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ENGINE UNIT REASSEMBLY

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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.

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  1. Click here

    SELECT NO. 2 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. A015B7L

        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.).

        Tip:

        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. A015AE9E02

        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.

        Table 1. Text in Illustration
        *A for Bank 1 *B for Bank 2
        *a Measuring Point - -
        A015CC1 Front - -
    4. A0155PPE01

      Select a new cylinder head gasket.

      Table 2. Text in Illustration
      *A for Bank 1 *B for Bank 2
      A015CC1 Front - -
      Tip:

      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.)
      Tip:

      *: 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.)
  2. Click here

    INSTALL NO. 2 CYLINDER HEAD GASKET


    1. A0159I0E02

      Remove any oil from the contact surface.

      Table 3. Text in Illustration
      *a Front
      *b Exhaust Side

    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.

  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. A0158EKE02

        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. A015AS3E04

      Step 2:


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

        Table 4. Text in Illustration
        *1 Painted Mark
        A015CC1 Front

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

    6. A0155Y5E03

      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
        A015CC1 Front
    7. A015B0JE03

      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
        A015CC1 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. A0157MM

      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.

      A015BZL
      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


    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. A015B7L

        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.).

        Tip:

        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. A015AE9E02

        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.

        Table 7. Text in Illustration
        *A for Bank 1 *B for Bank 2
        *a Measuring Point - -
        A015CC1 Front - -
    4. A0155PPE01

      Select a new cylinder head gasket.

      Table 8. Text in Illustration
      *A for Bank 1 *B for Bank 2
      A015CC1 Front - -
      Tip:

      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.)
      Tip:

      *: 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.)
  8. Click here

    INSTALL NO. 1 CYLINDER HEAD GASKET


    1. A015BBKE02

      Remove any oil from the contact surface.

      Table 9. Text in Illustration
      *a Front
      *b Exhaust Side

    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.

  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. A015DH8E02

        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. A015AS3E04

      Step 2:


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

        Table 10. Text in Illustration
        *1 Painted Mark
        A015CC1 Front

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

    6. A0155Y5E03

      Step 3:


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

        Table 11. Text in Illustration
        *1 Painted Mark
        A015CC1 Front
    7. A015B0JE03

      Step 4:


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

        Table 12. Text in Illustration
        *1 Painted Mark
        A015CC1 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. A0157MM

      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.

      A015BZL
      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. A0155HA

      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. A015D59

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

    2. A015DRP

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

    3. A015894

      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.

        A015BZL
        Note:

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

    4. A015DWJ

      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. A015DLD

      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. A015D82

      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. A015D9S

      Temporarily install the 2 union bolts by hand.

    8. A0158FDE02

      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 13. Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt
    9. A015D9S

      Tighten the 2 union bolts.

      17 N*m 173 kgf*cm 13 ft.*lbf
    10. A015ATK

      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. A015D59

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

    2. A015DRP

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

    3. A01569L

      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.

        A015BZL
        Note:

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

    4. A015666

      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. A0156V2

      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. A015CJ5

      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. A0158I9

      Temporarily install the 2 union bolts by hand.

    8. A0157CVE02

      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 14. Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt
    9. A0158I9

      Tighten the 2 union bolts.

      17 N*m 173 kgf*cm 13 ft.*lbf
    10. A015ATK

      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

    A015A17E02
    Note:

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

    Table 15. Text in Illustration
    *a Cylinder Block *b Timing Gear Case

    1. A015ARGE03

      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 16. Text in Illustration
      *a Seal Diameter: 4 to 5 mm - -
    2. A0155WUE02

      Install a new timing gear case gasket.

      Table 17. 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. A015B60E03

      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 18. 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 19. 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. A015689

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

    2. A015A1NE02

      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 20. Text in Illustration
      *1 Adhesive
    3. A0156ZYE02

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

      Table 21. 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. A015BQHE02

      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 22. 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. A0157A9

      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. A0158YT

      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. A015CYA

      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. A0158DD

      Hold the idle gear in a vise between aluminum plates.

      Note:

      Be careful not to damage the gears.

