ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block, cylinder head, crankshaft, connecting rod, camshaft and other parts.

  • When replacing an injector (including interchanging injectors between cylinders), common rail, cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.

PROCEDURE


  1. SELECT NO. 2 CYLINDER HEAD GASKET

    Click here

  2. INSTALL NO. 2 CYLINDER HEAD GASKET

    Click here

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


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

      Note

      Ensure that no oil is on the mounting surface of the cylinder head.

    2. Inspect the cylinder head bolts Click here.

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

    4. Step 1:


      1. B001YKCE02

        Install and uniformly tighten the 10 cylinder head bolts with the spacers in several steps, in the sequence shown in the illustration.

        Torque:
        80 N*m  { 816 kgf*cm, 59 ft.*lbf }

        Tech Tips


        • The cylinder head bolts are tightened in 4 progressive steps.

        • If a cylinder head bolt is broken or deformed, replace it.

    5. B001ZU3E10
      Text in Illustration
      *1 Painted Mark
      B001WGT Front

      Step 2:


      1. Mark the cylinder head bolt heads with paint as shown in the illustration.

      2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

    6. B001WP0E07
      Text in Illustration
      *1 Painted Mark
      B001WGT Front

      Step 3:


      1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

    7. B001ZE4E06
      Text in Illustration
      *1 Painted Mark
      B001WGT Front

      Step 4:


      1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

    8. Check that the painted marks are now facing the exhaust port side.

  4. INSTALL NO. 2 VALVE LASH ADJUSTER ASSEMBLY

    Note

    Be sure to inspect the valve lash adjuster before installing it Click here.


    1. Install the 16 No. 2 valve lash adjusters to the cylinder head.

      Tech Tips

      Install the lash adjuster at the same place it was removed from.

  5. INSTALL NO. 2 VALVE ROCKER ARM


    1. B001WVE

      Apply engine oil to the lash adjuster tips and valve stem ends.

    2. Install the 16 No. 2 valve rocker arms as shown in the illustration.

      Tech Tips

      Install the valve rocker arm at the same place it was removed from.

      B001YMM

  6. INSTALL NO. 5 CAMSHAFT BEARING CAP


    1. Align the camshaft bearing cap and the ring pins of the cylinder head, and install the cap.

  7. SELECT NO. 1 CYLINDER HEAD GASKET

    Click here

  8. INSTALL NO. 1 CYLINDER HEAD GASKET

    Click here

  9. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


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

      Note

      Ensure that no oil is on the mounting surface of the cylinder head.

    2. Inspect the cylinder head bolts Click here.

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

    4. Step 1:


      1. B001VTAE02

        Install and uniformly tighten the 10 cylinder head bolts with the spacers in several steps, in the sequence shown in the illustration.

        Torque:
        80 N*m  { 816 kgf*cm, 59 ft.*lbf }

        Tech Tips


        • The cylinder head bolts are tightened in 4 progressive steps.

        • If a cylinder head bolt is broken or deformed, replace it.

    5. B001ZU3E10
      Text in Illustration
      *1 Painted Mark
      B001WGT Front

      Step 2:


      1. Mark the cylinder head bolt heads with paint as shown in the illustration.

      2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

    6. B001WP0E07
      Text in Illustration
      *1 Painted Mark
      B001WGT Front

      Step 3:


      1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

    7. B001ZE4E06
      Text in Illustration
      *1 Painted Mark
      B001WGT Front

      Step 4:


      1. Tighten the cylinder head bolts by an additional 90° in the sequence shown in step 1.

    8. Check that the painted marks are now facing the intake port side.

  10. INSTALL NO. 1 VALVE LASH ADJUSTER ASSEMBLY

    Note

    Be sure to inspect the valve lash adjuster before installing it Click here.


    1. Install the 16 No. 1 valve lash adjusters to the cylinder head.

      Tech Tips

      Install the lash adjuster at the same place it was removed from.

  11. INSTALL NO. 1 VALVE ROCKER ARM


    1. B001WVE

      Apply engine oil to the lash adjuster tips and valve stem ends.

    2. Install the 16 No. 1 valve rocker arms as shown in the illustration.

      Tech Tips

      Install the valve rocker arm at the same place it was removed from.

