CYLINDER HEAD GASKET (w/ DPF) INSTALLATION

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.

  • When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.


  1. CHECK INJECTOR COMPENSATION CODE

    A0159NUE05

    Note


    • When an injector assembly is replaced, the new injector compensation code must be input into the ECM. When the ECM is replaced, all of the existing injector compensation codes must be input into the new ECM.

    • Injector compensation codes are unique, 30-digit, alphanumeric values printed on the head portion of each injector assembly. If an incorrect injector compensation code is input into the ECM, the engine assembly may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

    • When an injector compensation code is input into the ECM, the pilot quantity learning values stored in the ECM are initialized. Also, DTC P062F is stored when the pilot quantity learning values are initialized.

    Text in Illustration
    *1 Injector Compensation Code
    *a Example

    1. After replacing injector assemblies with new one(s), input injector compensation code(s) of the injector assemblies into the ECM as follows:

      Tech Tips


      • Each injector assembly has different fuel injection characteristics. In order to optimize the fuel injections, the ECM uses the compensation codes to balance the different fuel injections between each injector assembly.

      • When only one or more injector assemblies are replaced, input the injector compensation code(s), perform pilot quantity learning, and then clear the DTCs.

      • When the engine switch is turned on (IG) after replacing the ECM, DTC P062F is stored. This indicates that the injector compensation code(s) need to be registered. Manually clear the DTC upon completion of pilot quantity learning.


      1. Input the compensation code(s), which is/are imprinted on the head portion(s) of the new injector assemblies, into the GTS.

      2. Input the new injector compensation code(s) into the ECM using the GTS.

      3. Turn the GTS off and turn the engine switch off.

      4. Wait for at least 30 seconds.

      5. Turn the engine switch on (IG) and turn the GTS on.

      6. Perform pilot quantity learning.

      7. Clear DTC P062F stored in the ECM using the GTS Click here.

        Note

        If the DTCs are cleared without performing pilot quantity learning, DTC P062F is stored immediately after clearing DTCs.

    2. Register compensation codes.

      A015AIOE04

      1. Connect the GTS to the DLC3.

      2. Turn the engine switch on (IG).

        Note

        Do not start the engine.

      3. Turn the GTS on.

      4. A015BL1

        Enter the following menus: Engine and ECT / Utility / Injector Compensation.

      5. Press Next.

      6. A015BOM

        Press Next again to proceed.

      7. A015C4R

        Select "Set Compensation Code".

      8. Press Next.

      9. A0159FQ

        Select the number of the cylinder corresponding to the injector compensation code that you want to register.

      10. Press Next.

      11. A015CV0

        Register compensation code.


        1. Press Input.

        2. A0158O4

          Manually input the cylinder compensation code using the keyboard on the GTS screen. The code is a 30-digit, alphanumeric value printed on the injector head portion.

          Tech Tips

          Each injector compensation code is unique. The compensation code for each selected cylinder must be input into the GTS correctly.

        3. Confirm that the compensation code for the selected cylinder is correct, and then press OK.

      12. A015C7A

        Check that the compensation code displayed on the screen is correct by comparing it with the 30-digit alphanumeric value on the head portion of the injector assembly.

        Note

        If an incorrect injector compensation code is input into the ECM, the engine may rattle or engine idling may become rough. In addition, engine failure may occur and the life of the engine may be shortened.

        Tech Tips


        • If a wrong compensation code is input or read, return to the Input Value screen by pressing Input.

        • The saving process may fail due to a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and repeat this operation.

      13. Press Next to register the injector compensation code in the ECM.

        Tech Tips


        • If the registration process fails, the injector compensation code may be incorrect. Check the injector compensation code again.

        • If the input injector compensation code fails to register even though it is input correctly, there may be a problem with the wire harness or a bad connection with the DLC3. Check the wire harness and DLC3 connection. If no problem is found with either, the ECM may be malfunctioning. Check the ECM and restart this operation.

      14. A0158CJ

        If you want to continue with other compensation code registrations, press Next. To finish the registration, press Exit.

