CYLINDER HEAD GASKET(w/o DPF) INSTALLATION

CAUTION / NOTICE / HINT

Note


  • Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block, cylinder head, 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. CHECK INJECTOR COMPENSATION CODE

    Click here

  2. SELECT CYLINDER HEAD GASKET


    1. Set the 2 crankshaft pulley set bolts to the crankshaft.

    2. Clean the cylinder block with solvent.

    3. Inspect the protrusion for each cylinder.


      1. Set the piston of the cylinder to be measured to slightly before TDC.

      2. B001VM2

        Place a dial indicator on the cylinder block, and set the measuring tip as shown in the illustration.

        Note

        Make sure that the dial indicator is at a right angle to the cylinder block top surface.

      3. Set the dial indicator at 0 mm (0 in.).

        Tech Tips

        Make sure that the measuring tip is flat against the cylinder block surface and piston head when taking the measurements.

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

      5. Measure the piston protrusion value of each cylinder at 2 places as shown in the illustration below, making a total of 8 measurements.

        Standard piston protrusion
        0.520 to 0.780 mm (0.0205 to 0.0307 in.)

        If the protrusion is not as specified, remove and reinstall the piston and connecting rod.

        B001ZD4E01
        *1 for Bank 1:
        *2 Front
        *3 for Bank 2:
        *4 Measuring Point

    4. Select a new cylinder head gasket.

      B001W72E01
      *1 for Bank 1:
      *2 for Bank 2:
      *3 Front

      Tech Tips

      Cylinder head gaskets are marked A, B, C, D or E accordingly.

      New Installed Cylinder Head Gasket Thickness
      Item Cutout Specified Condition*
      A 1 1.20 to 1.30 mm (0.0472 to 0.0512 in.)
      B 2 1.25 to 1.35 mm (0.0492 to 0.0394 in.)
      C 3 1.30 to 1.40 mm (0.0512 to 0.0551 in.)
      D 4 1.35 to 1.45 mm (0.0531 to 0.0571 in.)
      E 5 1.40 to 1.50 mm (0.0551 to 0.0591 in.)

      Tech Tips

      *: The specified condition indicates the thickness of the gasket after tightening the cylinder head.


      1. Select the largest piston protrusion value from the measurements and then select a new appropriate gasket according to the table below.

        Standard Piston Protrusion
        Item Specified Condition
        A 0.520 to 0.575 mm (0.0205 to 0.0226 in.)
        B 0.575 to 0.625 mm (0.0226 to 0.0246 in.)
        C 0.625 to 0.675 mm (0.0246 to 0.0266 in.)
        D 0.675 to 0.725 mm (0.0266 to 0.0285 in.)
        E 0.725 to 0.780 mm (0.0285 to 0.0307 in.)

  3. INSTALL NO. 2 CYLINDER HEAD GASKET


    1. B001W31E01
      *1 Front
      *2 Exhaust Side

      Remove any oil from the contact surface.

    2. Place the cylinder head gasket on the cylinder block surface with the front face of the indicated mark "L" upward and facing the exhaust side.

  4. INSTALL NO. 1 CYLINDER HEAD GASKET


    1. B001ZGUE01
      *1 Exhaust Side
      *2 Front

      Remove any oil from the contact surface.

    2. Place the cylinder head gasket on the cylinder block surface with the front face of the indicated mark "R" upward and facing the exhaust side.

  5. 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. B001ZU3E09
      *1 Front
      *2 Painted Mark

      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. B001ZE4E05
      *1 Painted Mark
      *2 Front

      Step 3:


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

    7. B001ZE4E05
      *1 Painted Mark
      *2 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.

  6. 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. B001ZU3E09
      *1 Front
      *2 Painted Mark

      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. B001WP0E06
      *1 Painted Mark
      *2 Front

      Step 3:


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

    7. B001ZE4E05
      *1 Painted Mark
      *2 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.

  7. 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.

  8. INSTALL NO. 2 VALVE LASH ADJUSTER ASSEMBLY

    Note

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


    1. B001Y5C

      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.

  9. INSTALL NO. 1 VALVE LASH ADJUSTER ASSEMBLY

    Note

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


    1. B001XJ4

      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.

  10. INSTALL NO. 2 VALVE ROCKER ARM


    1. B001WVE

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

    2. B001YMM

      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.