      B001YMM

  12. INSTALL NO. 2 CAMSHAFT BEARING CAP


    1. Align the camshaft bearing cap and the ring pins of the cylinder head, and install the cap.

  13. SET NO. 1 CYLINDER TO 45° BEFORE TDC


    1. B00200O

      Using a bar, turn the crankshaft counterclockwise until the No. 1 cylinder is at a position 45° before TDC.

      Note

      Do not turn the crankshaft again until after the timing gear is installed.

      Tech Tips

      The No. 1 cylinder is at a position 45° before TDC if the crankshaft counterweight is overlapping the cylinder block hole as shown in the illustration.

    2. Remove the 2 crankshaft pulley set bolts.

  14. INSTALL NO. 1 AND NO. 2 CAMSHAFTS


    1. B001WH4

      Add more than 19 cc (1.16 cu. in.) of engine oil into the cylinder head side oil holes.

    2. B001WMX

      Apply engine oil to the rollers of the valve rocker arms and the camshaft housing of the cylinder head.

    3. B001YRW

      Install the camshafts.


      1. Apply engine oil to the camshaft journals, lobes, thrust portion and gears.

      2. Align the timing marks (2 dot marks) on the back side of the No. 1 and No. 2 camshaft timing gears as shown in the illustration.

      3. Place the camshafts into the cylinder head.

        Note

        Before and after setting the camshafts, firmly set the rocker arms to the lash adjusters.

        B001YMM
    4. B001ZQG

      Install the No. 1 camshaft bearing cap.


      1. Align the No. 1 camshaft bearing cap and the ring pins of the No. 2 camshaft bearing cap.

      2. Temporarily install the 4 bolts by hand.

    5. B001WD4

      Install the No. 3 camshaft bearing caps.


      1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper position and direction.

      2. Temporarily install the 8 bolts, which are not installed with the oil feed pipe, by hand.

    6. B001WPD

      Temporarily install the No. 1 and No. 2 camshaft oil feed pipes with the 8 bolts by hand.

      Note

      If even one of the pipe bolt holes does not match its camshaft bearing cap bolt hole, replace the camshaft oil feed pipe.

      Tech Tips

      The pipe is bent on the intake side, and straight on the exhaust side.

    7. B001WIN

      Temporarily install the 2 union bolts by hand.

    8. B001XQ4E02
      Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt

      Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

      Torque:
      for 12 mm head bolt of No. 1 camshaft bearing cap
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for 10 mm head bolt of No. 3 camshaft bearing cap
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. B001WIN

      Tighten the 2 union bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    10. B001X5L

      Remove the service bolt from the No. 1 camshaft timing gear.

      Note

      Do not drop the bolt into the engine.

  15. INSTALL NO. 3 AND NO. 4 CAMSHAFTS


    1. B001WH4

      Add more than 19 cc (1.16 cu. in.) of engine oil into the cylinder head side oil holes.

    2. B001WMX

      Apply engine oil to the rollers of the valve rocker arms and camshaft housing of the cylinder head.

    3. B001ZUT

      Install the camshafts.


      1. Apply engine oil to the camshaft journals, lobes, thrust portion and gears.

      2. Align the timing marks (1 dot mark) on the back side of the No. 3 and No. 4 camshaft timing gears as shown in the illustration.

      3. Place the camshafts into the cylinder head.

        Note

        Before and after setting the camshafts, firmly set the rocker arms to the lash adjusters.

        B001YMM
    4. B001YUL

      Install the No. 4 camshaft bearing cap.


      1. Align the No. 4 camshaft bearing cap and the ring pins of the No. 5 camshaft bearing cap.

      2. Temporarily install the 4 bolts by hand.

    5. B001YZR

      Install the No. 3 camshaft bearing caps.


      1. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper position and direction.

      2. Temporarily install the 8 bolts, which are not installed with the oil feed pipe, by hand.

    6. B001W00

      Temporarily install the No. 3 and No. 4 camshaft oil feed pipes with the 8 bolts by hand.

      Note

      If even one of the pipe bolt holes does not match its camshaft bearing cap bolt hole, replace the camshaft oil feed pipe.

      Tech Tips

      The pipe is bent on the intake side, and straight on the exhaust side.

    7. B001Z1W

      Temporarily install the 2 union bolts by hand.

