CAMSHAFT INSTALLATION

INSTALL CAMSHAFT
1. Set the crankshaft to 90° position from the TDC/compression.
2. Place the camshaft to the cylinder head as shown in the illustration.
  
  Note
  
  Apply engine oil to the cams, thrusts and gears of the camshaft as well as on the journal of the cylinder head.
3. Align the dot marks of the camshaft and No.2 camshaft by meshing the both gears before placing the No.2 camshaft.
4. Remove old packing (FIPG) from the camshaft bearing cap.
5. Apply seal packing to the specific places shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  
  Thickness
  
  1 mm (0.04 in.)
  Note
  
  Be careful not to adhere FIPG to the oil passage of the bearing cap.
  
  After applying FIPG, install the camshaft bearing cap within 3 minutes and then tighten its bolts within 15 minutes.
  
  Do not start the engine 2 hours after the installation.
6. Install the camshaft bearing cap as shown in the illustration.
7. Tighten the 15 bolts for the camshaft bearing cap in the specified order shown in the illustration.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
8. Adjust and inspect valve clearance.
  1. Fix the timing belt cover No.2 with the 4 bolts and nuts.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  2. Tighten the bolt for the camshaft timing pulley while holding the camshaft with a monkey wrench.
    
    Torque:
    
    98 N*m { 1,000 kgf*cm, 72 ft.*lbf }
  3. Adjust and inspect the valve clearance. Click here
  4. Remove the camshaft timing pulley and timing belt cover No.2.
INSTALL CAMSHAFT SETTING OIL SEAL
1. Apply a bit of MP grease to a new oil seal's lip.
  
  Note
  
  Keep the lip clean. Do not to bring dirt and dust on that area.
2. Using SST and a hammer, fit the oil seal.
  
  SST
  
  09608-06041
  
  Oil seal depth from flat end face
  
  0.5 to 1.5 mm (0.020 to 0.060 in.)
  
  Note
  
  Install the oil seal straight.
INSTALL INJECTOR ASSEMBLY

Click here
CHECK NOZZLE LEAKAGE PIPE LEAK

Click here
INSTALL TIMING BELT COVER NO.2
1. Remove old seal packing (FIPG) from the timing gear case.
2. Apply seal packing to the specific places shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  - After applying FIPG, install the timing belt No.2 cover within 3 minutes and tighten its bolts and nuts within 15 minutes.
  - Do not start the engine 2 hours after the installation.
3. Fix the timing belt cover No.2 with the 4 bolts and nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1
1. Using a 10 mm socket hexagon wrench, install the new plate washer and timing belt idler No.1.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL CAMSHAFT TIMING PULLEY
1. Install the camshaft timing pulley.
2. Tighten the bolt for the camshaft timing pulley while holding the camshaft with a monkey wrench.
  
  Torque:
  
  98 N*m { 1,000 kgf*cm, 72 ft.*lbf }
PISTON AND VALVE BREAK PREVENT WORK
1. When turning the camshaft with the timing belt removed, turn the crankshaft 90° counterclockwise.
  
  Note
  
  When installing the timing belt, it is necessary to return the camshaft to the timing marks and then turn the crankshaft clockwise so that it aligns with the timing marks as shown in the illustration.
INSTALL TIMING BELT
1. Check that the timing marks are aligned as shown in the illustration.
2. Install the timing belt to pump drive shaft pulley, camshaft timing pulley and timing belt idler No.1 in sequence.
3. Set the tensioner to the press upright.
  Note
  
  Do not allow the rod end to scratch and deform.
  
  Press the tensioner rod in upward.
  
  Protect a tip of the push rod with a rag in order to prevent damage.
4. Using a press, slowly apply 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force to the push rod.
  
  Note
  
  Do not apply loads 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) or more on the push rod.
5. Align the holes of push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.
6. Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.
7. Tighten the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Note
  
  Uniformly tighten the 2 bolts and install the tensioner
8. Remove the 1.5 mm hexagon wrench from the tensioner.
9. Turn the crankshaft in the clockwise direction twice, check that the timing marks are aligned as shown in the illustration.
INSTALL TIMING BELT COVER NO.1
1. Install the timing belt No.1 cover with the 6 bolts.
  
  Torque:
  
  6.0 N*m { 61 kgf*cm, 53 in.*lbf }
2. Install the wire harness clamp.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. 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 old seal packing (FIPG) from the cylinder head.
4. Apply a seal packing to the specific places described in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  After applying the seal packing, parts must be assembled within 3 minutes, and then tighten within 15 minutes.
  
