OIL PUMP (w/ DPF) INSTALLATION

INSTALL TIMING GEAR CASE ASSEMBLY

INSTALL INJECTION GEAR

INSTALL CRANKSHAFT TIMING GEAR

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

INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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

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

INSTALL TIMING GEAR CASE OIL SEAL

Tech Tips

There are 2 methods to remove the oil seal.

1. If the timing gear cover is removed from the cylinder block:

   
   

   1. Using a screwdriver and hammer, tap out the oil seal.

   2. 

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST

      09223-15020

      09502-12010

      09950-70010   ( 09951-07100 )

   3. Apply MP grease to the oil seal lip.

2. If the timing gear cover is installed to the cylinder block:

   
   

   1. 

      Text in Illustration

      *1	Protective Tape
      *a	Cut Position

      Using a knife, cut through the oil seal lip.

   2. Using a screwdriver, pry out the oil seal.

      Note

      Be careful not to damage the crankshaft.

   3. 

      Apply MP grease to the oil seal lip.

   4. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST

      09223-15020

      09502-12010

      09950-70010   ( 09951-07100 )

INSTALL TIMING GEAR COVER OIL SEAL

Tech Tips

There are 2 methods to remove the oil seal.

1. If the timing gear cover is removed from the cylinder block.

   
   

   1. Using a screwdriver and a hammer, tap out the oil seal.

   2. 

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST

      09214-76011

   3. Apply MP grease to a new oil seal lip.

2. 

   If the timing gear cover is installed to the cylinder block.

   
   

   1. Using SST, remove the oil seal.

      Text in Illustration

      *a	Hold
      *b	Turn

      SST

      09308-10010

      09950-40011   ( 09957-04010 )

      09950-60010   ( 09951-00350 )

   2. 

      Apply MP grease to a new oil seal lip.

   3. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing gear cover edge.

      SST

      09214-76011

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 }

INSTALL TIMING GEAR CASE

INSTALL OIL STRAINER SUB-ASSEMBLY

INSTALL OIL PAN SUB-ASSEMBLY

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.

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 }

3. Connect the engine oil level sensor connector.

INSTALL FRONT SUSPENSION MEMBER ASSEMBLY

1. Temporarily tighten the 4 bolts and install the front suspension member assembly.

2. Temporarily tighten the 2 nuts and 2 suspension dampers.

3. Fully tighten the 4 bolts.

   Torque:

   150 N*m  { 1530 kgf*cm, 111 ft.*lbf }

4. Fully tighten the 2 nuts and 2 suspension dampers.

   Torque:

   120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

INSTALL PRESSURE FEED TUBE ASSEMBLY

1. Connect the tube with the union bolt and a new gasket.

   Torque:

   42.1 N*m  { 430 kgf*cm, 31 ft.*lbf }

INSTALL STEERING GEAR OUTLET RETURN TUBE

1. Install the return tube.

   Torque:

   44 N*m  { 450 kgf*cm, 33 ft.*lbf }

2. 

   Face the claw to the vehicle is front, and install the return hose to the PS gear assembly with the clip.

3. 

   Install the hose with bolt (LHD steering position type only).

   Torque:

   18 N*m  { 184 kgf*cm, 13 ft.*lbf }

INSTALL STEERING TORQUE SHAFT ASSEMBLY

Text in Illustration

*a

Matchmark

1. Align the matchmarks on the torque shaft and bevel gear.

2. Tighten the bolt.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

3. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks on the sliding yoke and steering gear.

4. Tighten the bolt.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

1. Support the front suspension lower arm No. 1 LH with a jack, connect the front suspension lower arm No. 1 LH to the steering knuckle.

2. Install new castle nut to the steering knuckle.

   Torque:

   140 N*m  { 1428 kgf*cm, 103 ft.*lbf }

3. Install new cotter pin.

INSTALL FRONT STABILIZER BAR

1. Install the 4 bolts and connect the stabilizer bar.

   Torque:

   36 N*m  { 367 kgf*cm, 27 ft.*lbf }

TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH

1. Install the front shock absorber assembly LH and bolt, temporarily tighten the nut.

INSTALL TIE ROD END SUB-ASSEMBLY LH

1. Connect the tie rod end to the knuckle arm.

2. Install the nuts and new cotter pin.

   Torque:

   91 N*m  { 928 kgf*cm, 67 ft.*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 OIL PRESSURE SWITCHING VALVE ASSEMBLY

Text in Illustration

*1

O-ring

1. Apply a light coat of engine oil to the O-ring of the oil pressure switching valve.

   Note

   If reusing the oil pressure switching valve, be sure to inspect the O-ring.

2. Install the oil pressure switching valve with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   Make sure that the O-ring is not cracked or jammed when installing the valve.

3. Connect the oil pressure switching valve connector.

INSTALL CAMSHAFT POSITION SENSOR

INSTALL CRANKSHAFT POSITION SENSOR

1. 