    8. B001WDSE02
      Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt

      Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

      Torque:
      for 12 mm head bolt of No. 4 camshaft bearing cap
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for 10 mm head bolt of No. 3 camshaft bearing cap
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. B001Z1W

      Tighten the 2 union bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
    10. B001X5L

      Remove the service bolt from the No. 4 camshaft timing gear.

      Note

      Do not drop the bolt into the engine.

  16. INSTALL NO. 2 TIMING GEAR CASE INSULATOR (w/ Intercooler)

  17. INSTALL NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. Install the No. 2 vacuum transmitting pipe with the 3 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  18. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. Install the No. 1 vacuum transmitting pipe with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  19. CONNECT NO. 3 VACUUM TRANSMITTING HOSE (w/ Intercooler)

  20. CONNECT NO. 2 VACUUM TRANSMITTING HOSE (w/ Intercooler)

  21. INSTALL TIMING GEAR CASE SUB-ASSEMBLY

    Note

    When the contact surfaces shown below are wet, wipe them with an oil-free cloth before applying seal packing.

    B001Y3LE02
    Text in Illustration
    *a Cylinder Block *b Timing Gear Case

    1. Apply seal packing to the timing gear case as shown in the following illustration.

      Standard seal diameter
      4 to 5 mm (0.157 to 0.197 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • After applying seal packing, align the timing gear case with the engine within 3 minutes and tighten the bolts and nuts within 15 minutes.

      • Apply the seal packing in a continuous line.

      Tech Tips


      • The FIPG line is shown below.

      • Apply packing to the 5 seal surface areas.

      B001YKAE03
      Text in Illustration
      *a Seal Diameter: 4 to 5 mm - -
    2. B001XFLE04
      Text in Illustration
      *1 New Timing Gear Case Gasket
      *2 New O-Ring

      Install a new timing gear case gasket.

    3. Apply engine oil to 2 new O-rings and install them to the timing gear case.

    4. B001YYYE03
      Text in Illustration
      *1 Nut
      *2 14 mm Head Bolt
      *3 12 mm Head Bolt A
      *4 12 mm Head Bolt B

      Install the timing gear case with the 22 bolts and 2 nuts.

      Torque:
      for 14 mm head bolt (When "dry")
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      for 14 mm head bolt (When "wet")
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
      for 12 mm head bolt A and B
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for nut
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Note


      • The case is "dry" when there is absolutely no engine oil on the 14 mm head bolts and cylinder head bolt holes.

      • The case is "wet" when there is engine oil on the 14 mm head bolts and cylinder head bolt holes.

      Bolt Length
      Item Quantity Length
      A 4 20 mm (0.787 in.)
      B 8 45 mm (1.77 in.)

  22. INSTALL V-BANK SILENCER


    1. Align the alignment areas of the V-bank silencer and cylinder block, and install the V-bank silencer.

      Note

      Verify that the V-bank silencer is below the top surface of the intake port of the cylinder head RH and LH.

  23. INSTALL FUEL SUPPLY PUMP ASSEMBLY


    1. B001X3M

      Using an 8 mm x 1.25 pitch tap, remove the adhesive from the timing gear case side bolt hole.

    2. B001Z3HE05
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or more threads of the timing gear case bolt hole.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. B001Y2UE02
      Text in Illustration
      *1 New O-Ring

      Apply engine oil to a new O-ring and install it to the supply pump.

    4. Install the supply pump to the timing gear case.

      Note

      When installing the supply pump, do not hold the fuel pipe to prevent fuel leaks.


      1. Temporarily install the 2 nuts.

      2. Using a 6 mm hexagon wrench, install the hexagon bolt, and then tighten the 2 nuts.

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

  24. INSTALL STRAIGHT PIN


    1. Install the straight pin.

      Standard protrusion height
      4.5 to 7.0 mm (0.177 to 0.276 in.)

  25. ASSEMBLE FUEL SUPPLY PUMP DRIVE GEAR AND FUEL SUPPLY PUMP SHAFT SPROCKET


    1. Align the fuel supply pump drive gear to the fuel supply pump shaft sprocket straight pin and temporarily install it with the 4 bolts.

    2. Hold the fuel supply pump shaft sprocket in a vise between aluminum plates.

      Note

      Be careful not to damage the gears.

