ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL CYLINDER BLOCK DRAIN COCK PLUG


    1. Apply adhesive to the cylinder block drain cock plug.

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

    2. Install the cylinder block drain cock plug.

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

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A004OBVE02
      Text in Illustration
      *1 Service Bolt
      *2 Align

      Turn the crankshaft with a wrench to align the timing mark of the drive gear with that of the driven gear (1 dot mark each), and then mesh the gears and install the engine balancer to the engine.

    2. A004RHGE04

      Temporarily install the engine balancer bolts.

      Tech Tips

      The engine balancer bolts are tightened in 2 progressive steps.

    3. Step 1


      1. Uniformly tighten the 8 bolts in several passes in the sequence shown in the illustration.

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

    4. Step 2


      1. Mark the front of the engine balancer bolts with paint.

      2. Tighten the engine balancer bolts by 90°.

      3. Check that the painted marks are now at a 90° angle to the front.

    5. Remove the service bolt from the engine balancer.

  3. INSTALL OIL BAFFLE PLATE


    1. Install the oil baffle plate with the 2 bolts.

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

  4. INSTALL REAR CRANKSHAFT OIL SEAL


    1. Coat the lip of a new oil seal with MP grease.

    2. A004U34E04

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

      SST
      09223-56010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  5. SELECT CYLINDER HEAD GASKET

    Click here

  6. INSTALL CYLINDER HEAD GASKET

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  8. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Click here

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

  10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  11. INSTALL CAMSHAFT

    Click here

  12. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. Install the 2 keys to the crankshaft.

  13. INSTALL CAMSHAFT TIMING SPROCKET


    1. A004NXOE02
      Text in Illustration
      *1 Straight Pin
      *2 Timing Mark
      *3 Yellow Paint Mark

      Install the crankshaft timing sprocket and camshaft timing sprocket to the chain so that the timing marks of the sprockets and paint marks of the chain are aligned.

    2. Install the camshaft timing sprocket to the No. 2 camshaft by fitting the straight pin of the No. 2 camshaft into the hole on the camshaft timing sprocket.

    3. Install the crankshaft timing sprocket to the crankshaft.

    4. While holding the hexagon portion of the No. 2 camshaft, install and uniformly tighten the 4 bolts of the No. 2 camshaft.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  14. INSTALL OIL PUMP DRIVE GEAR


    1. Install the oil pump drive gear to the crankshaft.

  15. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the No. 1 chain vibration damper with the 2 bolts.

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

  16. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A004TCXE28
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      SST
      09240-00020   ( 09242-00200 )

    3. Install the chain tensioner with the 2 bolts.

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

    4. Remove SST.

  18. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. 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. A004SJ5E02

      Using SST, install a new pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  21. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  22. INSTALL OIL FILTER BRACKET

    Click here

  23. INSTALL OIL FILTER ELEMENT

    Click here

  24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  26. INSTALL NOZZLE HOLDER CLAMP SEAT

    Click here

  27. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  28. INSTALL WATER INLET HOUSING


    1. Install a new gasket and the water inlet housing with the 3 nuts.

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

  29. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install the sensor with the 4 bolts.

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

  30. INSTALL NO. 1 OIL COOLER BRACKET

    Click here

  31. INSTALL OIL COOLER ASSEMBLY

    Click here

  32. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  33. INSTALL WATER PUMP ASSEMBLY

    Click here

  34. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Install a new gasket to the sensor.

    2. A004QWQE02

      Using SST, install the sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  35. INSTALL CRANKSHAFT POSITION SENSOR


    1. Install the sensor with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Connect the sensor harness and install the clip.

  36. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  37. INSTALL INJECTOR ASSEMBLY

    Click here

  38. INSTALL NO. 1 NOZZLE LEAKAGE PIPE


    1. A004T4LE02
      Text in Illustration
      *1 Union Bolt

      Install 4 new gaskets and the No. 1 nozzle leakage pipe with the 4 union bolts and bolt.

      Torque:
      for union bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for bolt
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  39. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. Temporarily install the No. 2 nozzle leakage pipe and a new gasket with the check valve and bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the bolt.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }