ENGINE UNIT (w/ DPF) 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.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.

  • When replacing a fuel injector, check that the injection compensation codes of the fuel injectors installed on the cylinders match the ones registered in the ECM. If they do not match, correct the registered data Click here.


  1. INSTALL TIGHT PLUG

    Tech Tips


    • If coolant leaks from a tight plug or a plug is corroded, replace it.

    • Perform this procedure only when replacement of a tight plug is necessary.


    1. A01KGCGE15
      Text in Illustration
      *1 Adhesive

      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 at least 1 hour after the installation.

    2. Position A:


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

    3. Other Positions:


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

        A01KI4RE02
        SST
        09950-60010   ( 09951-00180, 09951-00190, 09951-00200, 09951-00350, 09951-00400, 09951-00450 )
        09950-70010   ( 09951-07100 )
        Text in Illustration
        *a Right Side *b Left Side
        *c Front Side *d Rear Side
        *e for RHD *f for LHD
        *g Stops - -

  2. INSTALL STUD BOLT

    Tech Tips

    Perform this procedure only when replacement of a stud bolt is necessary.


    1. Install the stud bolts.

      A01KFSRE03
      Text in Illustration
      *a Front Side *b Left Side
      *c Upper Side *d Lower Side

  3. INSTALL STRAIGHT PIN

    Tech Tips

    Perform this procedure only when replacement of a straight pin is necessary.


    1. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

      A01KHA0E05
      Text in Illustration
      *a Front Side *b Rear Side
      *c Until pin stops - -

  4. INSTALL RING PIN

    Tech Tips

    Perform this procedure only when replacement of a ring pin is necessary.


    1. Using a plastic-faced hammer, tap in new ring pins to the cylinder block.

      A01KFH0E01
      Text in Illustration
      *a Cylinder Head Side *b 6 mm or less

  5. INSTALL HOLE PLUG

    Tech Tips

    Perform this procedure only when replacement of the hole plug is necessary.


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

    2. Install the O-ring and hole plug with the bolt.

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

  6. INSTALL PLATE PLUG

    Tech Tips

    Perform this procedure only when replacement of the plate plug is necessary.


    1. Install a new O-ring and the plate plug with the bolt.

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

  7. INSTALL OIL FILTER BRACKET WITH HEAD STRAIGHT SCREW PLUG

    Tech Tips

    Perform this procedure only when replacement of the oil filter bracket with head straight screw plug is necessary.


    1. Install a new gasket and the oil filter bracket with head straight screw plug.

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

  8. INSTALL PLUG

    Note

    If coolant leaks from the plug or the plug is corroded, replace the plug.


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

    2. A01KFAHE01

      Apply adhesive onto the shaded area of the plug as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the plug within 3 minutes after applying adhesive.

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

  9. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    A01KF2ZE01

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

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

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

  10. INSTALL PISTON PIN

    A01KGTRE01

    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. A01KIJDE01

        Gradually heat the piston to about 80°C (176°F).

      3. Coat the piston pin with engine oil.

      4. A01KG4SE03
        Text in Illustration
        *a Front Mark (Arrow)
        *b Front Mark (Protrusion)

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

      5. A01KHGUE01

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

      6. A01KGC7E01

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

    2. A01KEI7E02
      Text in Illustration
      *a Coil Joint
      *b Oil Ring End Gap

      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. A01KGWSE05
        Text in Illustration
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *a Code Mark

        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 NAA
        No. 2 N
      3. A01KEZ5E03
        Text in Illustration
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring
        *3 Coil
        *4 Oil Ring
        *a Front Mark

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

        Note

        Do not align the ring ends.

  11. INSTALL CONNECTING ROD BEARING

    A01KFBKE01

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

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

  12. INSTALL CRANKSHAFT BEARING

    A01KH45E01

    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. A01KEA9E01

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

  13. INSTALL CRANKSHAFT

    A01KF4UE02

    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. A01KIFME03

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

    4. A01KGG6E01

      Install the 5 crankshaft bearing caps in their proper locations.