    3. Tighten the 4 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  26. INSTALL RADIAL BALL BEARING


    1. B001Z8AE02
      Text in Illustration
      *1 Radial Ball Bearing
      *2 Fuel Supply Pump Shaft Sprocket

      Using SST and a press, press in the radial ball bearing to the fuel supply pump shaft sprocket.

      SST
      09316-12010
      09950-60010   ( 09951-00580 )

      Note


      • Make sure to press in the bearing until the bearing contacts the fuel supply pump shaft sprocket, as shown in A in the illustration.

      • Make sure the sprocket outer edge is further outward than the bearing outer edge, as shown in B in the illustration.

  27. TEMPORARILY INSTALL FUEL SUPPLY PUMP DRIVE GEAR


    1. B001WHN

      Align the cutout of the supply pump drive gear and key of the supply pump, and temporarily install the fuel supply pump drive gear nut.

  28. SET NO. 1 AND NO. 2 CAMSHAFTS TO TDC


    1. B001X7I

      Using a wrench, turn the No. 1 camshaft and align the timing marks (1 dot mark) on the back side of the timing gears as shown in the illustration.

  29. INSTALL NO. 1 IDLE GEAR SHAFT


    1. B001XYO

      Apply engine oil to the contact surface of the idle gear shaft and the back side of the protrusion.

    2. Install the idle gear shaft to the cylinder block.

  30. ASSEMBLE SUB GEAR, IDLE GEAR SPRING AND IDLE GEAR (w/ Intercooler)


    1. A01WZET

      Hold the idle gear in a vise between aluminum plates.

      Note

      Be careful not to damage the gears.

    2. A01X7PP

      Align the right end of the idle gear spring to the notch of the idle gear and set it to the gear.

    3. A01X7DI

      Install the sub idle gear.


      1. Align the notch of the sub idle gear protrusion with the left end of the idle gear spring and install the sub idle gear to the idle gear.

      2. B001Y8CE03
        Text in Illustration
        *1 Service Bolt

        Using SST, turn the sub idle gear counterclockwise, and install an 8 mm x 1.25 pitch bolt with a length of 15 mm or more to the service hole.

        SST
        09960-10010   ( 09962-01000, 09963-00700 )
        Torque:
        13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  31. INSTALL IDLE GEAR ASSEMBLY


    1. B001Y1YE04
      Text in Illustration
      *1 Key

      Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

    2. Using a bar, turn the crankshaft clockwise to the No. 1 cylinder TDC position.

    3. Align the timing marks of the supply pump drive gear and idle gear, and the timing marks of the crankshaft timing gear and idle gear as shown in the illustration.

      B001ZXTE02
      Text in Illustration
      *A w/ Intercooler *B w/o Intercooler

    4. Apply engine oil to the idle gear thrust plate and gears.

    5. Install the idle gear thrust plate with the 2 bolts.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

    6. w/ Intercooler:

      Remove the service bolt.

  32. TIGHTEN FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. Using SST, hold the idle gear and tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }
      B001XUCE04
      Text in Illustration
      *A w/ Intercooler *B w/o Intercooler

  33. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Check that the timing marks of the following pairs of parts are aligned: 1) supply pump drive gear and idle gear: 2) crankshaft timing gear and idle gear: 3) RH and LH camshaft timing gears.

      B001XC0

  34. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET AND NO. 2 TIMING CHAIN


    1. B001W4J

      Align the 2 mark plates (yellow) on the No. 2 timing chain with the timing mark (1 dot mark) of the No. 2 camshaft timing sprocket as shown in the illustration.

    2. B001YKTE05
      Text in Illustration
      *1 Timing Mark

      Align the No. 2 timing chain mark plate (yellow) with the supply pump drive gear timing mark, and temporarily install the No. 2 camshaft timing sprocket with the 4 bolts.

    3. B001WY1E03

      Using SST, hold the No. 2 camshaft timing sprocket, and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  35. INSTALL NO. 1 CAMSHAFT TIMING SPROCKET AND NO. 1 TIMING CHAIN


    1. B001WAA

      Align the 2 mark plates (yellow) on the No. 1 timing chain with the timing mark (1 dot mark) of the No. 1 camshaft timing sprocket as shown in the illustration.

