ENGINE UNIT 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.

  • 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 (w/DPF: Click here, w/o DPF 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. 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 )
        A01BF41E02
        Text in Illustration
        *a Right Side *b Front Side
        *c Left Side *d Rear Side
        *e Stops - -

  2. INSTALL STUD BOLT

    Tech Tips

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


    1. Install the stud bolts.

      A01BC0UE02
      Text in Illustration
      *a Front Side *b Upper Side
      *c Left 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.

      A01BAXWE04
      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.

      A01BFEKE10
      Text in Illustration
      *a Cylinder Head Side *b 6 mm (0.413 in.) 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 NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01BGACE01

      Align the pin of the No. 1 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 }

  9. INSTALL PISTON PIN


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

      3. Coat the piston pin with engine oil.

      4. A01BC4BE02
        Text in Illustration
        *1 Front Mark (Arrow)
        *2 Front Mark (Protrusion)

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

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

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

    2. Install the piston rings.


      1. A01BEVAE01
        Text in Illustration
        *1 Coil Joint
        *2 Oil Ring End Gap

        Install the coil and oil ring by hand.

        Tech Tips

        Make sure the end gap of the oil ring and the coil joint are on opposite sides.

      2. A01BFWTE01
        Text in Illustration
        *1 No. 1 Compression Ring
        *2 No. 2 Compression Ring

        Using a piston ring expander, install the No. 1 and No. 2 compression rings with the code marks facing upward.

        Code Mark
        Item Specified Condition
        No. 1 compression ring w/ DPF NAC
        w/o DPF NAA
        No. 2 compression ring w/ DPF KD1
        w/o DPF N
      3. A01BBPQE02
        Text in Illustration
        *1 No. 1 Compression Ring
        *2 Coil
        *3 Oil Ring
        *4 No. 2 Compression Ring
        *5 Front Mark (Arrow)

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

        Note

        Do not align the ring ends.

  10. INSTALL CONNECTING ROD BEARING


    1. A01BHLDE01

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

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

  11. INSTALL CRANKSHAFT BEARING

    Tech Tips

    Upper bearings have an oil groove and oil hole. Lower bearings do not.


    1. A01BHH6E01

      Align the bearing claw with the claw groove of the cylinder block and push in the 5 upper bearings.

    2. A01BCRWE01

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

  12. INSTALL CRANKSHAFT


    1. A01BEEXE02

      Place the crankshaft on the cylinder block.

    2. Push the crankshaft in one direction and install one thrust washer to the No. 5 journal position with the oil groove facing outward.

    3. Push the crankshaft in the opposite direction and install the other thrust washer to the No. 5 journal position with the oil groove facing outward.

    4. A01BEFBE03

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

    5. A01BBG0E01

      Install the 5 crankshaft bearing caps to their proper locations.

    6. A01BDRXE02

      Install the crankshaft bearing cap bolts.

      Tech Tips


      • The crankshaft bearing cap bolts are tightened in 2 progressive steps.

      • If a crankshaft bearing cap bolt is broken or deformed, replace it.


      1. Apply a light coat of engine oil to the threads and under the bolt heads of the crankshaft bearing cap bolts.

      2. Install and uniformly tighten the 10 bolts of the crankshaft 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. A01BFXIE08
        Text in Illustration
        *1 Paint Mark
        *a Front

        Mark the front of each crankshaft bearing cap bolt with paint.

      4. Tighten the crankshaft bearing cap bolts by 90° in the numerical order shown in the previous illustration.

      5. Check that the paint marks are now at a 90° angle to the front.

    7. Check that the crankshaft turns smoothly.

    8. Check the crankshaft thrust clearance.

  13. INSTALL PISTON AND CONNECTING ROD


    1. A01BGEDE01
      Text in Illustration
      *1 Front Mark (Arrow)

      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 each numbered connecting rod cap with the correct 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. A01BESBE02
        Text in Illustration
        *1 Front Mark (Protrusion)
        A01BAZL Front

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

    3. A01BBX0E08
      Text in Illustration
      *1 Matchmark

      Install the connecting rod cap bolts.

      Tech Tips


      • The connecting rod cap bolts are tightened in 2 progressive steps.

      • If any connecting rod cap 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. A01BF6XE05
        Text in Illustration
        *1 Paint Mark
        *a Front

        Mark the front of each connecting rod cap bolt with paint.

      4. Tighten the connecting rod cap bolts by 90° as shown in the illustration.

      5. Check that the paint marks are now at a 90° angle to the front.

    4. Check the connecting rod thrust clearance Click here.

  14. INSTALL CYLINDER BLOCK OIL ORIFICE

  15. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. A01BFOG

      Remove any old seal packing (FIPG material).

