OIL PUMP (w/o EGR Cooler) INSTALLATION

INSTALL FUEL SUPPLY PUMP ASSEMBLY

1. Check that the injection gear in the timing gear case moves back and forth smoothly.

2. Install a new O-ring to the pump.

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

4. 

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

5. 

   Install the pump with the 2 nuts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

6. Set a new O-ring before tightening the set nut.

7. 

   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 }

8. 

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

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

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

9. 

   Connect the 2 connectors.

10. 

    Connect the 2 fuel hoses.

11. 

    Temporarily install the fuel inlet pipe with the union nuts.

    Note

    
    

    • If the supply pump is replaced, the fuel inlet pipe must be replaced.

    • Keep the fuel inlet pipe free of foreign matter.

12. Using a 17 mm 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 }

    Tech Tips

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

13. Using a 17 mm 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 }

    Tech Tips

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

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

    Torque:

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

15. 

    Install the clamp with the bolt.

    Torque:

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

INSTALL CRANKSHAFT POSITION SENSOR

1. Install the crankshaft position sensor with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

INSTALL CAMSHAFT POSITION SENSOR

1. Install the camshaft position sensor with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

INSTALL CRANKSHAFT PULLEY

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

2. Using SST, install the pulley bolt.

   SST

   09213-58014

   09330-00021

   Torque:

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

INSTALL VANE PUMP ASSEMBLY

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

2. Install the vane pump with the 2 nuts.

   Torque:

   41 N*m  { 418 kgf*cm, 30 ft.*lbf }

INSTALL VACUUM PUMP ASSEMBLY

1. Install 2 new O-rings to the vacuum pump.

2. Install the vacuum pump with the 2 nuts.

   Torque:

   21 N*m  { 210 kgf*cm, 15 ft.*lbf }

INSTALL ENGINE WATER PUMP ASSEMBLY

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 }

INSTALL NO. 2 TIMING BELT COVER

1. 

   Text in Illustration

   *1	Seal Packing

   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 seal packing, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

2. Clean the bolts and their holes.

3. 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

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

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL CAMSHAFT TIMING PULLEY

1. Install the camshaft timing pulley.

2. Install 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 CYLINDER HEAD COVER SUB-ASSEMBLY

INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

1. w/ Intercooler:

   
   

   1. Temporarily install the No. 2 nozzle leakage pipe with the 3 bolts.

   2. Temporarily install a new gasket and the union bolt.

   3. 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 }

2. w/o Intercooler:

   
   

   1. Temporarily install the No. 2 nozzle leakage pipe with the 2 bolts.

   2. Temporarily install a new gasket and the union bolt.

   3. Tighten the 2 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 }

3. Connect the 3 fuel hoses.

INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

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

2. w/ Intercooler:

   Install the bolt.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

   Note

   
   

   • If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.

   • Make sure that the inner rubbers of the injection pipe fit inside the clamps.

   • When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.

3. w/o Intercooler:

   Install the 2 bolts.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

   Note

   
   

   • If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection pipe clamp with a new one.

   • Make sure that the inner rubbers of the injection pipe fit inside the clamps.

   • When installing the pipe, check that the inner rubbers and the clamps are in their proper positions.

4. 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 }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

5. 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 }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ Intercooler)

TIGHTEN NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)

1. w/ Intercooler:

   
   

   1. Temporarily install the No. 1 EGR pipe and 2 new gaskets to the cylinder head and EGR valve adapter with the 2 nuts and 2 bolts.

      Note

      Make sure the claws of the gasket face the No. 1 EGR pipe as shown in the illustration.

   2. Tighten the 2 nuts labeled A.

      Torque:

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

   3. Tighten the 2 bolts labeled B.

      Torque:

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

      

      Text in Illustration

      *1

      New Gasket

      *2

      Claw

2. 

   Text in Illustration

   *1

   Claw

   w/o Intercooler:

   Install 2 new gaskets and the No. 1 EGR pipe with the 2 nuts and 2 bolts.

   Torque:

   13 N*m  { 133 kgf*cm, 10 ft.*lbf }

   Tech Tips

   Make sure the claws of the gasket face the No. 1 EGR pipe.

TIGHTEN INTAKE AIR CONNECTOR (w/ Intercooler)

INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)

INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)

1. w/ Intercooler:

   
   

   1. Install the electric vacuum regulating valve bracket with the 2 bolts.

      Torque:

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

   2. Install the No. 1 gas filter with gas filter bracket with the bolt.

      Torque:

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

   3. Connect the 6 vacuum hoses.

      Note

      Be sure to securely connect the vacuum hoses.

   4. Connect the 2 connectors.

2. w/o Intercooler:

   
   

   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.

   3. Connect the connector.

CONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)

1. Connect the No. 3 water by-pass pipe with wire harness with the 2 bolts.

   Torque:

   18 N*m  { 184 kgf*cm, 13 ft.*lbf }

INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

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

2. 

   Text in Illustration

   *1	No. 2 Injection Pipe
   *2	No. 2 Injection Pipe Clamp
   *3	No. 3 Injection Pipe Clamp
   *4	Painted Mark

   w/ Intercooler:

   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 }

   Tech Tips

   If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

3. 

   Text in Illustration

   *1	No. 1 Injection Pipe
   *2	No. 2 Injection Pipe Clamp
   *3	No. 3 Injection Pipe Clamp
   *4	Painted Mark

   w/o Intercooler:

   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 }

   Tech Tips

   If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

4. 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 }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

5. 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 }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)

1. 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 }

2. 

   Connect the 2 connectors.

INSTALL FUEL INLET PIPE SUB-ASSEMBLY

1. Temporarily install the fuel inlet pipe with the union nuts.

   Note

   
   

   • When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.

   • Keep the fuel inlet pipe free of foreign matter.

2. 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 }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

3. 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 }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

INSTALL MANIFOLD STAY (w/o Intercooler)

INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE (w/ Intercooler)

1. Install the manifold stay with vacuum switching valve with the 2 bolts.

   Torque:

   19 N*m  { 194 kgf*cm, 14 ft.*lbf }

2. Connect the 3 vacuum transmitting hoses and 2 vacuum switching valve connectors.

   Note

   Be sure to securely connect the vacuum transmitting hose.

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

1. 

   Text in Illustration

   *1	V-ribbed Belt Tensioner
   *2	Cylinder Block

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

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   Tech Tips

   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.

INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

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

   Torque:

   45 N*m  { 459 kgf*cm, 33 ft.*lbf }

INSTALL GENERATOR BRACKET

1. Install the generator bracket with the bolt.

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

INSTALL GENERATOR ASSEMBLY

1. 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 }

2. Install the generator wire with the nut.

   Torque:

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

3. Connect the generator connector.

INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY

1. Install the No. 1 viscous heater bracket with the 2 bolts.

   Torque:

   45 N*m  { 459 kgf*cm, 33 ft.*lbf }

INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY

INSTALL TIMING BELT

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 }

2. Install the wire harness clamp.

3. Install the water hose clamp with the bolt.

   Torque:

   18 N*m  { 184 kgf*cm, 13 ft.*lbf }