  Otherwise the material must be removed and reapplied.
  
  Do not start the engine 2 hour after the installation.
5. Install the cylinder head cover with 10 bolts and 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
6. Connect the ventilation hose.
7. Install a new nozzle holder seal.
INSTALL INJECTION PIPE
SST

09023-12701
Note
- When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipes No. 1, No. 2, No. 3, and No. 4.
- Keep clean the joint of the injection pipe.
1. Install the injection pipes.
  1. Temporarily install the 4 injection pipes.
  2. Install the injection pipe clamp No.3 in 2 nuts.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  3. Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.
    
    SST
    
    09023-12701
    
    Torque:
    
    Use union nut wrench and torque wrench
    
    32 N*m { 326 kgf*cm, 24 ft.*lbf }
INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
1. Install the vane pump oil reservoir assembly with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
INSTALL FAN & GENERATOR V BELT
1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.
  
  Note
  
  Make sure that the fan and generator V belt is set properly on each pulley.
2. Check that the indicator mark of the V-ribbed belt tensioner Click here.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
1. Install the engine service hole sub cover with the 5 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL FRONT DOOR SCUFF PLATE RH
INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)
1. Perform the same procedure as above on the opposite side. Click here
INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)
1. Perform the same procedure as above on the opposite side. Click here
CONNECT BATTERY NEGATIVE TERMINAL

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Thickness
1 mm (0.04 in.)

Oil seal depth from flat end face
0.5 to 1.5 mm (0.020 to 0.060 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

ADD ENGINE COOLANT

Firmly tighten the drain plugs and fill the radiator reserve tank assembly with coolant to the top of the inlet.
Loosen the bleeder plug of outlet housing.
When air is bled and the coolant drains out, firmly install the bleeder plug.

Add coolant up to the B line mark in the radiator reserve tank assembly and install the radiator cap.

Coolant capacity

Condition	Capacity
w/ rear heater	17.0 liters (18.0 US qts, 15.0 imp. qts)
w/o rear heater	15.0 liters (15.9 US qts, 13.2 imp. qts)

Warm up the engine.
After the engine cools down check that the coolant level is between the LOW and FULL level marks.

BLEED FUEL LINE
1. Push the priming pump for several times to fill up the fuel lines with fuel.

CHECK FUEL LEAK

PERFORM ACTIVE TEST

Connect the intelligent tester to the DLC3.
Turn the ignition switch on.
Turn the intelligent tester on.
Enter the following menus: Powertrain / ECD / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
Test the Fuel Leak	Pressurizes common rail internal fuel pressure, and checks for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected Above conditions preserved while test is ON

CHECK FOR ENGINE OIL LEAKS
CHECK FOR ENGINE COOLANT LEAKS

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.
2. Warm up the engine.
3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm², 19.9 psi), and check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

Torque:

13 N*m { 133 kgf*cm, 10 ft.*lbf }
CHECK IDLE SPEED
Note

This checking procedure should be done under the following condition.
Tech Tips
- Regarding the details about the intelligent tester, refer to its operator's manual.
- If the intelligent tester is not available, a tachometer's tester probe can substitute for it.
1. Connect the intelligent tester to the DLC3.
2. If the tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.
  
  SST
  
  09843-18030
3. Start the engine and check the idle speed.
  
  Idle speed
  
  700 to 800 rpm
  
  Tech Tips
  
  If the idle speed is not as specified, check by troubleshooting in the diagnostics section.
4. In case of the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe from terminal 9 of the DLC3 with SST.
5. Disconnect the intelligent tester from the DLC3.
INSPECT MAXIMUM ENGINE SPEED
Note

This checking procedure should be done under the following condition.
Tech Tips
- Regarding the details about the intelligent tester, refer to its operator's manual.
- If the intelligent tester is not available, a tachometer's tester probe can substitute for it.
1. Connect the intelligent tester to the DLC3.
2. If the tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.
  
  SST
  
  09843-18030
3. Start the engine.
4. Depress the accelerator pedal all the way to the limit.
5. Check the maximum speed.
  
  Maximum speed
  
  4500 to 4700 rpm
  
  Tech Tips
  
  If the maximum speed is not as specified, check by troubleshooting in the diagnostics section.
6. In case of the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe from terminal 9 of the DLC3 with SST.
7. Disconnect the intelligent tester from the DLC3.
PERFORM INITIALIZATION

Click here