ENGINE UNIT REASSEMBLY


  1. INSTALL TIGHT PLUG

    A01BDATE03

    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 the tight plug as shown in the illustration.

        SST
        09950-60010   ( 09951-00180, 09951-00190, 09951-00200, 09951-00350, 09951-00400, 09951-00450 )
        09950-70010   ( 09951-07100 )
        A01BFSWE01

  2. INSTALL STUD BOLT

    A01BGMVE01

  3. INSTALL STRAIGHT PIN

    A01BAXWE03

  4. INSTALL RING PIN

    A01BFEKE06

  5. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe with the bolt and new O-ring.

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

  6. INSTALL UNION


    1. Install a union.

  7. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    A01BGACE01

    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

    A01BGO8E01

    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. A01BBROE01

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

      3. Coat the piston pin with engine oil.

      4. A01BC4BE01

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

      5. A01BEAUE01

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

      6. A01BFSVE01

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

    2. A01BBKBE03

      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. A01BF0BE02

        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. A01BGO7E01

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

        Note

        Do not align the ring ends.

  9. INSTALL CONNECTING ROD BEARING

    A01BHLDE01

    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

    A01BHH6E01

    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

    A01BEEXE02

    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. A01BEFBE03

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

    4. A01BBG0E01

      Install the 5 crankshaft bearing caps in their proper locations.

    5. A01BDRXE02

      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. A01BFXIE04

        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

    A01BCH2E01

    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.

    2. A01BHRYE01

      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. A01BESBE01

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

    3. A01BBX0E03

      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. A01BF6XE04

        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

    A01BFIHE01

    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.

      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 the bolts within 15 minutes.

    4. A01BBAM

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

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

  15. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR

    A01BB7JE01

    1. Mount the balanceshaft between aluminium plates in a vise.

      Note

      Be careful not to damage the balance shaft.

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

    3. Install the bolt.

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

  16. INSTALL NO. 2 BALANCESHAFT SUB-ASSEMBLY

    A01BGEUE01

    1. Install the balanceshaft with the 2 bolts.

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

  17. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR

    A01BAG3E01

    1. Mount the balanceshaft between aluminium plates in a vise.

      Note

      Be careful not to damage the balanceshaft.

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

    3. Install the bolt.

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

  18. INSTALL NO. 1 BALANCESHAFT SUB-ASSEMBLY

    A01BDL1E01

    1. Install the balanceshaft 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. A01BC38E05

      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. A01BHVHE02

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

    4. A01BEOUE01

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

    5. A01BDDTE01

      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. A01BH33E02

      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. A01BFZ0E01

      Remove the screw plug.

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

    10. Install a new gasket and the screw plug.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  20. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. A01BGWK

      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

    A01BFXKE07

    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
      5 mm (0.20 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 }

  22. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

    A01BCWFE01

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

    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

  23. INSTALL INJECTION GEAR


    1. Install the injection pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    2. A01BF3PE01

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

    3. A01BCCDE01

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

    4. A01BHW8E01

      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 }

  24. INSTALL NO. 1 IDLE GEAR


    1. A01BBEME01

      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. A01BAO0E01

      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. A01BBDQE01

      Using snap ring pliers, install the snap ring.

    6. A01BDZ3E01

      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. A01BFECE01

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

      Note

      Be careful not to damage the gears.

    9. A01BH1KE01

      Remove the service bolt.

    10. A01BB0NE01

      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. A01BF16E01

      Using a snap ring pliers, install the snap ring.

    14. A01BH12E01

      Using SST, align the holes of the No. 1 idle 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. A01BD2SE04

      Install the gear shaft as shown in the illustration.

    16. A01BC82E01

      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. A01BHFOE02

      Position the thrust plate with the protrusion facing outward.

    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.