   Text in Illustration

   *1	O-ring
   *a	Engine Oil

   Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

2. TYPE A:

   

   Text in Illustration

   *1	Clamp	*2	Wire Harness Clamp (A)
   *3	Wire Harness Clamp (B)	*4	Protrusion

   
   

   1. Install the crankshaft position sensor with the bolt.

      Torque:

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

      Note

      Make sure that the O-ring is not damaged or does not jump out of position during installation.

   2. Install a new clamp.

      Note

      
      

      • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

      • Make sure the crankshaft position sensor wire harness is installed in the position shown in the illustration.

   3. Attach the crankshaft position sensor connector to the No. 1 vacuum transmitting pipe.

   4. Connect the crankshaft position sensor connector.

   5. Attach the 2 wire harness clamps (A, B).

3. TYPE B:

   

   Text in Illustration

   *1	Clamp	*2	Wire Harness Clamp (A)
   *3	Wire Harness Clamp (B)	*4	Protrusion
   *5	Bracket (Clamp)	-	-

   
   

   1. Install the crankshaft position sensor with the bolt.

      Torque:

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

      Note

      Make sure that the O-ring is not damaged or does not jump out of position during installation.

   2. Install the bracket (clamp) with the bolt.

      Torque:

      13 N*m  { 132 kgf*cm, 9.5 ft.*lbf }

   3. Install a new clamp.

      Note

      
      

      • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

      • Make sure the crankshaft position sensor wire harness is installed in the position shown in the illustration.

   4. Attach the crankshaft position sensor connector to the No. 1 vacuum transmitting pipe.

   5. Connect the crankshaft position sensor connector.

   6. Attach the 2 wire harness clamps (A, B).

   7. Attach the 2 wire harness clamps to the bracket (clamp).

INSTALL VACUUM PUMP

FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH

1. Fully tighten the nut.

   Torque:

   105 N*m  { 1071 kgf*cm, 77 ft.*lbf }

ADD ENGINE OIL

1. Add fresh oil and install the oil filler cap.

   Engine oil
   Item Oil Grade Oil Viscosity (SAE) w/ DPF ACEA C2 (Using engine oil other than ACEA C2 may damage catalytic converter) 0W-30 5W-30 w/o DPF G-DLD1, API CF-4, CF or ACEA B1 5W-30 10W-30 15W-40 20W-50

   Capacity
   Item Fill Amount Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 Imp. qts) Drain and refill without oil filter change 6.8 liters (7.2 US qts, 6.0 Imp. qts) Dry fill 7.7 liters (8.1 US qts, 6.8 Imp. qts)

BLEED AIR FROM FUEL SYSTEM

ADD ENGINE COOLANT

1. Pour coolant into the radiator until it overflows.

   Capacity
   Specification Capacity w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts) w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts) w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

   Note

   Do not substitute plain water for engine coolant.

   Tech Tips

   
   

   • Use of improper coolants may damage the engine cooling system.

   • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand.

   If the coolant level goes down, add coolant.

3. Install the radiator cap securely.

4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

5. Warm up the engine until the thermostat opens.

   
   

   1. While the thermostat is open, circulate the coolant for several minutes.

      Tech Tips

      The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

6. Maintain the engine speed at 2000 to 2500 rpm.

7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

   CAUTION:

   
   

   When squeezing the radiator hoses:

   • Wear protective gloves.

   • Be careful as the radiator hoses are hot.

   • Keep your hands away from the fan.

8. Stop the engine and wait until the coolant cools down.

9. Remove the radiator cap and check the coolant level inside the radiator.

10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

11. Check the coolant level inside the radiator reservoir tank again.

    If it is below the full level, add coolant.

INSPECT FOR OIL LEAK

1. Warm up the engine and inspect for oil leak.

INSPECT FOR FUEL LEAK

1. Perform the Active Test.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the ignition switch to ON.

   3. Turn the intelligent tester on.

   4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

   5. Perform the Active Test.

      Intelligent Tester Display	Test Part	Control Range	Diagnostic Note
      Test the Fuel Leak	Pressurize the common rail interior and check for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when ON is selected. Above conditions preserved while test is ON Tech Tips If this Active Test is performed when the engine is cold, combustion may become unstable. However, this is not a malfunction. It is only necessary to confirm that the pressure rises to the target pressure and that there are no fuel leaks.

INSPECT FOR COOLANT LEAK

1. Remove the radiator cap.

   CAUTION:

   To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

2. 

   Text in Illustration

   *1	Radiator Cap Tester

   Fill the radiator with coolant and attach a radiator cap tester.

3. Warm up the engine.

4. Pump it to 118 kPa (1.2 kgf/cm², 17.1 psi), then check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.

5. Reinstall the radiator cap.

INSPECT ENGINE OIL LEVEL

1. Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.

   If low, check for leakage and add oil up to the full level mark.

   Note

   Do not fill engine oil above the full level mark.