OIL PUMP (w/ DPF) INSTALLATION


  1. 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 }

  2. 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 }

  3. 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 }

  4. 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 }

  5. 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 }

  6. 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

  7. 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.

  8. 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.

  9. 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.

  10. 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 }

  11. 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 }

  12. 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 }

  13. 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 }

  14. INSTALL NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. Install the No. 1 oil pan cover with the 4 bolts.

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

  15. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 1 vacuum transmitting pipe with the bolt and nut.

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  16. INSTALL CRANKSHAFT PULLEY


    1. Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

    2. A01DMRSE01

      Using SST, install the pulley bolt.

      SST
      09213-58014
      09330-00021
      Torque:
      365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

  17. INSTALL CRANKSHAFT PULLEY COVER


    1. Install the crankshaft pulley cover with the 2 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  18. INSTALL VANE PUMP ASSEMBLY


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

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  19. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. Install the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

    3. Install the bracket with the bolt.

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

  20. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY


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

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Do not damage the O-ring.

  21. INSTALL CRANKSHAFT POSITION SENSOR


    1. A01DQA4

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

    2. Install the crankshaft position sensor with the bolt.

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

      Note

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

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

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

    4. Install a new clamp.

      Note


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

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

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

    6. Connect the crankshaft position sensor connector.

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

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

      A01DMYUE01
      Text in Illustration
      *1 Clamp *2 Wire Harness Clamp (A)
      *3 Wire Harness Clamp (B) *4 Protrusion
      *5 Bracket (Clamp) - -

  22. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the camshaft position sensor with the bolt.

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

  23. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 5 bolts.

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

      Tech Tips

      Firmly press and hold the No. 1 compressor mounting bracket against the cylinder block to eliminate any gaps. Then uniformly tighten the 5 bolts.

  24. INSTALL NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Install the spacer, No. 2 idle pulley and pulley plate with the bolt.

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

  25. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolt.

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

  26. INSTALL GENERATOR ASSEMBLY


    1. A01DSSJE01

      Install the generator with the 2 bolts.

      Torque:
      for bolt A
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }
      for bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  27. INSTALL INJECTOR ASSEMBLY

    Click here

  28. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

  29. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  30. INSTALL TIMING BELT

    Click here

  31. REMOVE ENGINE FROM ENGINE STAND


    1. A01DSKBE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 2 bolts as shown in the illustration.

      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Tech Tips

      Part No.

      No. 1 engine hanger 12284-30020
      No. 2 engine hanger 12282-67030
      Bolt 91552-81014 and 91642-81030

      Note

      Install the engine hangers with new bolts.

    2. Attach an engine sling device and hang the engine with a chain block.

    3. Remove the engine from the engine stand.

  32. INSTALL ENGINE ASSEMBLY

    Click here

  33. ADD ENGINE OIL


    1. Add new engine oil.

      Standard Oil Grade
      Item Oil Grade Oil Viscosity (SAE)
      w/ DPF

      ACEA C2

      (Using engine oil other than ACEA C2 may damage catalytic converter)

      - 0W-30

      - 5W-30

      (0W-30 is best choice for fuel economy and good starting in cold weather)
      w/o DPF

      G-DLD1, API CF-4, CF or ACEA B1

      (You may also use API CE or CD)

      - 5W-30

      - 10W-30

      - 15W-40

      - 20W-50
      Standard Capacity
      Item Specified Condition
      Drain and refill without oil filter change 6.7 liters (7.1 US qts, 5.9 Imp. qts)
      Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 Imp. qts)
      Dry fill 7.5 liters (7.9 US qts, 6.6 Imp. qts)

    2. Install the oil filler cap.

  34. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  35. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

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

    3. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

      Standard Capacity
      Item Specified Condition
      for Automatic Transmission w/ Rear Heater 14.9 liters (15.7 US qts, 13.1 Imp. qts)
      w/o Rear Heater 13.1 liters (13.8 US qts, 11.5 Imp. qts)
      for Manual Transmission w/ Rear Heater 15.0 liters (15.8 US qts, 13.2 Imp. qts)
      w/o Rear Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

      • Please contact your TOYOTA dealer for further details.

      • for Cold Area Specification Vehicles:

        Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

      Note

      Never use water as a substitute for engine coolant.

    4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

    5. Install the radiator reservoir cap.

    6. Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at 2500 to 3000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      4. Stop the engine and wait until the coolant cools down to ambient temperature.

        CAUTION:

        Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    8. After the coolant cools down, check that the coolant level is at the FULL line.

      If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

  36. BLEED AIR FROM FUEL SYSTEM


    1. A01DS6C

      Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • The maximum hand pump pumping speed is 2 strokes per second.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.

    2. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the engine switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the engine switch on (IG) and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DLTIE05
      Text in Illustration
      *a

      Reference

      (Active Test Operation)

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

      A01DUBQE04

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.

  37. INSPECT FOR COOLANT LEAK

    Note

    Before each inspection, turn the A/C switch off.

    CAUTION:

    Do not remove the radiator reservoir 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.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm2, 18 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

  38. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  39. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the engine switch on (IG).

      3. Turn the intelligent tester on.

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

      5. Perform the Active Test.

        Intelligent Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize common rail interior and check for fuel leaks Stop/Start

        • The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed.

        • The above conditions are maintained while the Active Test is being performed.

  40. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  41. INSPECT ENGINE IDLE SPEED

    Tech Tips


    • For more information about the intelligent tester, refer to its operator's manual.

    • If an intelligent tester is not available, use a tachometer's tester probe as a substitute.


    1. Connect the intelligent tester to the DLC3.

    2. A01DR2AE07
      Text in Illustration
      *a Front view of DLC3

      If a tester is not available, connect the tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18040

    3. Inspect the idle speed.

      Tech Tips


      • Make sure that the engine is warmed up.

      • Make sure that the A/C switch is off.

      • w/ DPF:

        Make sure that PM regeneration is not being performed.


      1. Start the engine and measure the idle speed.

        Idle Speed
        Item Specified Condition
        for Automatic Transmission 650 to 750 rpm
        for Manual Transmission w/ DPF 650 to 750 rpm
        w/o DPF 610 to 710 rpm

    4. Inspect the maximum speed.


      1. Start the engine.

      2. Fully depress the accelerator pedal.

      3. Measure the maximum speed.

        Maximum Speed
        Item Specified Condition
        w/ DPF 4500 to 4700 rpm
        w/o DPF 4450 to 4750 rpm

    5. If the tester probe of a tachometer is connected to the DLC3, disconnect the tester probe together with SST from terminal 9 of the DLC3.

    6. Disconnect the intelligent tester from the DLC3.

  42. INSPECT ENGINE OIL LEVEL


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

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

      Note

      Do not fill engine oil above the full level mark.

  43. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  44. INSTALL FRONT BUMPER LOWER COVER


    1. Install the front bumper lower cover with the clip and 5 bolts.

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