

  8. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    A01E0H9E01

    1. Align the pin of the oil nozzle with the pin hole of the cylinder block.

    2. Install the 4 oil nozzles together with the check valves.

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

  9. INSTALL PISTON PIN

    A01DVXUE01

    1. Assemble the piston and connecting rod.


      1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

      2. A01E2FEE01

        Gradually heat the piston to about 60°C (140°F).

      3. A01DZFXE01

        Coat the piston pin with engine oil.

      4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      5. A01DUXQE01

        Check the fit between the piston and piston pin. Try to move the piston back and forth on the piston pin.

      6. A01E2PE

        Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

    2. A01DVO2E01

      Install the piston rings.


      1. Install the coil and oil ring by hand.

        Tech Tips

        Face the end gap of the oil ring in the opposite direction of the coil joint.

      2. A01E232E01

        Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

        Code mark
        Number Mark
        No. 1 w/o EGR system NP
        w/o EGR cooler 1N or N1
        w/ EGR Cooler 1VN
        No. 2 N2

      3. Position the piston rings so that the ring ends are as shown.

        A01E2D2E01

        Note

        Do not align the ring ends.

  10. INSTALL CONNECTING ROD BEARING

    A01DZS0E01

    1. Align the bearing claw with the groove of the connecting rod or connecting cap.

    2. Install the bearings to the connecting rod and connecting rod cap.

  11. INSTALL CRANKSHAFT BEARING

    A01E213E01

    Tech Tips

    Upper bearings have an oil groove and oil hole. Lower bearings do not.


    1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

    2. A01DV1HE01

      Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

  12. INSTALL CRANKSHAFT

    A01E1TUE02

    1. Place the crankshaft on the cylinder block.

    2. Install the 2 upper thrust washers to the No. 5 journal position of the cylinder block.


      1. Push the crankshaft toward the front (rear) side.

      2. Install the 2 thrust washers with the oil grooves facing outward.

    3. A01DVC3E03

      Install the 2 thrust washers on the No. 5 bearing cap with the grooves facing outward.

    4. A01DZCNE01

      Install the 5 crankshaft bearing caps in their proper locations.

    5. A01DVTVE07

      Install the crankshaft bearing cap bolts.

      Tech Tips


      • The main bearing cap bolts are tightened in 2 progressive steps.

      • If a main bearing cap bolt is broken or deformed, replace it.


      1. Apply a light coat of engine oil to the threads and under the bolt heads of the main bearing caps.

      2. Install and uniformly tighten the 10 bolts of the main bearing caps in several passes in the sequence shown in the illustration.

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

        If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.

      3. A01DW4ZE07

        Mark the front of the main bearing cap bolts with paint.

      4. Retighten the main bearing cap bolts 90° in the numerical order shown on previous page.

      5. Check that the painted marks are now at a 90° angle to the front.

    6. Check that the crankshaft turns smoothly.

    7. Check the crankshaft thrust clearance.

  13. INSTALL PISTON AND CONNECTING ROD


    1. A01E1DGE01

      Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

    2. A01DVAWE01

      Place the connecting rod cap on the connecting rod.


      1. Match the numbered connecting rod cap with the connecting rod.

      2. Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

      3. A01DX3JE01

        Check that the front mark of the connecting rod cap is facing forward.

    3. A01DW42E01

      Install the connecting rod cap bolts.

      Tech Tips


      • The connecting rod cap bolts are tightened in 2 progressive steps.

      • If any connecting rod bolt is broken or deformed, replace it.


      1. Apply a light of engine oil on the threads and under the heads of the connecting rod cap bolts.

      2. Install and alternately tighten the bolts of the connecting rod cap in several passes.

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

        If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolts.

      3. A01DYYDE02

        Mark the front of the connecting rod cap bolts with paint.

      4. Retighten the connecting rod cap bolts 90° as shown.

      5. Check that the painted marks are now at a 90° angle to the front.

    4. Check that the crankshaft turns smoothly.

    5. Check the connecting rod thrust clearance Click here.

  14. INSTALL CYLINDER BLOCK OIL ORIFICE

  15. INSTALL ENGINE REAR OIL SEAL RETAINER

    A01E2JNE01

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

    2. Apply seal packing to the specific places described in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3 to 5 mm (0.12 to 0.20 in.)

      Note

      After applying FIPG, install the engine rear oil seal retainer within 3 minutes and tighten its bolts within 15 minutes.

