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ENGINE UNIT REASSEMBLY

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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.

Click here

PROCEDURE


  1. Click here

    SELECT NO. 2 CYLINDER HEAD GASKET

    Click here

  2. Click here

    INSTALL NO. 2 CYLINDER HEAD GASKET

    Click here

  3. Click here

    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.

        80 N*m 816 kgf*cm 59 ft.*lbf
        Tip:

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

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

    5. B001ZU3E10

      Step 2:


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

        Table 1. Text in Illustration
        *1 Painted Mark
        B001WGT Front

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

    6. B001WP0E07

      Step 3:


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

        Table 2. Text in Illustration
        *1 Painted Mark
        B001WGT Front
    7. B001ZE4E06

      Step 4:


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

        Table 3. Text in Illustration
        *1 Painted Mark
        B001WGT Front

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

  4. Click here

    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.

      Tip:

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

  5. Click here

    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.

      B001YMM
      Tip:

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

  6. Click here

    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. Click here

    SELECT NO. 1 CYLINDER HEAD GASKET

    Click here

  8. Click here

    INSTALL NO. 1 CYLINDER HEAD GASKET

    Click here

  9. Click here

    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.

        80 N*m 816 kgf*cm 59 ft.*lbf
        Tip:

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

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

    5. B001ZU3E10

      Step 2:


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

        Table 4. Text in Illustration
        *1 Painted Mark
        B001WGT Front

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

    6. B001WP0E07

      Step 3:


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

        Table 5. Text in Illustration
        *1 Painted Mark
        B001WGT Front
    7. B001ZE4E06

      Step 4:


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

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

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

  10. Click here

    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.

      Tip:

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

  11. Click here

    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.

      B001YMM
      Tip:

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

  12. Click here

    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. Click here

    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.

      Tip:

      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. Click here

    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.

        B001YMM
        Note:

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

    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.

      Tip:

      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

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

      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
      Table 7. Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt
    9. B001WIN

      Tighten the 2 union bolts.

      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. Click here

    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.

        B001YMM
        Note:

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

    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.

      Tip:

      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

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

      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
      Table 8. Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt
    9. B001Z1W

      Tighten the 2 union bolts.

      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. Click here

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

  17. Click here

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


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

      6.0 N*m 61 kgf*cm 53 in.*lbf
  18. Click here

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


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

      6.0 N*m 61 kgf*cm 53 in.*lbf
  19. Click here

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

  20. Click here

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

  21. Click here

    INSTALL TIMING GEAR CASE SUB-ASSEMBLY

    B001Y3LE02
    Note:

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

    Table 9. Text in Illustration
    *a Cylinder Block *b Timing Gear Case

    1. B001YKAE03

      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.

      Tip:

      • The FIPG line is shown below.

      • Apply packing to the 5 seal surface areas.

      Table 10. Text in Illustration
      *a Seal Diameter: 4 to 5 mm - -
    2. B001XFLE04

      Install a new timing gear case gasket.

      Table 11. Text in Illustration
      *1 New Timing Gear Case Gasket
      *2 New O-Ring

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

    4. B001YYYE03

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

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

      Table 13. Bolt Length
      Item Quantity Length
      A 4 20 mm (0.787 in.)
      B 8 45 mm (1.77 in.)
  22. Click here

    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. Click here

    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

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Table 14. Text in Illustration
      *1 Adhesive
    3. B001Y2UE02

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

      Table 15. Text in Illustration
      *1 New O-Ring

    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.

        21 N*m 214 kgf*cm 15 ft.*lbf
  24. Click here

    INSTALL STRAIGHT PIN


    1. Install the straight pin.

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

    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.

      25 N*m 250 kgf*cm 18 ft.*lbf
  26. Click here

    INSTALL RADIAL BALL BEARING


    1. B001Z8AE02

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

      09316-12010
      09950-60010 09951-00580
      Table 16. Text in Illustration
      *1 Radial Ball Bearing
      *2 Fuel Supply Pump Shaft Sprocket
      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. Click here

    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. Click here

    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. Click here

    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. Click here

    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

        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.

        09960-10010 09962-01000 09963-00700
        13 N*m 133 kgf*cm 10 ft.*lbf
        Table 17. Text in Illustration
        *1 Service Bolt
  31. Click here

    INSTALL IDLE GEAR ASSEMBLY


    1. B001Y1YE04

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

      Table 18. Text in Illustration
      *1 Key

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

    3. B001ZXTE02

      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.

      Table 19. 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.

      47 N*m 479 kgf*cm 35 ft.*lbf

    6. w/ Intercooler:

      Remove the service bolt.

  32. Click here

    TIGHTEN FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. B001XUCE04

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

      09960-10010 09962-01000 09963-00700
      68 N*m 693 kgf*cm 50 ft.*lbf
      Table 20. Text in Illustration
      *A w/ Intercooler *B w/o Intercooler
  33. Click here

    CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B001XC0

      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.