    2. B001VKYE05
      Text in Illustration
      *1 Timing Mark

      Align the No. 1 timing chain mark plate (yellow) with the supply pump drive gear timing mark, and temporarily install the No. 1 camshaft timing sprocket.

  36. INSTALL PUMP DRIVE SHAFT GEAR


    1. B001YCTE01

      Temporarily install the pump drive shaft gear with the 4 bolts.

    2. Using SST, hold the pump drive shaft gear and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  37. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  38. INSTALL NO. 2 CHAIN TENSIONER SLIPPER

  39. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B001Z0I

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

    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. Install the No. 2 chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench.

  40. 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 }

  41. INSTALL NO. 1 CHAIN TENSIONER SLIPPER

  42. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B001Z0I

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

    2. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

    3. Install the No. 1 chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench.

  43. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Remove the adhesive from the threads of the 2 screws and the bolt holes of the crankshaft.

    2. B001ZALE03
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the 2 screws.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Using a T30 "TORX" wrench, install the No. 1 crankshaft position sensor plate with the 2 screws.

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

      Note

      Make sure the "F" mark on the plate is facing towards the front side of the engine.

      Tech Tips

      When replacing the No. 1 crankshaft position sensor plate, perform "Crank Time Compensation Reset" Click here.

  44. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

    2. Rotate the crankshaft 2 revolutions or more so that the crankshaft key is 45° counterclockwise from the top. Check that the timing marks (1 dot mark each) of the RH and LH camshaft timing gears align. If not as specified, turn the crankshaft 1 revolution (360°) and align the timing marks. If the timing marks are deviated, reinstall the chain and camshaft.

      B00202ME06
      Text in Illustration
      *1 Key - -
      *a Top - -

    3. Remove the 2 crankshaft pulley set bolts.

  45. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. B001Y4AE02

      Place the timing chain cover on wooden blocks.

    2. Using SST and a hammer, tap in a new oil seal as shown in the illustration.

      SST
      09316-12010
      09950-70010   ( 09951-07100 )
      09950-60020   ( 09951-00890 )
      Standard depth A
      0.6 to 1.4 mm (0.0236 to 0.0551 in.)

  46. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Note

    When the contact surfaces shown below are wet, wipe them with an oil-free cloth before applying seal packing.

    B001WQ0E02
    Text in Illustration
    *1 Timing Gear Case *2 Timing Chain Cover

    1. B001ZOPE04
      Text in Illustration
      *1 New O-Ring

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

    2. Apply seal packing to the timing chain cover as shown in the following illustration.

      Standard seal diameter
      4 to 5 mm (0.157 to 0.197 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

      Note


      • After applying seal packing, align the timing chain cover with the timing gear case within 3 minutes and tighten the bolts and nuts within 15 minutes.

      • Apply the seal packing in a continuous line.

      • Make sure the seal packing does not become thinner than 4 mm (0.157 in.) at the areas labeled "B" in the illustration below.

      Tech Tips


      • The FIPG line is shown below.

      • Apply packing to the 6 seal surface areas.

      B00204ZE02
      Text in Illustration
      *a Seal Diameter: 4 to 5 mm - -

    3. Apply engine oil to the lip of the oil seal.

    4. Align and install the timing chain cover to the timing gear case knock pin and supply pump bearing.

      Note

      Make sure that the lip of the oil seal is properly installed.

    5. B001XFTE02
      Text in Illustration
      *1 Stud Bolt

      If the stud bolts are loose, tighten them using an E7 "TORX" wrench.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    6. B001XECE02
      Text in Illustration
      *1 Nut

      Install and uniformly tighten the 16 bolts and 4 nuts in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  47. INSTALL TIMING CHAIN COVER PLATE

    Click here

  48. INSTALL WATER PUMP ASSEMBLY

    Click here

  49. TEMPORARILY INSTALL INTAKE MANIFOLD


    1. B002004

      Install the gasket and temporarily install the No. 2 intake manifold with the 9 bolts.

    2. B001X5Y

      Install the gasket and temporarily install the No. 1 intake manifold with the 9 bolts.

    3. B001WZHE03

      Install the 2 gaskets and temporarily install the No. 3 intake manifold with the 16 bolts.