    2. Remove any old seal packing (FIPG material) from the cylinder block.

    3. Apply seal packing to the places 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

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

    4. Install the rear engine oil seal retainer with the 5 bolts. Uniformly tighten the 5 bolts in several passes.

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

  16. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR


    1. Mount the No. 2 balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the No. 2 balanceshaft.

    2. Align the balanceshaft knock pin hole with the knock pin. Then install the balanceshaft thrust washer and No. 2 balanceshaft driven gear.

    3. Install the bolt.

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

  17. INSTALL NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. Install the No. 2 balanceshaft with the 2 bolts.

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

  18. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR


    1. Mount the No. 1 balanceshaft between aluminum plates in a vise.

      Note

      Be careful not to damage the No. 1 balanceshaft.

    2. Align the balanceshaft knock pin hole with the knock pin. Then install the balanceshaft thrust washer and No. 1 balanceshaft driven gear.

    3. Install the bolt.

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

  19. INSTALL NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. Install the No. 1 balanceshaft with the 2 bolts.

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

  20. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. A01BHUXE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF
      *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 mm (0.16 in.)

      Note

      After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

    3. A01BHVHE04
      Text in Illustration
      *1 New Gasket

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

    4. Install 2 new O-rings.

    5. A01BDDTE01

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

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

    7. A01BBZS

      w/ DPF:

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

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      Text in Illustration
      A01BAZL Bolt A
      A01BE9I Bolt B
      A01BG19 Union bolt
    8. A01BBNC

      w/o DPF:

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

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      Text in Illustration
      A01BAZL Bolt
      A01BE9I Union bolt
    9. A01BFZ0E01

      Remove the screw plug and gasket.

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

    11. Install a new gasket and the screw plug.

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

  21. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. 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 }

  22. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material).

    2. A01BHNVE05

      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. A01BFHEE03

      w/o DPF:

      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 cylinder block stiffening plate within 3 minutes and tighten the bolts within 15 minutes of applying seal packing.

    4. w/ DPF:

      Install the oil pan with the 22 bolts and 2 nuts.

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

    5. w/o DPF:

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

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

  23. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install a new gasket and the engine oil level sensor with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  24. INSTALL CRANKSHAFT TIMING GEAR


    1. A01BCWFE01

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

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

    3. Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  25. INSTALL INJECTION GEAR


    1. Install a new O-ring and the fuel supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Make sure that the key slot of the injection gear fits over the key (protrusion) of the supply pump.

    3. A01BF3PE01

      Align the "3" marks of the No. 2 balanceshaft driven gear and injection gear.

    4. A01BCCDE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    5. A01BHW8E01

      Temporarily install the injection gear set nut.

    6. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  26. INSTALL CRANKSHAFT TIMING GEAR


    1. A01BCWFE01

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

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

    3. Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  27. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01BDU4E01
      Text in Illustration
      *1 Engine Oil

      Apply a coat of engine oil to the No. 1 idle gear shaft.

    2. A01BD2SE07
      Text in Illustration
      *1 Oil Hole

      Install the No. 1 gear shaft as shown in the illustration.

  28. INSTALL NO. 1 IDLE GEAR


    1. A01BBEME03
      Text in Illustration
      *1 Cutout Mark

      Mount the No. 1 idle gear in a vise.

      Tech Tips

      Make sure the cutout mark of the idle gear faces down.

      Note

      Be careful not to damage the gear.

    2. A01BAO0E03
      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 between the spring ends.

    5. Using snap ring pliers, install the shaft snap ring.

    6. A01BDZ3E03
      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. A01BFECE03
      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. A01BH1KE02
      Text in Illustration
      *1 Service Bolt

      Remove the service bolt.

    10. A01BB0NE03
      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 between the spring ends.

    13. Using snap ring pliers, install the snap ring.

    14. A01BH12E03
      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. A01BC82E04
      Text in Illustration
      *a Turn

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

    16. Using SST, turn the injection gear and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    17. A01BFRNE02
      Text in Illustration
      *1 Service Bolt

      Position the thrust plate with the protrusion facing forward.

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

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

    19. Remove the service bolt.

  29. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the No. 1 crankshaft position sensor plate with the set key.

    2. Install the No. 1 crankshaft position sensor plate with the cupped side facing outward.

      Tech Tips

      When replacing the No. 1 crankshaft position sensor plate, perform "Crank Time Compensation Reset" (w/DPF: Click here, w/o DPF: Click here.

  30. INSTALL OIL CHECK VALVE SUB-ASSEMBLY (w/ DPF)


    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 }

  31. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. A01BFDUE01
      Text in Illustration
      *A w/ DPF
      *B w/o DPF
      *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 cover within 3 minutes and tighten bolts within 15 minutes of applying seal packing.