  34. Click here

    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

      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.

      Table 21. Text in Illustration
      *1 Timing Mark
    3. B001WY1E03

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

      09960-10010 09962-01000 09963-01000
      25 N*m 250 kgf*cm 18 ft.*lbf
  35. Click here

    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

      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.

      Table 22. Text in Illustration
      *1 Timing Mark
  36. Click here

    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.

      09960-10010 09962-01000 09963-01000
      25 N*m 250 kgf*cm 18 ft.*lbf
  37. Click here

    INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

      21 N*m 214 kgf*cm 15 ft.*lbf
  38. Click here

    INSTALL NO. 2 CHAIN TENSIONER SLIPPER

  39. Click here

    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.

      10 N*m 102 kgf*cm 7 ft.*lbf

    4. Remove the hexagon wrench.

  40. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

      21 N*m 214 kgf*cm 15 ft.*lbf
  41. Click here

    INSTALL NO. 1 CHAIN TENSIONER SLIPPER

  42. Click here

    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.

      10 N*m 102 kgf*cm 7 ft.*lbf

    4. Remove the hexagon wrench.

  43. Click here

    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

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Table 23. Text in Illustration
      *1 Adhesive

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

      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.

      Tip:

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

  44. Click here

    CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


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

    2. B00202ME06

      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.

      Table 24. Text in Illustration
      *1 Key - -
      *a Top - -

    3. Remove the 2 crankshaft pulley set bolts.

  45. Click here

    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.

      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. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    B001WQ0E02
    Note:

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

    Table 25. Text in Illustration
    *1 Timing Gear Case *2 Timing Chain Cover

    1. B001ZOPE04

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

      Table 26. Text in Illustration
      *1 New O-Ring

    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.

      B00204ZE02
      Tip:

      • The FIPG line is shown below.

      • Apply packing to the 6 seal surface areas.

      Table 27. 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

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

      6.0 N*m 61 kgf*cm 53 in.*lbf
      Table 28. Text in Illustration
      *1 Stud Bolt
    6. B001XECE02

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

      25 N*m 250 kgf*cm 18 ft.*lbf
      Table 29. Text in Illustration
      *1 Nut
  47. Click here

    INSTALL TIMING CHAIN COVER PLATE

    Click here

  48. Click here

    INSTALL WATER PUMP ASSEMBLY

    Click here

  49. Click here

    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.

      Table 30. Bolt Length
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)
  50. Click here

    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

      Install an O-ring to each injector as shown in the illustration.

      Table 31. Text in Illustration
      *1 New O-Ring

    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

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

      Table 32. Text in Illustration
      *1 New Washer
      *2 Nozzle Holder Clamp
      *a Downward
      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

      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.

      Table 33. Text in Illustration
      *1 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.

      Tip:

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

    12. B001WNI

      Tighten the 4 holder clamp bolts.

      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.

      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.

      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. Click here

    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

      Install an O-ring to each injector as shown in the illustration.

      Table 34. Text in Illustration
      *1 New O-Ring

    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

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

      Table 35. Text in Illustration
      *1 New Washer
      *2 Nozzle Holder Clamp
      *a Downward
      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

      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.

      Table 36. Text in Illustration
      *1 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.

      Tip:

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

    12. B001WSZ

      Tighten the 4 holder clamp bolts.

      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.

      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.

      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. Click here

    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
      Table 37. 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.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 38. Text in Illustration
      B001XPG Bolt
      B001WGT Nozzle Holder Clamp Seat
      Tip:

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

  53. Click here

    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
      Table 39. 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.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 40. Text in Illustration
      B001XPG Bolt
      B001WGT Nozzle Holder Clamp Seat
      Tip:

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

  54. Click here

    INSTALL FUEL INJECTOR LH (w/ DPF)

    Note:

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

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


    1. B001XP2

      Install 4 new injection nozzle seats to the cylinder head sub-assembly.

    2. B001WDWE01

      Install 4 new fuel injector seals to each fuel injector as shown in the illustration.

      Table 41. Text in Illustration
      *1 Fuel Injector Seal

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

    4. B001Z3TE01

      Install the O-rings to each fuel injector as shown in the illustration.

      Table 42. Text in Illustration
      *1 O-Ring

    5. Insert the 4 fuel injectors into the cylinder head sub-assembly.

      Note:

      • Insert the fuel injector until it touches the nozzle seat surface.

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

      • Always return an fuel injector to the same place it was removed from.

    6. For an fuel injector that has been replaced with a new fuel injector, register the injector compensation code (Click here).

    7. B001YKQE01

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

      Table 43. Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *3 Nozzle Holder Seal
      Note:

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

    8. B001WGJ

      Temporarily install the common rail assembly LH with the 2 bolts.