    5. A01KI2OE02

      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 the 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. A01KEAKE12
        Text in Illustration
        *a Painted Mark
        *b Front

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

      4. Retighten the main bearing cap bolts 90° in the numerical order shown above.

      5. Check that the painted mark is now at a 90° angle to the front.

    6. Check that the crankshaft turns smoothly.

    7. Check the crankshaft thrust clearance.

  14. INSTALL PISTON AND CONNECTING ROD

    A01KHDYE02

    1. 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.

      Text in Illustration
      *a Front Mark (Arrow)
    2. A01KHQYE01

      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. A01KHBGE03
        Text in Illustration
        *a Front
        *b Front Mark (Protrusion)

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

    3. A01KI72E09
      Text in Illustration
      *a Matchmark

      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 coat of engine oil to 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 bolt.

      3. A01KIN9E07
        Text in Illustration
        *a Painted Mark
        *b Front

        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 mark is now at a 90° angle to the front.

    4. Check that the crankshaft turns smoothly.

    5. Check the connecting rod thrust clearance Click here.

  15. INSTALL CYLINDER BLOCK OIL ORIFICE

  16. INSTALL REAR ENGINE OIL SEAL RETAINER

    A01KHRVE01

    1. Remove any old seal packing material.

      Text in Illustration
      *1 Seal Packing

    2. Remove oil seal packing from the cylinder block.

    3. 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
      4.0 mm (0.16 in.)

      Note

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

    4. A01KEHO

      Install the retainer with the 5 bolts. Alternately tighten the 7 bolts in several passes.

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

  17. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR

    A01KGNYE01

    1. Mount the balance shaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balance shaft.

    2. Align the balance shaft knock pin with the knock pin hole. Then install the balance shaft thrust washer and balance shaft driven gear.

    3. Install the bolt.

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

  18. INSTALL NO. 2 BALANCESHAFT SUB-ASSEMBLY

    A01KGVYE01

    1. Install the balance shaft with the 2 bolts.

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

  19. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR

    A01KIEFE01

    1. Mount the balance shaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balance shafts.

    2. Align the balance shaft knock pin with the knock pin hole. Then install the balance shaft thrust washer and balance shaft driven gear.

    3. Install the bolt.

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

  20. INSTALL NO. 1 BALANCESHAFT SUB-ASSEMBLY

    A01KIMFE01

    1. Install the balance shaft with the 2 bolts.

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

  21. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old seal packing material.

    2. A01KGD1E01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the timing gear case as shown in the illustration.

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

      Note

      Install the timing gear case within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    3. A01KH2EE05
      Text in Illustration
      *1 New Gasket

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

    4. A01KEDVE04
      Text in Illustration
      *1 New O-Ring

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

    5. A01KFN8E01

      Align the "2" marks of the balance shaft driven gear No. 1 and oil pump drive gear.

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

    7. A01KIK4E01
      Text in Illustration
      *1 Union Bolt

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

      Torque:
      Bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
    8. A01KI67E01

      Remove the straight screw plug.

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

    10. Reinstall a new gasket and the screw plug.

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

  22. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01KFE7

      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 }

  23. INSTALL OIL PAN SUB-ASSEMBLY

    A01KIAPE06
    Text in Illustration
    *1 Seal Packing

    1. Remove any old seal packing 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
      4.0 mm (0.16 in.)

      Note

      Install the oil pan within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    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 vinyl tube to the oil pan.

  24. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install a new gasket to the engine oil level sensor.

    2. Install the engine oil level sensor with the 4 bolts.

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

  25. INSTALL CRANKSHAFT TIMING GEAR

    A01KHA2E01

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

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

    3. Using SST and a hammer, tap in the timing gear.

      SST
      09223-00010

  26. 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. A01KFEFE01

      Align the "3" marks of the No. 2 balance shaft driven gear and injection pump gear.