  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. 5 CAMSHAFT BEARING CAP


    1. B001ZYR

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

  13. INSTALL NO. 2 CAMSHAFT BEARING CAP


    1. B001WTI

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

  14. 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 the 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

        B001YMM

        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.

      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. B001Z4AE02
      *a 12 mm Head Bolt
      *b 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 bolt from the No. 4 camshaft timing gear.

      Note

      Do not drop the bolt into the engine.

  15. INSTALL NO. 1 AND NO. 2 CAMSHAFT


    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

        B001YMM

        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.

      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. B001ZA3E02
      *a 12 mm Head Bolt
      *b 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 bolt from the No. 1 camshaft timing gear.

      Note

      Do not drop the bolt into the engine.

  16. INSTALL TIMING GEAR CASE SUB-ASSEMBLY


    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.

      B001YKAE05
      *1 2.5 mm (0.0984 in.)
      *2 2.0 mm (0.0787 in.)
      *3 Seal Diameter: 4 to 5 mm
    2. B001XFLE03
      *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. B001YYYE02
      *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 (case is dry)
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      for 14 mm head bolt (case is 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.)

  17. INSTALL V-BANK SILENCER


    1. B001XGZ

      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.

  18. 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. B001Z3HE04
      *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. B001Y2UE03
      *1 New O-Ring

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

    4. B001WXP

      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 }

  19. INSPECT RADIAL BALL BEARING

    Click here

  20. 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 nut.

  21. 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.

  22. 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. B001Z32

      Install the idle gear shaft to the cylinder block.

  23. INSTALL IDLE GEAR ASSEMBLY


    1. B001Y1YE03
      *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.

      B001ZXTE01
      *1 w/ Intercooler:
      *2 w/o Intercooler:

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

    5. B001Z1KE03
      *1 w/ Intercooler:
      *2 w/o Intercooler:

      Install the idle gear thrust plate with the 2 bolts.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }
    6. B001YVH

      w/ Intercooler:

      Remove the service bolt.

  24. 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 }
      B001XUCE03
      *1 w/ Intercooler:
      *2 w/o Intercooler:

  25. 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

  26. 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. B001YKTE04
      *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 }

  27. 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. B001VKYE04
      *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.

  28. 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 }

  29. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. B001WGZ

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

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

  30. INSTALL NO. 2 CHAIN TENSIONER SLIPPER

    B001ZYT

  31. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


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

    2. B001Z0I

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

    3. B001Z8I

      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.

  32. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. B001XUH

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

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

  33. INSTALL NO. 1 CHAIN TENSIONER SLIPPER

    B001XAX

  34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


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

    2. B001Z0I

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

    3. B001W1S

      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.

  35. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. B001ZAL

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

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. B001Y05

      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.

  36. 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.

      B00202ME04
      *1 Top
      *2 Key

    3. Remove the 2 crankshaft pulley set bolts.

  37. 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.)

  38. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. B001ZOPE03
      *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.

    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.

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

      1. Using an E7 "TORX" wrench, tighten the stud bolts.

        Torque:
        6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    5. B001WJOE02
      *a Nut

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

  39. 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. B001XTTE02

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

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

  40. TEMPORARILY INSTALL COMMON RAIL ASSEMBLY RH

    Click here

  41. TEMPORARILY INSTALL COMMON RAIL ASSEMBLY LH

    Click here

  42. INSTALL FUEL INJECTOR RH

    Click here

  43. INSTALL FUEL INJECTOR LH

    Click here

  44. REMOVE COMMON RAIL ASSEMBLY RH

    Click here

  45. REMOVE COMMON RAIL ASSEMBLY LH

    Click here

  46. REMOVE INTAKE MANIFOLD


    1. B001ZTA

      Remove the 16 bolts, 2 gaskets and intake manifold.

