ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. INSTALL INJECTION PUMP OIL SEAL


    1. B003N3ZN01

      Using SST and a hammer, tap in a new injection pump oil seal until its surface is flush with the timing gear cover edge.

      SST
      09223-15020
      09502-12010
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the supply pump oil seal at an angle.

    2. Apply MP grease to the lip of the injection pump oil seal.

  2. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. B003MBPN01

      Using SST and a hammer, tap in a new front crankshaft oil seal until its surface is flush with the timing gear cover edge.

      SST
      09214-76011

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the front crankshaft oil seal at an angle.

    2. Apply MP grease to the lip of the front crankshaft oil seal.

  3. INSTALL REAR ENGINE OIL SEAL


    1. B003PR2N01

      Using SST and a hammer, tap in a new rear engine oil seal until its surface is flush with the rear engine oil seal retainer edge.

      SST
      09518-36030
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the rear engine oil seal at an angle.

    2. Apply MP grease to the lip of the rear engine oil seal.

  4. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Remove any old seal packing (FIPG material) from the cylinder block sub-assembly.

    2. B003OSTC06
      *a Seal Packing

      Apply seal packing to the places shown in the illustration.

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

      Note

      After applying seal packing, install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 15 minutes.

    3. Install the rear engine oil seal retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

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

  5. INSTALL NO. 2 BALANCESHAFT DRIVEN GEAR


    1. Mount the No. 2 balanceshaft sub-assembly between aluminum plates in a vise.

      Note

      Be careful not to damage the No. 2 balanceshaft sub-assembly.

    2. Align the balanceshaft knock pin with the knock pin hole. Then install the balanceshaft thrust washer and No. 2 balanceshaft driven gear to the No. 2 balanceshaft sub-assembly.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  6. INSTALL NO. 2 BALANCESHAFT SUB-ASSEMBLY


    1. Install the No. 2 balanceshaft sub-assembly to the cylinder block sub-assembly with the 2 bolts.

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

  7. INSTALL NO. 1 BALANCESHAFT DRIVEN GEAR


    1. Mount the No. 1 balanceshaft sub-assembly between aluminum plates in a vise.

      Note

      Be careful not to damage the No. 1 balanceshaft sub-assembly.

    2. Align the balanceshaft knock pin with the knock pin hole. Then install the balanceshaft thrust washer and No. 1 balanceshaft driven gear to the No. 1 balanceshaft sub-assembly.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  8. INSTALL NO. 1 BALANCESHAFT SUB-ASSEMBLY


    1. Install the No. 1 balanceshaft sub-assembly to the cylinder block sub-assembly with the 2 bolts.

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

  9. INSTALL TIMING GEAR CASE ASSEMBLY


    1. B003ODXC01
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block sub-assembly.

    2. B003SF1C02
      *1 New Gasket

      Install a new gasket to the groove of the timing gear case assembly.

    3. Remove any old seal packing (FIPG material).

    4. B003JX7C06
      *a Seal Packing

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

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

      Note

      After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

    5. B003RJZN03

      Align the "2" marks of the No. 1 balanceshaft driven gear and oil pump drive gear.

    6. Install the timing gear case assembly to the cylinder block sub-assembly with the union bolt and 8 bolts.

      Torque:
      for union bolt (A)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  10. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer sub-assembly with the 2 bolts and 2 nuts.

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

  11. INSTALL OIL PAN SUB-ASSEMBLY

    B003KION01

    1. Remove any old seal packing (FIPG material).

    2. Apply seal packing to the oil pan sub-assembly as shown in the illustration.

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

      Note

      After applying seal packing, install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 15 minutes.

    3. Install the oil pan sub-assembly to the cylinder block sub-assembly with the 22 bolts and 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  12. INSTALL INJECTION GEAR


    1. Install a new O-ring and the fuel supply pump assembly with the 2 nuts.

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

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Fit the key (protrusion) of the fuel supply pump assembly into the key slot of the injection gear.

    3. B003RDT

      Align the "3" marks of the No. 2 balanceshaft driven gear and injection gear.

    4. B003K0ZC01
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    5. B003NR4N02

      Install the injection gear set nut.

    6. Using SST, tighten the set nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

  13. INSTALL CRANKSHAFT TIMING GEAR


    1. B003JA1N02

      Position the crankshaft timing gear with the "1" timing marks facing forward.