    3. A01KFBLE04
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection pump gear.

    4. A01KFICE01

      Install the injection pump gear set nut.

    5. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  27. INSTALL NO. 1 IDLE GEAR


    1. A01KHSGE05
      Text in Illustration
      *a Cut-Off Mark

      Mount the No. 1 idle gear in a vise.

      Tech Tips

      The cut-off mark of the idle gear faces down.

      Note

      Be careful not to damage the gear.

    2. A01KE9QE04
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub-Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

    3. Install the No. 2 idle sub-gear.

    4. Install the wave washer.

      Tech Tips

      Fit the pins on the gears to the spring ends.

    5. A01KF0UE01

      Using snap ring pliers, install the snap ring.

    6. A01KG8SE05
      Text in Illustration
      *1 Service Bolt

      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 install a service bolt.

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

    7. Remove the No. 1 idle gear from the vise and turn it upside down.

    8. A01KG2EE04
      Text in Illustration
      *a Upward

      Mount the No. 1 idle gear and No. 2 idle sub-gear in a vise.

      Note

      Be careful not to damage the gears.

    9. A01KH5OE03
      Text in Illustration
      *1 Service Bolt

      Remove the service bolt.

    10. A01KED4E04
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 idle Sub-Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

    11. Install the No. 1 idle sub-gear.

    12. Install the wave washer.

      Tech Tips

      Fit the pins on the gears to the spring ends.

    13. A01KFI4E01

      Using a snap ring pliers, install the snap ring.

    14. A01KIF4E04
      Text in Illustration
      *1 Service Bolt
      *a Upward

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

      SST
      09960-10010   ( 09962-01000, 09963-00600 )
    15. A01KHR3E04
      Text in Illustration
      *1 Engine Oil

      Apply a coat of engine oil to the gear shaft.

    16. A01KH2BE09
      Text in Illustration
      *a Oil Hole

      Install the gear shaft as shown in the illustration.

    17. A01KELUE01
      Text in Illustration
      *a Turn

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

    18. Using SST, turn the supply pump gear, and align the "4" timing marks of the idle gear and supply pump gear, and mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    19. A01KEKGE05
      Text in Illustration
      *1 Service Bolt
      *a Protrusion

      Position the thrust plate with the protrusion facing forward.

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

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

    21. Remove the service bolt.

  28. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A01KIQKE01

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

    2. Install the sensor plate, facing the cup side outward.

  29. INSTALL OIL CHECK VALVE SUB-ASSEMBLY


    1. Using a 6 mm hexagon wrench, install the oil check valve with the bolt.

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

  30. INSTALL TIMING GEAR CASE


    1. Remove any old seal packing material.

    2. A01KIM1E01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the timing gear cover as shown in the illustration.

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

      Note

      Install the timing gear case within 3 minutes and tighten bolts within 15 minutes of applying seal packing.

    3. A01KGIA

      Install 3 new O-rings to the timing gear case assembly.

    4. Install the timing gear case with the 14 bolts and 2 nuts.

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

  31. INSTALL ENGINE WATER PUMP ASSEMBLY

    A01KHSB

    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 }

  32. INSTALL CYLINDER HEAD GASKET

    A01KHD0E03

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

      Text in Illustration
      *a Measuring Tip
      *b Protrusion
    2. A01KH52E03
      Text in Illustration
      *a Measuring Point

      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 that cylinder.

      Standard piston protrusion
      0.005 to 0.254 mm (0.0002 to 0.0100 in.)

      Tech Tips

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

    4. A01KGPSE03
      Text in Illustration
      *a Cutout Mark
      A01KFFI Front

      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
      Item Specified Condition
      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.