    2. B001X5Y

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

    3. B002004

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

  47. INSTALL NOZZLE HOLDER GASKET LH

    Click here

  48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

    Click here

  49. INSTALL NOZZLE HOLDER SEAL LH

    Click here

  50. INSTALL OIL SEPARATOR ASSEMBLY

    Click here

  51. INSTALL NOZZLE HOLDER GASKET RH

    Click here

  52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

    Click here

  53. INSTALL NOZZLE HOLDER SEAL RH

    Click here

  54. INSTALL CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)

    Click here

  55. INSTALL CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)

    Click here

  56. INSTALL VACUUM PUMP ASSEMBLY (w/ Intercooler)

    Click here

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

    Click here

  58. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ Intercooler)

    Click here

  59. INSTALL GLOW PLUG ASSEMBLY

    Click here

  60. INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

  61. INSTALL WATER OUTLET PIPE

    Click here

  62. INSTALL WATER OUTLET

    Click here

  63. INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET

    Click here

  64. INSTALL CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)


    1. B001YN2

      Install the clutch flexible hose bracket with the 2 bolts.

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

  65. INSTALL STARTER HOSE BRACKET


    1. B001YOU

      Install the starter hose bracket with the 2 bolts.

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

  66. INSTALL STARTER ASSEMBLY

    Click here

  67. INSTALL WATER PUMP ASSEMBLY

    Click here

  68. CONNECT INLET WATER HOSE

  69. INSTALL NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)

    Click here

  70. INSTALL NO. 2 IDLER PULLEY (w/ Viscous Heater)

    Click here

  71. INSTALL FAN BRACKET SUB-ASSEMBLY

    Click here

  72. INSTALL TIMING GEAR COVER INSULATOR (w/ Intercooler)

    Click here

  73. INSTALL THERMOSTAT

    Click here

  74. INSTALL WATER INLET

    Click here

  75. INSTALL NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)

    Click here

  76. INSTALL VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater)

    Click here

  77. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  78. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  79. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

    Click here

  80. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  81. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  82. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  83. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

    Click here

  84. INSTALL OIL FILTER ELEMENT

    Click here

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

    Click here

  86. INSTALL CRANKSHAFT PULLEY

    Click here

  87. CONNECT NO. 2 OIL COOLER HOSE

    Click here

  88. CONNECT NO. 1 OIL COOLER HOSE

  89. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  90. INSTALL STIFFENER INSULATOR RH (w/ Intercooler)

    Click here

  91. INSTALL COMPRESSOR BRACKET

    Click here

  92. INSTALL NO. 2 CYLINDER BLOCK INSULATOR

  93. INSTALL ENGINE MOUNTING BRACKET LH

    Click here

  94. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  95. INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    Click here

  96. INSTALL TURBOCHARGER WIRE

    Click here

  97. INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET

    Click here

  98. INSTALL NO. 1 CYLINDER BLOCK INSULATOR

  99. INSTALL ENGINE MOUNTING BRACKET RH

    Click here

  100. INSTALL NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)

    Click here

  101. INSTALL NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  102. INSTALL AIR TUBE SUPPORT

    Click here

  103. INSTALL NO. 1 INTAKE AIR CONNECTOR BRACKET

    Click here

  104. INSTALL NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH

    Click here

  105. INSTALL NO. 2 VENTILATION TUBE SUB-ASSEMBLY

    Click here

  106. INSTALL NO. 2 TURBOCHARGER STAY

    Click here

  107. CONNECT NO. 2 OUTLET TURBO OIL HOSE

    Click here

  108. INSTALL NO. 2 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  109. INSTALL FRONT WATER BY-PASS JOINT

    Click here

  110. INSTALL NO. 3 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  111. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  112. CONNECT NO. 2 TURBO WATER HOSE

  113. CONNECT BREATHER PLUG LH

    Click here

  114. CONNECT NO. 3 VENTILATION HOSE

  115. INSTALL NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH

    Click here

  116. INSTALL NO. 1 VENTILATION TUBE SUB-ASSEMBLY

    Click here

  117. INSTALL NO. 1 TURBOCHARGER STAY

    Click here

  118. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  119. CONNECT NO. 1 OUTLET TURBO OIL HOSE

  120. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  121. CONNECT NO. 2 TURBO WATER HOSE

  122. CONNECT BREATHER PLUG RH

    Click here

  123. CONNECT NO. 2 VENTILATION HOSE

  124. INSTALL GENERATOR ASSEMBLY

    Click here

  125. INSTALL NO. 1 INTAKE AIR CONNECTOR PIPE

    Click here

  126. INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  127. INSTALL ENGINE ASSEMBLY


    1. Install the engine assembly to the vehicle Click here.

  128. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.