ENGINE UNIT (w/ DPF) 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.


  1. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01DR7AE01

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

      SST
      09518-36030
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

    2. Apply MP grease to the lip of the oil seal.

  2. INSTALL SUPPLY PUMP OIL SEAL


    1. A01DQ9SE02

      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 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

    2. Apply MP grease to the lip of the oil seal.

  3. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01DMLAE01

      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

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

    2. Apply MP grease to the lip of the oil seal.

  4. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Remove any old seal packing (FIPG material) from the oil pan and cylinder block.

    2. A01DUP4E01
      Text in Illustration
      *1 Seal Packing

      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 (0.157 in.)

      Note

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

    3. Install the rear engine oil seal retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

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

  5. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR


    1. Mount the balanceshaft between aluminum 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 }

  6. INSTALL NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. Install the balanceshaft with the 2 bolts.

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

  7. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR


    1. Mount the balanceshaft between aluminum 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 }

  8. INSTALL NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. Install the balanceshaft with the 2 bolts.

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

  9. INSTALL TIMING GEAR CASE ASSEMBLY


    1. A01DNXAE02
      Text in Illustration
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block.

    2. A01DTQUE01
      Text in Illustration
      *1 New Gasket

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

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

    4. A01DNVVE01
      Text in Illustration
      *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 (0.157 in.)

      Note

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

    5. A01DT5A

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

      Text in Illustration
      A01DQPB Union Bolt
      A01DMKT Bolt A
      A01DPHJ Bolt B

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

      Torque:
      for union bolt
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  10. INSTALL OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing (FIPG material) and be careful not to drop any oil on the contact surfaces of the cylinder block, engine rear oil seal retainer and oil pan.

    2. Install a new gasket to the cylinder block.

    3. A01DQ31E01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes after applying seal packing.

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

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

      Torque:
      15 N*m  { 148 kgf*cm, 11 ft.*lbf }

  11. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer with the 2 nuts.

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

  12. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


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

    2. A01DOSQE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the No. 2 oil pan as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.157 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan within 3 minutes after applying seal packing.

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

    3. Install the No. 2 oil pan with the 13 bolts and 2 nuts.

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

  13. 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

      Fit the key (protrusion) of the fuel supply pump into the key slot of the injection gear.

    3. A01DT2NE01

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

    4. A01DMAGE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    5. A01DO8ZE02

      Install the injection gear set nut.

    6. Using SST, tighten the set nut.

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

  14. INSTALL CRANKSHAFT TIMING GEAR

    A01DRQTE01

    1. Position the crankshaft timing gear with timing mark 1 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

  15. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01DUCJE01
      Text in Illustration
      *1 Engine Oil

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

    2. A01DQXPE07
      Text in Illustration
      *1 Oil Hole

      Install the gear shaft as shown in the illustration.

  16. INSTALL NO. 2 IDLE SUB GEAR


    1. A01DQ1BE03
      Text in Illustration
      *1 Cutout Mark

      Mount the No. 1 idle gear in a vise.

      Note

      Be careful not to damage the gear.

      Tech Tips

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

    2. A01DOBFE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

      Tech Tips

      Fit the pins on the gears between the spring ends.

    3. Install the No. 2 idle sub gear.

    4. Install the wave washer.

    5. A01DPS4E01

      Using snap ring pliers, install the shaft snap ring.

    6. A01DOWME03
      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.

  17. INSTALL NO. 1 IDLE SUB GEAR


    1. A01DQVNE03
      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.

    2. A01DUPNE02
      Text in Illustration
      *1 Service Bolt

      Remove the service bolt.

    3. A01DT7LE03
      Text in Illustration
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

      Tech Tips

      Fit the pins on the gears between the spring ends.

    4. Install the No. 1 idle sub gear.

    5. Install the wave washer.

    6. A01DON7E01

      Using snap ring pliers, install the shaft snap ring.

    7. A01DOSVE03
      Text in Illustration
      *1 Service Bolt
      *a Upward

      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 )

  18. INSTALL NO. 1 IDLE GEAR


    1. A01DQVCE04
      Text in Illustration
      *a Turn

      Align the "4" and "5" timing marks of the idle gear and crankshaft timing gear.

    2. 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, 09963-00700 )
    3. A01DQ8YE02
      Text in Illustration
      *1 Service Bolt

      Position the idle gear thrust plate with the protrusion facing forward.

    4. Align the bolt holes and install the idle gear thrust plate with the 2 bolts.

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

    5. Remove the service bolt.

  19. 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" Click here.