        Gasket Size to be Used
        Gasket Size Gasket Size
        A 0.005 to 0.054 mm (0.0002 to 0.0021 in.)
        B 0.055 to 0.104 mm (0.0022 to 0.0041 in.)
        C 0.105 to 0.154 mm (0.0041 to 0.0061 in.)
        D 0.155 to 0.204 mm (0.0061 to 0.0080 in.)
        E 0.155 to 0.204 mm (0.0061 to 0.0080 in.)
    5. A01KIMV

      Place the cylinder head on the cylinder block.

      Text in Illustration
      A01KFFI Front

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

        Note

        Make sure the gasket is installed in the collect direction.

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

  33. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    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 to the threads and under the heads of the cylinder head bolts.

    2. A01KEWBE01

      Install and uniformly tighten the 18 cylinder head bolts and 18 washers 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.)
      B 167 mm (6.57 in.)

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

    3. A01KFEKE04
      Text in Illustration
      *a Painted Mark
      *b Front

      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.

  34. INSTALL CAMSHAFT


    1. A01KI2EE03
      Text in Illustration
      *1 Set Key

      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. Install the camshaft.


      1. A01KFGIE06
        Text in Illustration
        *1 Key Groove
        *a Upward

        Apply MP grease to the thrust portion of the camshaft.

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

      3. A01KGP2E01

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

    3. A01KEFRE08
      Text in Illustration
      *1 Seal Packing
      *a Oil Passage

      Remove any old seal packing 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 seal packing to come into contact with the oil passage of the bearing cap.

      • After applying seal packing, 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. A01KEE1E01

        Install the 5 bearing caps in their proper locations.

      2. A01KGI2E02

        Apply a light coat of engine oil to 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 }

  35. INSTALL CAMSHAFT SETTING OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

    2. A01KFLPE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the oil seal retainer edge.

      SST
      09608-06041

  36. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    A01KG4RE05
    Text in Illustration
    *a Alignment Mark

    1. Align the alignment mark of the crankshaft pulley and timing gear case cover by rotating the crankshaft clockwise.

      Tech Tips

      Make sure that both cam-noses (intake side and exhaust side) of the No. 1 cylinder face upward.

  37. INSPECT VALVE CLEARANCE


    1. Check only the valves indicated.


      1. A01KG3PE05
        Text in Illustration
        *1 Exhaust
        *2 Intake
        *a Front

        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 the valve clearance measurements that are not within 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. Check only the valves indicated.


      1. A01KEKNE04
        Text in Illustration
        *1 Exhaust
        *2 Intake
        *a Front

        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 the valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

  38. ADJUST VALVE CLEARANCE


    1. Remove the camshafts Click here.

    2. Remove the 8 valve lifters.

    3. A01KF1SE01

      Using a micrometer, measure the thickness of the removed lifter.

    4. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

      A B C
      New lifter thickness Used lifter thickness Measured valve clearance
      New Lifter Thickness
      Intake A = B + (C - 0.25 mm (0.0098 in.))
      Exhaust A = B + (C - 0.40 mm (0.00157 in.))

    5. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips

      Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

    6. Install the selected valve lifter.

      A01KH6KE01
      Text in Illustration
      *1 Valve Lifter Selection Chart (Intake) *2 Installed lifter thickness mm (in.)
      *3 Measured clearance mm (in.) - -
      A01KGOWE01
      Text in Illustration
      *1 Valve Lifter Selection Chart (Intake) *2 Installed lifter thickness mm (in.)
      *3 Measured clearance mm (in.) - -
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm (0.2067 in.) shim with a No. 40 lifter.
      New Lifter Thickness (mm (in.))
      Shim No. Thickness Shim No. Thickness Shim No. Thickness
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -
      A01KGZKE01
      Text in Illustration
      *1 Valve Lifter Selection Chart (Exhaust) *2 Installed lifter thickness mm (in.)
      *3 Measured clearance mm (in.) - -
      A01KFUGE01
      Text in Illustration
      *1 Valve Lifter Selection Chart (Exhaust) *2 Installed lifter thickness mm (in.)
      *3 Measured clearance mm (in.) - -
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a No. 42 lifter.
      New lifter thickness (mm (in.))
      Shim No. Thickness Shim No. Thickness Shim No. Thickness
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -

    7. Install the camshaft Click here.

  39. INSTALL CYLINDER BLOCK INSULATOR


    1. Install the cylinder block insulator to the cylinder head.

  40. INSTALL NO. 2 TIMING BELT COVER

    A01KG80E03
    Text in Illustration
    *1 Seal Packing

    1. Apply seal packing 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 }

  41. INSTALL CAMSHAFT TIMING PULLEY


    1. Install the camshaft timing pulley.

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

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

  42. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.


    1. A01KGMP

      Install 4 new injection nozzle seats to the cylinder head.

    2. A01KH3LE03
      Text in Illustration
      *1 O-Ring

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

    3. Install one of the O-rings to each injector as shown in the illustration.

    4. Install the 4 injectors into the cylinder head.

      Note


      • Install the injector until it touches the injection nozzle seat surface.

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

      • Always reinstall 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. A01KIR7

      Temporarily install the 4 injection pipes with the union nuts.

      Note

      When replacing an injector, it is necessary to replace the 4 injection pipes with new ones.

      Tech Tips

      To position the injectors, loosely tighten the union nuts.

    7. A01KGXQ

      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.

    8. A01KGUME06
      Text in Illustration
      *1 Union Bolt
      *2 Gasket
      *3 Hollow Screws

      Set the nozzle leakage pipe and 5 new gaskets in place.

    9. Apply a small amount of clean engine oil to the 4 injector hollow screws and union bolt.

    10. Temporarily install the nozzle leakage pipe with the 4 injector hollow screws and union bolt.

    11. A01KHB7E03

      Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

      Text in Illustration
      *1 Washer
      *a Downward

      Note


      • A01KIJGE06

      • The fork portion of the No. 1 nozzle holder clamp must be set on the injector.

      • Before tightening the bolts, check that the No. 1 nozzle holder clamps are set properly.

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

      • When tightening the bolts, be careful so as not to tilt the bolt or clamp.

      • Do not reuse the washer.

      Text in Illustration
      *1 No. 1 Nozzle Holder Clamp

      Tech Tips

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

    12. Tighten the 4 No. 1 nozzle holder clamp bolts.

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

    13. Loosen the union nuts and remove the 4 injector pipes.

    14. A01KHBVE07
      Text in Illustration
      *1 Union Bolt

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

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

      Note

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

    15. 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.

  43. INSPECT NOZZLE LEAKAGE PIPE ASSEMBLY LEAK


    1. A01KGJTE02

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


      1. Install a new gasket and the No. 2 nozzle leakage pipe to the cylinder head with SST.

        SST
        09280-00010
        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }
        Text in Illustration
        *1 No. 2 Nozzle Leakage Pipe
        *2 Gasket

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

      3. A01KHBVJ02

        Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe, maintain 250 kPa (2.5 kgf/cm2, 36 psi) of pressure for 60 seconds and check that no bubbles form.

        SST
        09992-00242

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

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

        Note

        Never reinstall the disassembled union bolt to the engine.

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01KG75E04
      Text in Illustration
      *a Upper Side of Cylinder Head Cover

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

      Note


      • Do not install the gaskets at an angle.

      • Keep the lip of the gasket free from foreign materials.

    2. Install a new cylinder head cover gasket to the cylinder head cover.

    3. A01KF06E07
      Text in Illustration
      *1 Seal Packing

      Remove any old seal packing material from the cylinder head.

    4. 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.

      • After applying seal packing, install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes.

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

    5. A01KINQE01

      Install the cylinder head cover with the 10 bolts and 2 nuts in the order shown in the illustration in 2 progressive steps.

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

  45. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new holder seals.

  46. INSTALL OIL FILLER CAP GASKET

  47. INSTALL OIL FILLER CAP SUB-ASSEMBLY