    3. A01BCW4

      w/ DPF:

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

    4. A01BHC0E02
      Text in Illustration
      *1 New O-Ring

      w/o DPF:

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

    5. Install the timing gear cover with the 14 bolts and 2 nuts.

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

  32. INSTALL WATER PUMP ASSEMBLY


    1. Install a new gasket and the water pump with the 5 bolts and 2 nuts.

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

  33. INSTALL CYLINDER HEAD GASKET


    1. A01BE2OE02
      Text in Illustration
      *1 Measuring Tip
      *2 Protrusion

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

    2. A01BBDME02
      Text in Illustration
      *1 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. A01BCENE02
      Text in Illustration
      *1 Cutout Mark
      A01BAZL 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
      Mark A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      Mark B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      Mark C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      Mark D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      Mark 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 Piston Protrusion
        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 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
    5. A01BDYHE02

      Place the cylinder head on the cylinder block.


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

        Text in Illustration
        A01BAZL Front

        Note

        Make sure the gasket is installed in the correct direction.

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

  34. 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. A01BBWTE01

      Install the 18 cylinder head bolts and 18 washers and tighten the bolts in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Standard Bolt Length
      Item Specified Condition
      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. A01BDGEE03
      Text in Illustration
      *1 Paint Mark
      *a 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 paint marks are now facing rearward.

  35. INSTALL CAMSHAFT


    1. A01BE1FE02
      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 prevent the top of the piston from hitting against the valve head.

    2. Install the camshaft.


      1. Apply engine oil to the thrust portion of the camshaft.

      2. A01BHTRE04
        Text in Illustration
        *1 Key Groove
        *a Upward

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

      3. A01BCWVE01

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

    3. Remove any old seal packing (FIPG material) from the camshaft bearing cap.

    4. A01BCC1E05

      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.)
      Text in Illustration
      *1 Seal Packing
      *2 Oil Passage

      Note


      • Do not allow seal packing to contact the oil passage of the bearing cap.

      • After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after installation.


      1. A01BANQE01

        Install the 5 bearing caps to 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 }

  36. 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

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    A01BES8E04
    Text in Illustration
    *1 Matchmark

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

      Tech Tips

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

  38. INSPECT VALVE CLEARANCE

    A01BGD1E04
    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)
        Item Specified Condition
        Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
        Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)

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

    2. Turn the crankshaft 360° to set the No. 4 cylinder to TDC/compression.

    3. A01BH8PE03
      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
        Item Specified Condition
        Intake 0.20 to 0.30 mm (0.008 to 0.012 in.)
        Exhaust 0.35 to 0.45 mm (0.014 to 0.018 in.)

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

  39. ADJUST VALVE CLEARANCE


    1. Remove the camshafts Click here.

    2. Remove the 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 is within the specified range.

      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.).

      A01BCV9E01
      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
      A 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.) lifter with a No. 40 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
      A01BHLKE01
      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
      A 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.) lifter with a No. 42 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -

    6. Install the selected valve lifters.

    7. Install the camshafts Click here.

  40. INSTALL CYLINDER BLOCK INSULATOR


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

  41. INSTALL NO. 2 TIMING BELT COVER

    A01BD0OE01

    1. Apply seal packing (FIPG) to the 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. Clean the bolts and their holes.

    3. Apply adhesive to 2 or 3 threads at the end of 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 }

  42. INSTALL CAMSHAFT TIMING PULLEY


    1. A01BG3CE01

      Install the camshaft timing pulley.

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

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

  43. INSTALL INJECTOR ASSEMBLY

    Note

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


    1. A01BFIW

      Install 4 new injection nozzle seats to the cylinder head.

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

    3. A01BDYAE07

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

    4. Insert the 4 injectors into the cylinder head.

      Note


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

      Tech Tips

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

      Note


      • A01BFJDE04

        The fork portion of the nozzle holder clamp must be set on the injector.

      • Before tightening the bolts, check that the No. 1 nozzle holder clamp is set properly.

      • To tighten 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 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. A01BGXP

      Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01BC5NE01

      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 assembly.

    9. A01BH1AE02

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

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

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

    12. Tighten the 4 holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A01BGQ1E03

      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.

    14. 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.

    15. Remove the 4 injection pipes.

  44. INSPECT FOR FUEL LEAK


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


      1. A01BGIFE01

        Install a new gasket and the No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        90904-30012 (Gasket)
        SST
        09280-00010
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

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

      3. Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe, maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds and check that no bubbles form.

        SST
        09992-00242

        Note

        Before checking for leakage, be sure to remove the ball and spring in the check valve.

      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 check valve to the engine.

  45. 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. Remove any old seal packing (FIPG material) from the cylinder head.

    4. A01BDVZE01

      Apply seal packing to the 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.

      • Install the head cover within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the cylinder head cover.

    5. A01BGDAE01

      Temporarily install the cylinder head cover with the 10 bolts and 2 nuts in the order shown in the illustration. Then, tighten 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 }

    6. Connect the ventilation hose.

    7. Install 4 new nozzle holder seals.

  46. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new nozzle holder seals.

  47. INSTALL OIL FILLER CAP SUB-ASSEMBLY