    2. Align the key groove of the crankshaft timing gear with the set key on the crankshaft.

    3. Using SST and a hammer, tap on the crankshaft timing gear to install it.

      SST
      09223-00010

  14. INSTALL NO. 1 IDLE GEAR SHAFT


    1. B003PMOC06
      *a Engine Oil

      Apply a coat of engine oil to the No. 1 idle gear shaft.

    2. B003KV4C07
      *a Oil Hole

      Install the No. 1 idle gear shaft as shown in the illustration.

  15. INSTALL NO. 2 IDLE SUB GEAR


    1. B003RNAC03
      *a Cutout Mark

      Mount the No. 1 idle gear in a vise.

      Note

      Be careful not to damage the No. 1 idle gear.

      Tech Tips

      Make sure the cutout mark of the No. 1 idle gear faces down.

    2. B003JNVC01
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

      Tech Tips

      Fit the pins on the No. 1 idle gears between the spring ends.

    3. Install the No. 2 idle sub gear.

    4. Install the wave washer.

    5. Using snap ring pliers, install the snap ring.

    6. B003NYEC01
      *1 Service Bolt

      Using SST, align the holes of the No. 1 idle gear and No. 2 idle sub gear by turning the No. 2 idle sub gear clockwise and install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    7. Remove the No. 1 idle gear from the vise and turn it upside down.

  16. INSTALL NO. 1 IDLE SUB GEAR


    1. B003NXOC01
      *a Upward

      Mount the No. 1 idle gear and No. 2 idle sub gear in a vise.

      Note

      Be careful not to damage the gears.

    2. B003QEXC01
      *1 Service Bolt

      Remove the service bolt.

    3. B003QWMC01
      *1 Wave Washer
      *2 No. 1 Idle Sub Gear
      *3 Idle Gear Spring

      Install the idle gear spring.

      Tech Tips

      Fit the pins on the No. 1 idle gears between the spring ends.

    4. Install the No. 1 idle sub gear.

    5. Install the wave washer.

    6. Using snap ring pliers, install the snap ring.

    7. B003P4UC01
      *1 Service Bolt
      *a Upward

      Using SST, align the holes of the No. 1 idle gear and No. 1 idle sub gear by turning the No. 1 idle sub gear clockwise, and install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

  17. INSTALL NO. 1 IDLE GEAR


    1. B003RFAC02
      *a Turn

      Align the "4" and "5" timing marks of the No. 1 idle gear and crankshaft timing gear.

    2. Using SST, turn the injection gear and align the "4" timing marks of the No. 1 idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. B003QU6C02
      *1 Service Bolt

      Position the idle gear thrust plate with the protrusion facing forward.

    4. Align the bolt holes and install the idle gear thrust plate with the 2 bolts.

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

    5. Remove the service bolt.

  18. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the No. 1 crankshaft position sensor plate with the set key.

    2. Install the No. 1 crankshaft position sensor plate to the crankshaft with the cupped side facing outward.

  19. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. B003MSFC01
      *a Seal Packing

      Apply seal packing to the timing gear cover as shown in the illustration.

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

      Note

      After applying seal packing, install the timing gear cover within 3 minutes and tighten the bolts within 15 minutes.

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

    4. Install the timing gear cover to the timing gear case assembly with the 14 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    5. B003QVB

      Remove the screw plug and gasket.

    6. Pour approximately 50 cc (3.05 cu. in.) of engine oil into the oil pump.

    7. Install a new gasket and the screw plug.

      Torque:
      41.5 N*m  { 423 kgf*cm, 31 ft.*lbf }

    8. Install the No. 1 vacuum transmitting pipe with the bolt.

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

  20. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install a new gasket and the engine water pump assembly to the cylinder block sub-assembly with the 5 bolts and 2 nuts.

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

  21. INSTALL CYLINDER HEAD GASKET

    Click here

  22. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  23. INSTALL VALVE LIFTER


    1. Install the valve lifters to the cylinder head sub-assembly.

    2. Check that each valve lifter rotates smoothly by hand.

  24. INSTALL CAMSHAFT SUB-ASSEMBLY

    Click here

  25. INSTALL NO. 2 TIMING BELT COVER

    Click here

  26. INSTALL CAMSHAFT TIMING PULLEY

    Click here

  27. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  28. INSTALL INJECTOR ASSEMBLY

    Click here

  29. INSPECT FOR FUEL LEAK

    Click here

  30. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  31. INSTALL OIL FILLER CAP SUB-ASSEMBLY