ENGINE UNIT (w/o DPF) REASSEMBLY


  1. INSTALL TIGHT PLUG

    A01KGCGE15
    Text in Illustration
    *1 Adhesive

    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 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.

        SST
        09950-60010   ( 09951-00180, 09951-00190, 09951-00200, 09951-00350, 09951-00400, 09951-00450 )
        09950-70010   ( 09951-07100 )
        A01KI4RE02
        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

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

  3. INSTALL STRAIGHT PIN

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

  4. INSTALL RING PIN

    A01KHV7E12
    Text in Illustration
    *a Cylinder Head Side *b 6 mm (0.413 in.) or less

  5. 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 }

    2. Install the union.

  6. 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.

  7. 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 }

  8. 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. A01KG4SE04
        Text in Illustration
        *a Front Marks

        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. A01KHEFE07
      Text in Illustration
      *a Coil Joint
      *b Oil Ring Ends

      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
        *2 No. 2
        *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 NPR
        No. 2 N
      3. A01KHL1E05
        Text in Illustration
        *1 No. 1
        *2 No. 2
        *3 Coil
        *4 Oil
        *a Front Mark

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

        Note

        Do not align the ring ends.

  9. 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.

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

  11. 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.

  12. 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
    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. A01KI72E11
      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.

  13. INSTALL CYLINDER BLOCK OIL ORIFICE

  14. INSTALL REAR ENGINE OIL SEAL RETAINER

    A01KFABE02

    1. Remove any old packing (FIPG) material.

    2. Remove oil seal packing (FIPG) from the cylinder block.

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

      Text in Illustration
      *a Seal Diameter: 3 to 5 mm (0.12 to 0.20 in.)
      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.

    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 }

  15. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR

    A01KGNYE01

    1. Mount the balance shaft between aluminium 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 }

  16. 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 }

  17. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR

    A01KIEFE01

    1. Mount the balance shaft between aluminium 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 }

  18. 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 }

  19. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old packing (FIPG) material.

    2. A01KIK1E12
      Text in Illustration
      *1 Seal Packing
      *2 Gasket
      *a Seal Diameter: 5 mm

      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 within 3 minutes and tighten the bolts within 15 minutes of applying FIPG.

    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. A01KFTEE02

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

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

      Remove the screw plug.

    9. Pour in approximately 20 cc (0.12 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 }

  20. 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 }

  21. INSTALL OIL PAN SUB-ASSEMBLY (w/ Heater)

    A01KIAPE08
    Text in Illustration
    *1 Seal Packing

    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
      4.0 mm (0.16 in.)
    3. A01KGMZE04
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the cylinder block stiffening plate 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 stiffening plate and oil pan within 3 minutes and tighten the bolts within 15 minutes of applying FIPG.

    4. Install the stiffening plate and oil pan with the 22 bolts and 2 nuts.

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

    5. Install the vinyl tube to the oil pan.

  22. INSTALL OIL PAN SUB-ASSEMBLY (w/o Heater)

    A01KIAPE08
    Text in Illustration
    *1 Seal Packing

    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
      4.0 mm (0.16 in.)

      Note

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

    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.

  23. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

    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

  24. INSTALL INJECTION GEAR


    1. Install the injection 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. A01KFBLE05
      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 }

  25. 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. A01KG8SE06
      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. A01KH2BE12
      Text in Illustration
      *a Oil Hole

      Install the gear shaft as shown in the illustration.

    16. A01KECKE06
      Text in Illustration
      *a Turn

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

    17. 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 )
    18. A01KEKGE05
      Text in Illustration
      *1 Service Bolt
      *a Protrusion

      Position the thrust plate with the protrusion facing forward.

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

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

    20. Remove the service bolt.

  26. 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.

  27. INSTALL TIMING GEAR CASE


    1. Remove any old packing (FIPG) material.

    2. A01KH0SE03
      Text in Illustration
      *a Seal Diameter: 3 to 5 mm

      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

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

    3. A01KG58E04
      Text in Illustration
      *1 New O-Ring

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

    4. A01KGWVE01

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

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

  28. INSTALL 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 }

  29. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01KEWBE01

    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. 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 }
      HINT
      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. A01KFEKE05
      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 mark is now facing rearward.

  30. INSTALL CAMSHAFT


    1. A01KI2EE04
      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. A01KFGIE08
        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. A01KEFRE10
      Text in Illustration
      *1 Oil Passage
      *2 Seal Packing
      *a Seal Diameter: 4 mm

      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 come into contact with 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. 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 }

  31. 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

  32. 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.

  33. INSPECT VALVE CLEARANCE

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

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

      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 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.

  34. 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 (0.00158 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.

      A01KI2YE01
      Text in Illustration
      *1 Intake Valve Lifter Chart (1/2) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      A01KFC5E01
      Text in Illustration
      *1 Intake Valve Lifter Chart (2/2) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness 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 (0.0158 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) - -
      A01KEHUE01
      Text in Illustration
      *1 Exhaust Valve Lifter Chart (1/3) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      A01KF7IE01
      Text in Illustration
      *1 Exhaust Valve Lifter Chart (2/3) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      A01KH8WE01
      Text in Illustration
      *1 Exhaust Valve Lifter Chart (3/3) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness 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.

  35. INSTALL CYLINDER BLOCK INSULATOR

  36. INSTALL NO. 2 TIMING BELT COVER


    1. A01KG80E04
      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 FIPG, install the No. 2 timing belt cover within 3 minutes and tighten the 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 }

  37. INSTALL CAMSHAFT TIMING PULLEY


    1. A01KG6WE01

      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  { 999 kgf*cm, 72 ft.*lbf }

  38. INSTALL INJECTOR ASSEMBLY

    A01KEGHE03

    Note


    • Register the injector compensation code in the ECM when replacing the fuel injector with a new one. Record the injector compensation code of the fuel injector and keep them in the correct order so that they can be easily installed.

      Text in Illustration
      *a #1, #2 Cylinder
      *b #3, #4 Cylinder
      *c Injector Compensation Code

    • The correct shape of cylinders (#1,#2) is different from that of the cylinders (#3,#4).

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


    1. A01KESYE01

      Install 4 new injection nozzle seats to the cylinder head.

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

    3. A01KHMFE11

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

    4. Insert the 4 injectors into the cylinder head.

      Text in Illustration
      *1 New O-Ring

      Note


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

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

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

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

    6. A01KGHVE02
      Text in Illustration
      *1 Washer
      *2 Downward
      *a Nozzle Clamp Holder

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

      Tech Tips

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

      Note


      • 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. A01KGHK

      Temporarily install the 4 injection pipes with the union nuts.

      Note

      When replacing the fuel injector with a new one, replace the injection pipe No. 1, No. 2, No. 3 or No. 4 with new ones.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01KGXQE01

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

    10. A01KGUME08
      Text in Illustration
      *1 Union Bolt
      *2 Hollow Screw

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

    11. A01KG6DE01

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

    12. Tighten the 4 holder clamp bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    13. A01KG4UE07
      Text in Illustration
      *1 Union Bolt
      *2 Hollow Screw

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

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

      Note

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

    14. Tighten the union bolt.

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

      Note

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

    15. Remove the 4 injection pipes.

  39. 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. A01KF06E09
      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 FIPG 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. A01KINQ

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

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

  40. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new holder seals.

  41. INSTALL OIL FILLER CAP GASKET

  42. INSTALL OIL FILLER CAP SUB-ASSEMBLY