    3. A01DW0I

      Install the retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

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

  16. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old packing (FIPG) material.

    2. A01DW8HE02

      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
      5 mm (0.20 in.)

      Note

      Install the timing gear case assembly within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

    3. A01DYNME01

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

    4. A01E2GZE01

      Install 2 new O-rings to the cylinder block groove of the timing gear case.

    5. Align the mark on the oil pump drive gear with the mark on the timing gear case.

    6. A01DXR2E01

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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf, for union bolt (A) }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for bolt }
    7. A01E2YEE01

      Remove the screw plug.

    8. Pour in approximately 20 cc (0.12 cu in.) of engine oil into the oil pump.

    9. Install a new gasket and the screw plug.

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

  17. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. 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 }

  18. INSTALL OIL PAN SUB-ASSEMBLY

    A01E0W7E01

    1. Remove any old packing (FIPG) material.

    2. 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 diameter
      4 mm (0.16 in.)

      Note

      Install the oil pan assembly within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

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

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

    4. Install the oil level gauge sensor with the 4 bolts.

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

  19. INSTALL CRANKSHAFT TIMING GEAR

    A01DVITE01

    1. Position the crankshaft timing gear with timing mark 1 facing forward.

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

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

      SST
      09223-00010

  20. INSTALL INJECTION GEAR


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

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

    2. Temporarily install the injection gear with the nut.

      Tech Tips

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

    3. A01DWZSE01

      Install a new O-ring to the injection gear.

    4. A01DV5GE01

      Install the the injection gear set nut.

    5. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  21. INSTALL NO. 2 IDLE SUB GEAR

    A01E12GE01

    1. Using a cloth or equivalent, mount the No. 1 idle gear in a vise as shown in the illustration.

      Note

      Be careful not to damage the gear.

    2. A01DXLPE01

      Install the gear spring.

    3. Install the No. 2 idle sub gear.

      Tech Tips

      Align the pins on the gears with the spring ends.

    4. Install the wave washer.

    5. A01E01BE01

      Using snap ring pliers, install the snap ring.

    6. A01E16C

      Using SST, align the holes of the No. 1 idle gear and No. 2 idle sub gear by turning the No. 2 idle sub gear clockwise, and temporarily install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
      Recommended Service Bolt
      Thread diameter Thread pitch Bolt length
      6.0 mm (0.23 in.) 1.0 mm (0.03 in.) Approx. 19 mm (0.75 in.)

    7. Align the gear teeth of the No. 1 idle gear and No. 2 idle sub gear, and tighten the service bolt.

  22. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01DVPDE05

      Install the gear shaft as shown in the illustration

  23. INSTALL NO. 1 IDLE GEAR


    1. A01DW82E01

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

    2. Using SST, turn the injection 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 )
    3. A01DZQ6E01

      Position the thrust plate with the protrusion facing forward.

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

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

    5. Remove the service bolt.

  24. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the sensor plate with the set key.

    2. Install the sensor plate with the cupped side facing outward.

  25. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. A01DVM3E01

      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
      3 to 5 mm (0.12 to 0.20 in.)

      Note

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

    3. A01DYKIE01

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

    4. A01E28YE01

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

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

  26. INSTALL WATER PUMP ASSEMBLY

    A01DWA8

    1. 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 }

  27. INSTALL CYLINDER HEAD GASKET

    A01E1XTE01

    1. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

    2. A01DWGGE01

      Measure the piston protrusion of each cylinder at 2 points as shown in the illustration.

    3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

      Piston protrusion
      0.005 to 0.255 mm (0.0002 to 0.0100 in.)

      Tech Tips

      When the removing piston and connecting rod assembly: If the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01DXBTE01

      Select a new cylinder head gasket.

      Tech Tips

      New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

      New installed cylinder head gasket thickness
      Mark Thickness
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)

      1. Select the largest piston protrusion value from the measurements made. Then select a new appropriate gasket according to the table below.

        Use gasket size
        Gasket Size Piston Protrusion
        Use A 0.005 to 0.054 mm (0.0002 to 0.0021 in.)
        Use B 0.055 to 0.104 mm (0.0022 to 0.0041 in.)
        Use C 0.105 to 0.154 mm (0.0041 to 0.0061 in.)
        Use D 0.155 to 0.204 mm (0.0061 to 0.0080 in.)
        Use E 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
    5. A01E1R6E01

      Place the cylinder head on the cylinder block.