    2. A0157WU

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

    3. A0159DS

      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. A015BI8E02

        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 23. Text in Illustration
        *1 Service Bolt
  31. Click here

    INSTALL IDLE GEAR ASSEMBLY


    1. A0159YZE02

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

      Table 24. Text in Illustration
      *1 Key

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

    3. A0156OHE02

      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 25. 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. A015CQOE02

      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 26. Text in Illustration
      *A w/ Intercooler *B w/o Intercooler
  33. Click here

    CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A015CBJ

      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. A015BCX

      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. A015AR8E02

      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 27. Text in Illustration
      *1 Timing Mark
    3. A015DE3E01

      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. A015C75

      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. A015DHEE02

      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 28. Text in Illustration
      *1 Timing Mark
  36. Click here

    INSTALL PUMP DRIVE SHAFT GEAR


    1. A015E0QE01

      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. A015BK9

      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. A015BK9

      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. A01589ZE01

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Table 29. 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. A0157BOE03

      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 30. Text in Illustration
      *1 Key - -
      *a Top - -

    3. Remove the 2 crankshaft pulley set bolts.

  45. Click here

    INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A015DD9E01

      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

    A015B9GE02
    Note:

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

    Table 31. Text in Illustration
    *1 Timing Gear Case *2 Timing Chain Cover

    1. A0157K4E02

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

      Table 32. 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.

      A0155Q9E03
      Tip:

      • The FIPG line is shown below.

      • Apply packing to the 6 seal surface areas.

      Table 33. 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. A0157DPE02

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

      6.0 N*m 61 kgf*cm 53 in.*lbf
      Table 34. Text in Illustration
      *1 Stud Bolt
    6. A0159IYE02

      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 35. Text in Illustration
      *1 Nut
  47. Click here

    INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the cover plate with the 4 bolts.

      9.1 N*m 93 kgf*cm 81 in.*lbf
  48. Click here

    INSTALL WATER PUMP ASSEMBLY


    1. A0158CTE01

      Temporarily install a new gasket and the water pump with the 9 bolts and 2 nuts.

      Table 36. Bolt Length
      Item Length
      Bolt A 30 mm (1.18 in.)
      Bolt B 80 mm (3.15 in.)
    2. A0158CTE02

      Uniformly tighten the 9 bolts and 2 nuts of the water pump in the order shown in the illustration.

      25 N*m 250 kgf*cm 18 ft.*lbf
      Note:

      After installing all of the bolts and nuts, check that all of the bolts and nuts are tightened to the torque specification.

  49. Click here

    TEMPORARILY INSTALL INTAKE MANIFOLD


    1. A0156RZ

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

    2. A0159XZ

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

    3. A015DAAE01

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

      Table 37. 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. A0155RO

      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. A0158MYE03

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

      Table 38. 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. A0159Q5E06

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

      Table 39. 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. A01587D

      Temporarily install the common rail LH with the 2 bolts.

    8. A015DOI

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

    9. A0159P5E04

      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 40. Text in Illustration
      *1 Nozzle Leakage Pipe

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

    11. A01588V

      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. A015AEN

      Tighten the 4 holder clamp bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf
    13. A015DOI

      Remove the 4 injection pipes.

    14. A01587D

      Remove the 2 bolts and common rail LH.

    15. A015770

      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. A0155MP

      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. A0155RO

      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. A0158MYE03

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

      Table 41. 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. A0159Q5E06

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

      Table 42. 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. A015CJG

      Temporarily install the common rail RH with the 2 bolts.

    8. A0155SN

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

    9. A0159P5E04

      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 43. Text in Illustration
      *1 Nozzle Leakage Pipe

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

    11. A0156JF

      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. A01575P

      Tighten the 4 holder clamp bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf
    13. A0155SN

      Remove the 4 injection pipes.

    14. A015CJG

      Remove the 2 bolts and common rail RH.

    15. A015DTQ

      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. A0157TL

      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. A015E8O

      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. A0157JO

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 44. Text in Illustration
      A015DIT 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. A015E4ME01

      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 45. Text in Illustration
      A015DIT Bolt
      A015CC1 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. A01587H

      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. A015D5W

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 46. Text in Illustration
      A015DIT 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. A015872E01

      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 47. Text in Illustration
      A015DIT Bolt
      A015CC1 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 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. A0157PJ

      Install 4 new injection nozzle seats to the cylinder head.