      15. Turn the GTS off and turn the engine switch off.

      16. Wait for at least 30 seconds.

      17. Turn the engine switch on (IG), and then turn the GTS on.

      18. Perform pilot quantity learning.

      19. Clear DTC P062F stored in the ECM using the GTS Click here.

        Note

        If the DTCs are cleared without performing pilot quantity learning, DTC P062F is stored immediately after clearing DTCs.

  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. 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.).

        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.

        A015AE9E02
        Text in Illustration
        *A for Bank 1 *B for Bank 2
        *a Measuring Point - -
        A015CC1 Front - -

    4. Select a new cylinder head gasket.

      A0155PPE01
      Text in Illustration
      *A for Bank 1 *B for Bank 2
      A015CC1 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. A0159I0E02
      Text in Illustration
      *a Front
      *b 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. A015BBKE02
      Text in Illustration
      *a Front
      *b 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 "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. A0158EKE02

        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. A015AS3E04
      Text in Illustration
      *1 Painted Mark
      A015CC1 Front

      Step 2:


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

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

    6. A0155Y5E03
      Text in Illustration
      *1 Painted Mark
      A015CC1 Front

      Step 3:


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

    7. A015B0JE03
      Text in Illustration
      *1 Painted Mark
      A015CC1 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. A015DH8E02

        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. A015AS3E04
      Text in Illustration
      *1 Painted Mark
      A015CC1 Front

      Step 2:


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

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

    6. A0155Y5E03
      Text in Illustration
      *1 Painted Mark
      A015CC1 Front

      Step 3:


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

    7. A015B0JE03
      Text in Illustration
      *1 Painted Mark
      A015CC1 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. 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.

      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. 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. 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. 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.

      Tech Tips

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

      A015BZL

  11. 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.

      Tech Tips

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

      A015BZL

  12. INSTALL NO. 5 CAMSHAFT BEARING CAP


    1. 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. 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. 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.

        Note

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

        A015BZL
    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.

      Tech Tips

      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
      Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt

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

      Torque:
      for 12 mm head bolt of No. 4 camshaft bearing cap
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for 10 mm head bolt of No. 3 camshaft bearing cap
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. A0158I9

      Tighten the 2 union bolts.

      Torque:
      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.

  15. INSTALL NO. 1 AND NO. 2 CAMSHAFT


    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.

        Note

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

        A015BZL
    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.

      Tech Tips

      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
      Text in Illustration
      *1 12 mm Head Bolt
      *2 10 mm Head Bolt

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

      Torque:
      for 12 mm head bolt of No. 1 camshaft bearing cap
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for 10 mm head bolt of No. 3 camshaft bearing cap
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    9. A015D9S

      Tighten the 2 union bolts.

      Torque:
      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.

  16. INSTALL TIMING GEAR CASE SUB-ASSEMBLY

    Note

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

    A015A17E02
    Text in Illustration
    *a Cylinder Block *b Timing Gear Case

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

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

      Note


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

      • Apply the seal packing in a continuous line.

      Tech Tips


      • The FIPG line is shown below.

      • Apply packing to the 5 seal surface areas.

      A015ARGE03
      Text in Illustration
      *a Seal Diameter: 4 to 5 mm - -
    2. A0155WUE02
      Text in Illustration
      *1 New Timing Gear Case Gasket
      *2 New O-Ring

      Install a new timing gear case gasket.

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

    4. A015B60E03
      Text in Illustration
      *1 Nut
      *2 14 mm Head Bolt
      *3 12 mm Head Bolt A
      *4 12 mm Head Bolt B

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

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

      Note


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

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

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

  17. 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.

  18. 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
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A0156ZYE02
      Text in Illustration
      *1 New O-Ring

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

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

      Note

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


      1. Temporarily install the 2 nuts.

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

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

  19. INSTALL FUEL PUMP MOTOR WIRE


    1. A0155WZ

      Install the fuel pump wire with the bolt.

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

      Tech Tips

      Attach the claw of the bracket to the timing gear case when installing the bracket.

  20. INSPECT RADIAL BALL BEARING


    1. A015998

      Turn the bearing, and check that the bearing moves smoothly and quietly.

      If it moves roughly or noisily, replace the radial ball bearing.

  21. 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.

  22. 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.

  23. 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.