  20. 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 }

  21. INSTALL TIMING GEAR COVER


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

    2. A01DR91E01
      Text in Illustration
      *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 (0.157 in.)

      Note

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

    3. A01DLW6E01
      Text in Illustration
      *1 New O-Ring

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

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    5. A01DNLA

      Remove the screw plug and gasket.

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

    7. Install a new gasket and the screw plug.

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

  22. 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 }

  23. INSTALL CYLINDER HEAD GASKET


    1. A01DO5FE02
      Text in Illustration
      *1 Measuring Tip
      *2 Protrusion

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

    2. A01DNZME02
      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 each cylinder.

      Piston protrusion
      0.005 to 0.255 mm (0.000197 to 0.0100 in.)

      Tech Tips

      After installing the piston and connecting rod assembly, if the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01DSFXE02
      Text in Illustration
      *1 Cutout Mark
      A01DQPB 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 Cylinder Head Gasket Thickness
      Mark Specified Condition
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      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 gasket according to the table below.

        Gasket Size
        Item Specified Condition
        Piston protrusion 0.005 to 0.054 mm (0.000197 to 0.00213 in.) 0.055 to 0.104 mm (0.00217 to 0.00409 in.) 0.105 to 0.154 mm (0.00413 to 0.00606 in.) 0.155 to 0.204 mm (0.00610 to 0.00803 in.) 0.205 to 0.255 mm (0.00807 to 0.0100 in.)
        Gasket to be used A B C D E
    5. A01DQRZE02

      Place the cylinder head gasket on the cylinder block.

      Text in Illustration
      A01DQPB Front

      Note

      Make sure the gasket is installed facing the proper direction.

  24. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01DOXYE01

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • If any bolt is broken or deformed, replace it Click here.


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

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    3. Install the 18 washers with the 18 cylinder head bolts, and uniformly 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 one the cylinder head bolts does not meet the torque specification, replace it.

    4. A01DO0IE03
      *1 Painted Mark
      *a Front

      Mark the front of each cylinder head bolt with paint.

    5. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

    6. Tighten the cylinder head bolts by an additional 90°.

    7. Check that the painted marks are now facing rearward.

  25. INSTALL VALVE LIFTER


    1. Install the valve lifters.

    2. Check that each valve lifter rotates smoothly by hand.

  26. INSTALL CAMSHAFT


    1. A01DNP0E02
      Text in Illustration
      *1 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. A01DMSQE04

      Install the camshaft.


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

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

        Text in Illustration
        *1 Key Groove
        *a Upward
      3. A01DO2KE01

        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. A01DPBKE05
      Text in Illustration
      *1 Seal Packing
      *2 Oil Passage

      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 (0.157 in.)

      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.

    5. A01DN0LE01

      Install the 5 bearing caps to their proper locations.

    6. A01DQBLE02

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

    7. 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 }
    8. A01DS1JE01

      Install a new camshaft oil seal.


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

      2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.

        SST
        09608-06041

  27. INSTALL CYLINDER BLOCK INSULATOR


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

  28. INSTALL NO. 2 TIMING BELT COVER


    1. A01DQJWE02
      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 seal packing, 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 }

  29. INSTALL CAMSHAFT TIMING PULLEY


    1. 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 }

  30. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  31. INSTALL INJECTOR ASSEMBLY

    Note

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


    1. A01DOTZ

      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. A01DNRYE01
      Text in Illustration
      *1 New O-Ring

      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. A01DPVGE02
      Text in Illustration
      *1 Washer
      *a Downward

      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.

    7. Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01DQZTE01

      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. A01DSB2E02

      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 nozzle holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A01DNR5E05
      Text in Illustration
      *1 Union Bolt

      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.

  32. INSPECT FOR FUEL LEAK


    1. A01DRWCE01

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


      1. Install a new gasket and the and 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. A01DQYJE01

        Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe, maintain 100 kPa (1.0 kgf/cm2, 15 psi) of pressure for 60 seconds and check that no bubbles form.

        SST
        09992-00242

      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 union bolt to the engine.

  33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DQ7HE01
      Text in Illustration
      *1 No. 3 Cylinder Head Cover Gasket
      *2 Cylinder Head Cover

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

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

    3. A01DP0AE06

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      A01DTZQ Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder 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.

    4. Install a new cylinder head cover gasket to the cylinder head cover.

    5. A01DMOQE01

      Temporarily install the 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. Install 4 new nozzle holder seals.

  34. INSTALL OIL FILLER CAP SUB-ASSEMBLY