      Bolt Length
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)

  50. INSTALL FUEL INJECTOR LH (w/o DPF)

    Note

    Be sure to install the injector, holder clamp and bolt in their original positions.


    1. B001XTI

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a light coat of clean engine oil to 4 new O-rings.

    3. B001Y7PE03
      Text in Illustration
      *1 New O-Ring

      Install an O-ring 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 nozzle seat surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return 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. B001WH0E01
      Text in Illustration
      *1 New Washer
      *2 Nozzle Holder Clamp
      *a Downward

      Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

      Note


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

      • Before tightening the bolts, check that the nozzle holder clamps are 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 later step.

      • When tightening the bolts, pay attention not to tilt the bolt and clamp.

      • Do not reuse the washer.

    7. B001WBH

      Temporarily install the common rail LH with the 2 bolts.

    8. B001WP6

      Temporarily install the 4 new injection pipes to the common rail and injectors.

    9. B001ZGHE07
      Text in Illustration
      *1 Nozzle Leakage Pipe

      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.

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

    11. A01X1PC

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

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

    12. B001WNI

      Tighten the 4 holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    13. B001WP6

      Remove the 4 injection pipes.

    14. B001WBH

      Remove the 2 bolts and common rail LH.

    15. B001XPH

      Tighten the 4 hollow screws.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

    16. B001Z7T

      Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

  51. INSTALL FUEL INJECTOR RH (w/o DPF)

    Note

    Be sure to install the injector, holder clamp and bolt in their original positions.


    1. B001XTI

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a light coat of clean engine oil to 4 new O-rings.

    3. B001Y7PE03
      Text in Illustration
      *1 New O-Ring

      Install an O-ring 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 nozzle seat surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return 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. B001WH0E01
      Text in Illustration
      *1 New Washer
      *2 Nozzle Holder Clamp
      *a Downward

      Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

      Note


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

      • Before tightening the bolts, check that the 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 later step.

      • When tightening the bolts, pay attention not to tilt the bolt and clamp.

      • Do not reuse the washer.

    7. A01WZX8

      Temporarily install the common rail RH with the 2 bolts.

    8. A01XAFW

      Temporarily install the 4 new injection pipes to the common rail and injectors.

    9. B001ZGHE07
      Text in Illustration
      *1 Nozzle Leakage Pipe

      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.

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

    11. A01X6BD

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

      Tech Tips

      To position the injectors, loosely tighten the 4 hollow screws and union bolt.

    12. B001WSZ

      Tighten the 4 holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    13. A01XAFW

      Remove the 4 injection pipes.

    14. A01WZX8

      Remove the 2 bolts and common rail RH.

    15. B001Z5S

      Tighten the 4 hollow screws.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note

      If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

    16. B001XNI

      Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

  52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (w/ DPF)


    1. A01XB1H

      Temporarily install 2 service stud bolts (8 mm x 1.25 pitch with a length of 30 mm or more) to the 2 locations shown in the illustration.

    2. A01XBWK

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001XPG Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    3. Install a new cylinder head cover gasket LH and new No. 4 cylinder head cover gasket to the cylinder head cover LH.

      Note

      Remove any oil from the contact surface.

    4. Using the service stud bolts as guides, place the cylinder head cover LH on the cylinder head.

    5. Remove the 2 service stud bolts.

    6. B001W6LE02

      Temporarily install the cylinder head cover LH with the 18 bolts and 4 nozzle holder clamp seats. Tighten the 18 bolts and 4 nozzle holder clamp seats in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      B001XPG Bolt
      B001WGT Nozzle Holder Clamp Seat

      Tech Tips

      After tightening the bolts, check that the bolts at step 16 and 24 are tightened to the specified torque.

  53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH (w/ DPF)


    1. A01X3V9

      Temporarily install 2 service stud bolts (8 mm x 1.25 pitch with a length of 30 mm or more) to the 2 locations shown in the illustration.

    2. A01X8T7

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      B001XPG Seal Packing

      Note


      • Remove any oil from the contact surface.

      • Install the cylinder head cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

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

    3. Install a new cylinder head cover gasket RH and new No. 3 cylinder head cover gasket to the cylinder head cover RH.

      Note

      Remove any oil from the contact surface.