  25. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A01BFVGE01

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

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

  26. INSTALL TIMING GEAR CASE


    1. Remove any old packing (FIPG) material.

    2. A01BHJOE01

      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. A01BHC0E01

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

    4. A01BD4BE01

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

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

  27. INSTALL WATER PUMP ASSEMBLY

    A01BHZ7

    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 }

  28. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01BBWTE01

    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. A01BDGEE02

      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 at a 180° angle to the front.

  29. INSTALL CAMSHAFT


    1. A01BE1FE01

      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. A01BHTRE02

        Apply MP grease to the thrust portion of the camshaft.

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

      3. A01BCWVE01

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

    3. A01BCC1E04

      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. A01BANQE01

        Install the 5 bearing caps in their proper locations.

      2. A01BH68E02

        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 }

  30. INSTALL CAMSHAFT SETTING OIL SEAL


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

    2. A01BDHOE01

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

      SST
      09608-06041

  31. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    A01BES8E03

    1. Align the alignment marks 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.

  32. INSPECT VALVE CLEARANCE

    A01BGD1E03

    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. A01BH8PE02

      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.

  33. ADJUST VALVE CLEARANCE


    1. Remove the camshafts Click here.

    2. Remove the 8 valve lifters.

    3. A01BF23E01

      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.).

      A01BG3IE01
      A01BAD4E01
      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) - -
      A01BEDME01
      A01BBJGE01
      A01BDZZE01
      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) - -

    6. Install the selected valve lifters.

    7. Install the camshafts Click here.

  34. INSTALL CYLINDER BLOCK INSULATOR

  35. INSTALL NO. 2 TIMING BELT COVER


    1. A01BD0OE01

      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 }

  36. INSTALL CAMSHAFT TIMING PULLEY


    1. A01BG3CE01

      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  { 1,000 kgf*cm, 72 ft.*lbf }

  37. INSTALL INJECTOR ASSEMBLY

    A01BEN4E01

    Note

    When replacing the injector assembly with a new one, register the injector compensation code manually in the ECM using the intelligent tester, as each injector assembly has a different injection characteristic.


    1. A01BBVS

      While registering the injector compensation codes, put tags with cylinder numbers (#1 to #4) on the new injectors in order to match them into the correct cylinders.

    2. Register the injector compensation code manually Click here.

    3. A01BBRP

      Install a new injection nozzle seat onto the cylinder head.

    4. A01BA5VE02

      Install a new O-ring.

      Tech Tips

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

    5. Install the injector assembly into each cylinder referring to the tags with cylinder numbers (#1 to #4).

      Note

      If the wrong injector assembly is installed on the cylinder, rough idling or noise may occur.

    6. Temporarily install the 4 injection pipes.

      Note

      When replacing the injector, replace the injection pipe as well.

      Tech Tips

      Hand tighten the union nuts of the injection pipes.

    7. A01BE7Q

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

    8. Temporarily install the nozzle leakage pipe assembly and 5 new nozzle leakage pipe gaskets and hand tighten the 4 hollow screws and union bolt until them cannot turn.

      Note

      Check the injector hollow screws and union bolt for any deformation or damage.

    9. A01BEKZ

      Install the 4 nozzle holder clamps and 4 new washers with the 4 bolts.

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

      Note


      • Do not install the washers in the wrong direction.

      • Clip the injector at the fork portion with a clamp which is set on the head of the cam cap bolt. At this time, check that the clamp does not hold the injector at the part where the spring is attached.

      • Temporarily torque the clamp bolts by hand until the bolt touches the washer, then tighten them by the specified torque.

    10. A01BE25E02

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

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

    11. Tighten the union bolt.

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

      Note

      If the bolt is excessively tightened, replace the nozzle leakage pipe assembly with a new one.

    12. Remove injection pipe No. 1, No. 2, No. 3, and No. 4.

  38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BE87E03

      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. A01BE6DE02

      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. A01BBDL

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

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

  39. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new holder seals.

  40. INSTALL OIL FILLER CAP GASKET

  41. INSTALL OIL FILLER CAP SUB-ASSEMBLY