    9. B001VYV

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

    10. B001W3V

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

      Table 44. Text in Illustration
      B001XPG Injector Hollow Screw
      B001WGT Bolt

    11. Tighten the 4 clamp bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf

    12. Remove the 4 injection pipes.

    13. Remove the 2 bolts and common rail assembly LH.

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

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

  55. Click here

    INSTALL FUEL INJECTOR RH (w/ DPF)

    Note:

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

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


    1. B001XP2

      Install 4 new injection nozzle seats to the cylinder head sub-assembly.

    2. B001WDWE01

      Install 4 new fuel injector seals to each fuel injector as shown in the illustration.

      Table 45. Text in Illustration
      *1 Fuel Injector Seal

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

    4. B001Z3TE01

      Install the O-rings to each fuel injector as shown in the illustration.

      Table 46. Text in Illustration
      *1 O-Ring

    5. Insert the 4 fuel injectors into the cylinder head sub-assembly.

      Note:

      • Insert the fuel injector until it touches the nozzle seat surface.

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

      • Always return an fuel injector to the same place it was removed from.

    6. For an fuel injector that has been replaced with a new fuel injector, register the injector compensation code (Click here).

    7. B001YKQE01

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

      Table 47. Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *3 Nozzle Holder Seal
      Note:

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

    8. A01WZTU

      Temporarily install the common rail assembly RH with the 2 bolts.

    9. B001ZTJ

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

    10. B001YFK

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

      Table 48. Text in Illustration
      B001XPG Injector Hollow Screw
      B001WGT Union Bolt

    11. Tighten the 4 clamp bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf

    12. Remove the 4 injection pipes.

    13. Remove the 2 bolts and common rail assembly RH.

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

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

  56. Click here

    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. Click here

    INSTALL CYLINDER HEAD COVER INSULATOR LH (w/ DPF)

  58. Click here

    INSTALL CYLINDER HEAD COVER INSULATOR RH (w/ DPF)

  59. Click here

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


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

      10 N*m 102 kgf*cm 7 ft.*lbf
  60. Click here

    INSTALL NOZZLE HOLDER GASKET LH (w/o DPF)

    Click here

  61. Click here

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

    Click here

  62. Click here

    INSTALL NOZZLE HOLDER SEAL LH (w/o DPF)

    Click here

  63. Click here

    INSTALL OIL SEPARATOR ASSEMBLY

    Click here

  64. Click here

    INSTALL NOZZLE HOLDER GASKET RH (w/o DPF)

    Click here

  65. Click here

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

    Click here

  66. Click here

    INSTALL NOZZLE HOLDER SEAL RH (w/o DPF)

    Click here

  67. Click here

    INSTALL OIL FILLER CAP GASKET

  68. Click here

    INSTALL OIL FILLER CAP SUB-ASSEMBLY

  69. Click here

    INSTALL SCAVENGING PUMP ASSEMBLY

    Click here

  70. Click here

    INSTALL OIL PUMP ASSEMBLY

    Click here

  71. Click here

    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.

      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. Click here

    INSTALL REAR ENGINE OIL SEAL RETAINER

    Click here

  73. Click here

    INSTALL OIL REGULATOR ASSEMBLY

    Click here

  74. Click here

    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.

      10 N*m 102 kgf*cm 7 ft.*lbf
  75. Click here

    INSTALL NO. 1 OIL PAN BAFFLE PLATE


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

      10 N*m 102 kgf*cm 7 ft.*lbf
  76. Click here

    INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  77. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  78. Click here

    INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  79. Click here

    INSTALL OIL PAN DRAIN PLUG


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

      38 N*m 387 kgf*cm 28 ft.*lbf
  80. Click here

    INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  81. Click here

    INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. B001WLFE02

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

      Table 49. Text in Illustration
      *1 New O-Ring

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

      21 N*m 214 kgf*cm 15 ft.*lbf
  82. Click here

    INSTALL OIL FILTER ELEMENT

    Click here

  83. Click here

    INSTALL OIL COOLER RELIEF VALVE ASSEMBLY


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

      25 N*m 250 kgf*cm 18 ft.*lbf
  84. Click here

    INSTALL OIL COOLER ASSEMBLY

    Click here

  85. Click here

    INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

    Click here

  86. Click here

    INSTALL TIMING GEAR COVER SPACER (w/ Intercooler)

    Click here

  87. Click here

    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

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

      Table 50. Text in Illustration
      *1 Service Hole
      *2 Protrusion

    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.

      115 N*m 1168 kgf*cm 84 ft.*lbf

    6. Remove the service bolt.

  88. Click here

    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. Click here

    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. Click here

    INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  91. Click here

    INSTALL CAMSHAFT POSITION SENSOR

    Click here