  24. INSTALL IDLE GEAR ASSEMBLY


    1. A0159YZE02
      Text in Illustration
      *1 Key

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

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

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

      A0156OHE02
      Text in Illustration
      *A w/ Intercooler *B w/o Intercooler

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

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

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

    6. w/ Intercooler:

      Remove the service bolt.

  25. 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 }
      A015CQOE02
      Text in Illustration
      *A w/ Intercooler *B w/o Intercooler

  26. 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.

      A015CBJ

  27. 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
      Text in Illustration
      *1 Timing Mark

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

    3. A015DE3E01

      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 }

  28. 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
      Text in Illustration
      *1 Timing Mark

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

  29. 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.

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

  30. INSTALL NO. 2 CHAIN VIBRATION DAMPER


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

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

  31. INSTALL NO. 2 CHAIN TENSIONER SLIPPER

  32. 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.

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

    4. Remove the hexagon wrench.

  33. INSTALL NO. 1 CHAIN VIBRATION DAMPER


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

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

  34. INSTALL NO. 1 CHAIN TENSIONER SLIPPER

  35. 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.

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

    4. Remove the hexagon wrench.

  36. 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
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

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

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

      Note

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

      Tech Tips

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

  37. 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.

      A0157BOE03
      Text in Illustration
      *1 Key - -
      *a Top - -

    3. Remove the 2 crankshaft pulley set bolts.

  38. 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.

      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.)

  39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Note

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

    A015B9GE02
    Text in Illustration
    *1 Timing Gear Case *2 Timing Chain Cover

    1. A0157K4E02
      Text in Illustration
      *1 New O-Ring

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

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

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

      Note


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

      • Apply the seal packing in a continuous line.

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

      Tech Tips


      • The FIPG line is shown below.

      • Apply packing to the 6 seal surface areas.

      A0155Q9E03
      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
      Text in Illustration
      *1 Stud Bolt

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

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    6. A0159IYE02
      Text in Illustration
      *1 Nut

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

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

  40. INSTALL FUEL INJECTOR SEAL


    1. Install 2 new fuel injector seals.

  41. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Note

    If there is foreign matter on the installation surface of the exhaust fuel addition injector, be sure to clean it before installation.


    1. A015ABNE01
      Text in Illustration
      *1 Nozzle Holder Clamp

      Install 2 new gaskets, the 2 exhaust fuel addition injectors, 2 nozzle holder clamps and 2 new washers with the 2 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Align the nozzle holder clamp with the cutouts of the injector as shown in the illustration.

  42. 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.

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

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    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
      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.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      A015DIT Bolt
      A015CC1 Nozzle Holder Clamp Seat

      Tech Tips

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

  44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    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
      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.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      A015DIT Bolt
      A015CC1 Nozzle Holder Clamp Seat

      Tech Tips

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

  45. INSTALL FUEL INJECTOR LH

    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
      Text in Illustration
      *1 New O-Ring

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

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

    4. Insert the 4 injectors into the cylinder head.

      Note


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

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

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

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A01588XE01
      Text in Illustration
      *1 New Washer

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

      Note

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

    7. 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.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Bolt

    10. Tighten the 4 holder clamp bolts.

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

    11. Remove the 4 injection pipes.

    12. Remove the 2 bolts and common rail LH.

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

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

  46. INSTALL FUEL INJECTOR RH

    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
      Text in Illustration
      *1 New O-Ring

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

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

    4. Insert the 4 injectors into the cylinder head.

      Note


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

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

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

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A01588XE01
      Text in Illustration
      *1 New Washer

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

      Note

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

    7. 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.

      Text in Illustration
      A015DIT Injector Hollow Screw
      A015CC1 Union Bolt

    10. Tighten the 4 holder clamp bolts.

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

    11. Remove the 4 injection pipes.

    12. Remove the 2 bolts and common rail RH.

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

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

  47. 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.

  48. INSTALL CYLINDER HEAD COVER INSULATOR LH

  49. INSTALL CYLINDER HEAD COVER INSULATOR RH

  50. INSTALL NO. 2 FUEL PUMP BRACKET


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

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

  51. 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.

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

  52. INSTALL VACUUM PUMP ASSEMBLY


    1. A015CP4

      Apply engine oil to 2 new O-rings.