      1. Place the cylinder head gasket on the cylinder block.

        Note

        Be careful of the installation direction.

      2. Place the cylinder head on the cylinder head gasket.

  28. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01E12RE01

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • If any bolt is broken or deformed, replace it.


    1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

    2. Install and uniformly tighten the 18 cylinder head bolts, in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt length A
      110 mm (4.33 in.)
      Bolt length B
      167 mm (6.57 in.)

      If any of the cylinder head bolts does not meet the torque specification, replace it.

    3. A01DYXOE02

      Mark the front of the cylinder head bolts with paint.

    4. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

    5. Finally, tighten the cylinder head bolts by an additional 90°.

    6. Check that the painted marks are now facing rearward.

  29. INSTALL CAMSHAFT

    A01E2S9E01

    1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    2. A01DXL7E02

      Install the camshaft.


      1. Apply MP grease to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head, facing the key groove upward.

      3. A01DV15E01

        Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

    3. A01DYANE03

      Remove any old packing (FIPG) material from the camshaft bearing cap.

    4. Apply seal packing to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note


      • Do not allow FIPG to contact the oil passage of the bearing cap.

      • After applying FIPG, install the camshaft bearing caps within 3 minutes and fasten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.


      1. A01E2XHE01

        Install the 5 bearing caps in their proper locations.

      2. A01E0JJE02

        Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

      3. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

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

    5. Install the camshaft oil seal.

  30. INSPECT VALVE CLEARANCE

    A01DX9JE02

    1. Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

    2. Turn the crankshaft 360° to set the No. 4 cylinder to TDC / compression.

    3. A01E0RDE02

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

  31. ADJUST VALVE CLEARANCE


    1. Adjust the valve clearance Click here.

  32. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, holder clamp, washer and bolt in their original positions.


    1. A01DYB9E01

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a small amount of clean engine oil to 4 new O-rings.

    3. A01E0HXE06

      Install an O-ring to each injector as shown in the illustration.

    4. Insert the 4 injectors into the cylinder head.

      Note


      • Insert the injector until it touches the nozzle sheet surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return an injector to the same place it was removed from.

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A01DWZ6E04

      Temporarily install 4 new washers and the 4 nozzle holder clamps with the 4 bolts.

      Note

      Make sure that the washers face the direction shown in the illustration.

      Tech Tips

      Apply a small amount of clean engine oil to the threads and under the heads of the clamp bolts.

      Note


      • A01DV3XE04

        The fork portion of the nozzle holder clamp must be set to the injector.

      • Before tightening the bolts, check that the nozzle holder clamp is set properly.

      • To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in the following step.

      • When tightening the bolts, pay attention not to tilt the bolt and clamp.

      • Do not reuse the washer.

      • If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

    7. Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01E2T3E01

      Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.

      If scratches or dents are present, replace the nozzle leakage pipe.

    9. A01DVA2E03

      Set the leakage pipe and 5 new gaskets in place.

    10. Apply a small amount of oil to the 4 hollow screws and union bolt.

    11. Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

    12. Tighten the 4 holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A01DVZRE06

      Tighten the 4 hollow screws in order from 1 to 4.

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

      Note

      If an hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

    14. Tighten the union bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

    15. Remove the 4 injection pipes.

  33. CHECK FOR FUEL LEAKS


    1. A01E0SLE03

      Check that there are no leaks from the nozzle leakage pipe connection.


      1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        SST
        09280-00010
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

      3. A01DX5HE01

        Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds to check that no bubbles form.

        SST
        09992-00242

        Note

        Before checking the leakage, be sure to remove the ball and spring in the check valve.

      4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

      5. Remove SST, No. 2 nozzle leakage pipe and gasket.

        Note

        Never reinstall the disassembled union bolt on the engine.

  34. INSTALL CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


    1. A01E2IC

      Install the block insulator to the head.

  35. INSTALL NO. 2 TIMING BELT COVER

    A01E1J8E01

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

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

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

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

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

  36. INSTALL CAMSHAFT TIMING PULLEY

    A01DV9RE01

    1. Install the camshaft timing pulley.

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

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  37. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DZAXE01

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

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

    3. A01E1YSE02

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

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

      Note


      • Remove any oil from the contact surface.

      • Install the belt cover within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the seal packing.

    4. A01DZGHE01

      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 }

  38. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new nozzle holder seals.

  39. INSTALL OIL FILLER CAP SUB-ASSEMBLY