    2. A0158GAE01

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

      Table 48. Text in Illustration
      *1 New O-Ring

    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. A01588XE01

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

      Table 49. Text in Illustration
      *1 New Washer
      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. A0156IV

      Temporarily install the common rail LH with the 2 bolts.

    8. A01591Y

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

    9. A015BOU

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

      Table 50. Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Bolt

    10. Tighten the 4 holder clamp bolts.

      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. Click here

    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. A0157PJ

      Install 4 new injection nozzle seats to the cylinder head.

    2. A0158GAE01

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

      Table 51. Text in Illustration
      *1 New O-Ring

    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. A01588XE01

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

      Table 52. Text in Illustration
      *1 New Washer
      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. A0157EO

      Temporarily install the common rail RH with the 2 bolts.

    8. A015A5S

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

    9. A015BLL

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

      Table 53. Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Union Bolt

    10. Tighten the 4 holder clamp bolts.

      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. 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)


    1. A0155LDE02

      Press 4 new nozzle holder gaskets into the cylinder head cover LH.

      Note:

      After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

      Table 54. Text in Illustration
      *1 Nozzle Holder Gasket
  61. Click here

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


    1. A0157H8

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 55. Text in Illustration
      A015DIT 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.

    2. Install a new gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surface.

    3. A015CG8E01

      Temporarily install the cylinder head cover with the 17 bolts. Tighten the 17 bolts in the order shown in the illustration.

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

      After tightening the bolts, check that the bolts at step 11 and 19 are tightened to the specified torque.

  62. Click here

    INSTALL NOZZLE HOLDER SEAL LH (w/o DPF)


    1. Press 4 new holder seals into the cylinder head cover LH.

  63. Click here

    INSTALL OIL SEPARATOR ASSEMBLY


    1. Install a new gasket to the oil separator.

      Note:

      Remove any oil from the contact surface.

    2. Install the oil separator with the 3 bolts.

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

    INSTALL NOZZLE HOLDER GASKET RH (w/o DPF)


    1. A0155LDE02

      Press 4 new nozzle holder gaskets into the cylinder head cover RH.

      Note:

      After installing the nozzle holder gasket, check that it does not protrude from the cylinder head cover.

      Table 56. Text in Illustration
      *1 Nozzle Holder Gasket
  65. Click here

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


    1. A015BYJ

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 57. Text in Illustration
      A015DIT 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.

    2. Install a new gasket to the cylinder head cover.

      Note:

      Remove any oil from the contact surface.

    3. A0155ERE01

      Temporarily install the cylinder head cover with the 18 bolts. Tighten the 18 bolts in the order shown in the illustration.

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

      After tightening the bolts, check that the bolts at step 11 and 20 are tightened to the specified torque.

  66. Click here

    INSTALL NOZZLE HOLDER SEAL RH (w/o DPF)


    1. Press 4 new holder seals into the cylinder head cover RH.

  67. Click here

    INSTALL OIL FILLER CAP GASKET

  68. Click here

    INSTALL OIL FILLER CAP SUB-ASSEMBLY

  69. Click here

    INSTALL SCAVENGING PUMP ASSEMBLY


    1. Install the scavenging pump with the 4 bolts.

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

    INSTALL OIL PUMP ASSEMBLY


    1. Install the oil pump with the 4 bolts.

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

    INSTALL REAR CRANKSHAFT OIL SEAL


    1. A015DZME01

      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

    A0155SME01
    Note:

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


    1. A015CW8E03

      Apply seal packing in a continuous line as shown in the illustration.

      Seal diameter
      3.0 to 5.0 mm (0.118 to 0.197 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Note:

      • Remove any oil from the contact surface.

      • Install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

    2. Apply engine oil to the oil seal lip.

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

    4. A015B7UE01

      Install and uniformly tighten the 10 bolts in the order shown in the illustration.

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

      • When installing the oil seal retainer, make sure the lip of the oil seal is not damaged.

      • When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.

  73. Click here

    INSTALL OIL REGULATOR ASSEMBLY


    1. Install the oil regulator with the 4 bolts.

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

    Note:

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


    1. Install the cylinder block oil hole gasket.

    2. Apply a light coat of engine oil to 3 new O-rings and set the 3 O-rings to the oil regulator and scavenging pump.

    3. A0158IZE01

      Apply seal packing to the No. 1 oil pan as shown in the illustration.

      Standard seal diameter
      3.5 to 4.0 mm (0.134 to 0.157 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Note:

      • For the 3 bolt holes labeled with arrows, apply the seal packing on the outer edges. For the other bolt holes, apply the seal packing on the inner edges.

      • Make sure to apply a continuous bead of seal packing as shown in the illustration. If the bead breaks, overlap 3 mm (0.118 in.) of seal packing and continue the bead.

      • Remove any oil and old seal packing from the contact surface.

      • Install the No. 1 oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing.

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

    4. A015A12E01

      Install the No. 1 oil pan and oil reflector plate with the 20 bolts and 2 nuts.

      25 N*m 250 kgf*cm 18 ft.*lbf
      Table 58. Bolt Length
      Item Quantity Length
      Bolt A 7 70 mm (2.76 in.)
      Bolt B 8 20 mm (0.787 in.)
      Bolt C 5 30 mm (1.18 in.)
  77. Click here

    INSTALL OIL STRAINER SUB-ASSEMBLY


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

    2. Install the oil strainer with the 2 bolts.

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

    INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Note:

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


    1. A0156WIE01

      Apply seal packing to the No. 2 oil pan as shown in the illustration.

      Standard seal diameter
      5.0 to 6.0 mm (0.197 to 0.236 in.)
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Note:

      • For the bolt and pin holes, make sure to apply seal packing to the inner sides.

      • Make sure to apply a continuous bead of seal packing as shown in the illustration. If the bead breaks, overlap 3.0 mm (0.118 in.) of seal packing and continue the bead.

      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.

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

    2. Install the No. 2 oil pan with the 10 bolts and 2 nuts.

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


    1. Install a new gasket and the sensor with the 4 bolts.

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

    INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. A015CNAE02

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

      Table 59. 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


    1. A015AAWE08

      Clean the inside of the oil filter cap, its threads and its O-ring groove.

    2. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

    3. Set a new oil filter element in the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap by hand.

    6. A015CT2E02

      Using SST, tighten the oil filter cap.

      09228-06501
      25 N*m 255 kgf*cm 18 ft.*lbf
      Note:

      • Make sure that the oil filter is installed securely as shown in the illustration.

      • Be careful that the O-ring does not get caught between any surrounding parts.

    7. A0158YG

      Install the No. 2 engine under cover seal to the No. 2 engine under cover with the 2 bolts.

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


    1. A015DHH

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

    2. A0156HU

      Install the oil cooler with the 2 bolts and 2 nuts.

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

    INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY


    1. Remove the adhesive from the threads of the oil pressure sender gauge and the bolt hole of the oil filter bracket.

    2. A015C43E01

      Apply adhesive to 2 or 3 threads of the oil pressure sender gauge.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
      Note:

      Do not apply adhesive to the oil inlet port of the sensor.

    3. A0155E5

      Install the oil pressure sender gauge.

      15 N*m 153 kgf*cm 11 ft.*lbf
      Note:

      Do not start the engine within 1 hour after installation.

    4. Connect the oil pressure sender gauge connector.

  86. Click here

    INSTALL TIMING GEAR COVER SPACER (w/ Intercooler)


    1. Install the timing gear cover spacer with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
  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. A015DNAE02

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

      Table 60. 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. A015CV2E01

      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


    1. Apply a light coat of engine oil to the O-ring.

      Note:

      When reusing the sensor, inspect the O-ring.

      If the O-ring has scratches or cuts, replace the sensor.

    2. A015B82

      Install the sensor with the bolt.

      5.0 N*m 51 kgf*cm 44 in.*lbf

    3. Connect the sensor wire harness clamp.

  91. Click here

    INSTALL CAMSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring.

      Note:

      When reusing the sensor, inspect the O-ring.

      If the O-ring has scratches or cuts, replace the sensor.

    2. A015CJR

      Install the sensor with the bolt.

      5.0 N*m 51 kgf*cm 44 in.*lbf

    3. Connect the sensor connector.