    4. Using the service stud bolts as guides, place the cylinder head cover RH on the cylinder head.

    5. Remove the 2 service stud bolts.

    6. B001WNCE02

      Temporarily install the cylinder head cover RH with the 19 bolts and 4 nozzle holder clamp seats. Tighten the 19 bolts and 4 nozzle holder clamp seats in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      B001XPG Bolt
      B001WGT Nozzle Holder Clamp Seat

      Tech Tips

      After tightening the bolts, check that the bolts at step 16 and 25 are tightened to the specified torque.

  54. INSTALL FUEL INJECTOR LH (w/ DPF)

    Note


    • Be sure to install the injector, holder clamp and bolt to their original positions.

    • Before installing the injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head and injector. If there is foreign matter, remove it before installing the injector.


    1. B001XP2

      Install 4 new injection nozzle seats to the cylinder head.

    2. B001Z34E01
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of clean engine oil to 4 new O-rings.

    3. Install 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 nozzle seat surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return 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. B001W0ZE01
      Text in Illustration
      *1 New Washer

      Temporarily install 4 new washers and the 4 nozzle holder clamps with the 4 clamp bolts.

      Note

      When temporarily installing the nozzle holder clamp bolt to the nozzle holder clamp, make sure that the bolt and clamp are not at an angle.

    7. B001WGJ

      Temporarily install the common rail LH with the 2 bolts.

    8. B001VYV

      Temporarily install 4 new injection pipes to the common rail and injector.

    9. B001W3V

      Temporarily install the No. 2 nozzle leakage pipe and 4 used gaskets with the 4 injector hollow screws and 2 bolts.

      Text in Illustration
      B001XPG Injector Hollow Screw
      B001WGT Bolt

    10. Tighten the 4 holder clamp bolts.

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

    11. Remove the 4 injection pipes.

    12. Remove the 2 bolts and common rail LH.

    13. Remove the 4 injector hollow screws and 4 gaskets.

    14. Remove the 2 bolts and No. 2 nozzle leakage pipe.

  55. INSTALL FUEL INJECTOR RH (w/ DPF)

    Note


    • Be sure to install the injector, holder clamp and bolt to their original positions.

    • Before installing the injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head and injector. If there is foreign matter, remove it before installing the injector.


    1. B001XP2

      Install 4 new injection nozzle seats to the cylinder head.

    2. B001Z34E01
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of clean engine oil to 4 new O-rings.

    3. Install 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 nozzle seat surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return 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. B001W0ZE01
      Text in Illustration
      *1 New Washer

      Temporarily install 4 new washers and the 4 nozzle holder clamps with the 4 clamp bolts.

      Note

      When temporarily installing the nozzle holder clamp bolt to the nozzle holder clamp, make sure that the bolt and clamp are not at an angle.

    7. A01WZTU

      Temporarily install the common rail RH with the 2 bolts.

    8. B001ZTJ

      Temporarily install 4 new injection pipes to the common rail and injector.

    9. B001YFK

      Temporarily install the No. 1 nozzle leakage pipe and 4 used gaskets with the 4 injector hollow screws and union bolt.

      Text in Illustration
      B001XPG Injector Hollow Screw
      B001WGT Union Bolt

    10. Tighten the 4 holder clamp bolts.

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

    11. Remove the 4 injection pipes.

    12. Remove the 2 bolts and common rail RH.

    13. Remove the 4 injector hollow screws and 4 gaskets.

    14. Remove the union bolt and No. 1 nozzle leakage pipe.

  56. REMOVE INTAKE MANIFOLD


    1. Remove the 16 bolts, 2 gaskets and intake manifold.

    2. Remove the 9 bolts, No. 1 intake manifold and gasket.

    3. Remove the 9 bolts, No. 2 intake manifold and gasket.

  57. INSTALL CYLINDER HEAD COVER INSULATOR LH (w/ DPF)

  58. INSTALL CYLINDER HEAD COVER INSULATOR RH (w/ DPF)

  59. INSTALL NO. 2 FUEL PUMP BRACKET (w/ DPF)


    1. Install the No. 2 fuel pump bracket with the bolt.

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

  60. INSTALL NOZZLE HOLDER GASKET LH (w/o DPF)

    Click here

  61. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (w/o DPF)

    Click here

  62. INSTALL NOZZLE HOLDER SEAL LH (w/o DPF)

    Click here

  63. INSTALL OIL SEPARATOR ASSEMBLY

    Click here

  64. INSTALL NOZZLE HOLDER GASKET RH (w/o DPF)

    Click here

  65. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH (w/o DPF)

    Click here

  66. INSTALL NOZZLE HOLDER SEAL RH (w/o DPF)

    Click here

  67. INSTALL OIL FILLER CAP GASKET

  68. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  69. INSTALL SCAVENGING PUMP ASSEMBLY

    Click here

  70. INSTALL OIL PUMP ASSEMBLY

    Click here

  71. INSTALL REAR CRANKSHAFT OIL SEAL


    1. B001VKKE02

      Place the oil seal retainer on wooden blocks.

    2. Using SST and a hammer, tap in a new oil seal as shown in the illustration.

      SST
      09223-56010
      Standard depth A
      2.7 to 3.7 mm (0.106 to 0.147 in.)

      Note


      • Keep the lip free from foreign matter.

      • Do not tap on the seal at an angle.

  72. INSTALL REAR ENGINE OIL SEAL RETAINER

    Click here

  73. INSTALL OIL REGULATOR ASSEMBLY

    Click here

  74. INSTALL INLET OIL PUMP PIPE


    1. Apply a light coat of engine oil to a new O-ring, and install it to the inlet oil pump pipe.

    2. Install the inlet oil pump pipe with the 3 bolts.

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

  75. INSTALL NO. 1 OIL PAN BAFFLE PLATE


    1. Install the No. 1 oil pan baffle plate with the 5 bolts.

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

  76. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  77. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  78. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  79. INSTALL OIL PAN DRAIN PLUG


    1. Install a new gasket and the oil pan drain plug.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  80. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  81. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. B001WLFE02
      Text in Illustration
      *1 New O-Ring

      Apply a light coat of engine oil to 2 new O-rings, and set them to the oil filter bracket.

    2. Install the oil filter bracket with the 3 bolts and 2 nuts.

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

  82. INSTALL OIL FILTER ELEMENT

    Click here

  83. INSTALL OIL COOLER RELIEF VALVE ASSEMBLY


    1. Install a new gasket and the oil cooler relief valve.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  84. INSTALL OIL COOLER ASSEMBLY

    Click here

  85. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  86. INSTALL TIMING GEAR COVER SPACER (w/ Intercooler)

    Click here

  87. INSTALL CRANKSHAFT PULLEY

    Note

    This procedure is intended for removal/installation of the crankshaft pulley only. Do not use this procedure for removal/installation of the flywheel or the drive plate and ring gear.


    1. B001XNPE04
      Text in Illustration
      *1 Service Hole
      *2 Protrusion

      Align the crankshaft pulley and the crankshaft knock pin, and temporarily install the crankshaft pulley with the 3 bolts.

    2. Install the 2 bolts to the bolt holes of the crankshaft rear side.

    3. Using a bar, turn the crankshaft until the crankshaft pulley service hole is a little to the right of bottom dead center.

    4. Install a 14 mm x 1.5 pitch service bolt with a length of 70 mm or more to the crankshaft pulley service hole, and hold the crankshaft using the timing chain cover protrusion.

    5. B001Y21E02

      Uniformly tighten the 3 bolts in 2 passes in the order shown in the illustration.

      Torque:
      115 N*m  { 1168 kgf*cm, 84 ft.*lbf }

    6. Remove the service bolt.

  88. CONNECT NO. 2 OIL COOLER HOSE


    1. Align the white paint marks on the oil cooler hose and oil filter bracket and connect the hose. Then connect the other side to the water pump and attach the oil cooler hose to the clamp.

      Note

      Make sure to maintain a space between the oil cooler hose and crankshaft pulley, and the oil cooler hose and V-ribbed belt idler pulley.

  89. CONNECT NO. 1 OIL COOLER HOSE


    1. Face the pink paint mark on the oil cooler hose toward the front side of the engine and connect the hose to the oil filter bracket. Then connect the other side to the water pump.

      Note

      Make sure to maintain a space between the oil cooler hose and crankshaft pulley.

  90. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  91. INSTALL CAMSHAFT POSITION SENSOR

    Click here