    2. Install the 2 O-rings to the vacuum pump.

    3. A0159XFE01

      Install the vacuum pump so that the coupling teeth of the vacuum pump (labeled A) and the groove of the camshaft (labeled B) are aligned.

      Note

      Be careful not to damage the O-ring.

    4. A0155AS

      Install the vacuum pump with the 3 bolts.

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

      Note

      Confirm that the vacuum pump is not at an angle, and that there is no clearance between the fitting surfaces.

  53. INSTALL GLOW PLUG ASSEMBLY


    1. Clean the glow plug and glow plug hole.

    2. A01558XE02
      Text in Illustration
      *a 12 Thread Roots

      Apply adhesive to 3 or more thread roots in the area shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    3. Using a 10 mm deep socket wrench, install the 8 glow plugs.

      Torque:
      12 N*m  { 125 kgf*cm, 9 ft.*lbf }

  54. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Install the 2 glow plug connectors by uniformly tightening the 8 nuts.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

    2. Install the 8 screw grommets.

    3. Connect the 2 wire harnesses with the 2 nuts and 2 screw grommets.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  55. INSTALL WATER OUTLET PIPE


    1. Install 2 new gaskets and the water outlet pipe with the 4 bolts.

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

      Tech Tips

      The gasket claw should face toward the water outlet pipe.

  56. INSTALL WATER OUTLET


    1. Install a new gasket and the water outlet with the 2 bolts, and then connect the water outlet to the No. 2 water hose joint.

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

  57. INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET


    1. Install the No. 2 intercooler support bracket with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  58. INSTALL STARTER HOSE BRACKET


    1. Install the starter hose bracket with the 2 bolts.

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

  59. INSTALL STARTER ASSEMBLY


    1. Install the starter with the 2 bolts.

      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }
    2. A015CSYE01
      Text in Illustration
      *1 Yellow Mark

      Connect the 2 starter hoses.

    3. Attach the harness clamp and connect the wire harness.

    4. Connect the starter wire with the nut.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

    5. Connect the starter connector.

  60. INSTALL WATER PUMP ASSEMBLY


    1. A0158CTE01

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

      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.

      Torque:
      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.

  61. CONNECT INLET WATER HOSE

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


    1. A015AJ7

      Temporarily install the No. 2 idler pulley bracket with the bolt.

    2. Temporarily install the 2 bolts to the No. 2 idler pulley bracket bolt hole.

    3. A015BQBE01

      Uniformly tighten the 3 bolts of the No. 2 idler pulley bracket in the order shown in the illustration.

      Torque:
      49 N*m  { 495 kgf*cm, 36 ft.*lbf }

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


    1. A0159CU

      Install the collar, No. 2 idler pulley and cover with the bolt.

      Torque:
      49 N*m  { 495 kgf*cm, 36 ft.*lbf }

  64. INSTALL FAN BRACKET SUB-ASSEMBLY


    1. A015AIZE01

      Install the fan bracket with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 30 mm (1.18 in.)
      Bolt B 80 mm (3.15 in.)

  65. INSTALL TIMING GEAR COVER INSULATOR


    1. w/o Viscous Heater:

      Install the timing gear cover insulator with the 2 bolts.

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

    2. w/ Viscous Heater:

      Install the timing gear cover insulator.

  66. INSTALL THERMOSTAT


    1. A01560RE01

      Install a new gasket to the thermostat.

      Note

      When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the groove of the gasket is properly installed onto the thermostat, as shown in the illustration.

    2. Insert the thermostat into the water pump with the jiggle valve facing straight upward.

      Tech Tips

      The jiggle valve may be set within 30° of either side of the prescribed position.

  67. INSTALL WATER INLET


    1. A015E4IE01

      Install the water inlet with the 4 bolts.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
    2. A015CD1

      Connect the No. 2 oil cooler hose to the clamp and water pump.

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


    1. A0155QF

      Install the No. 1 idler pulley bracket with the bolt.

      Torque:
      49 N*m  { 495 kgf*cm, 36 ft.*lbf }

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

    A01560B

    1. Install the heater assembly with the 2 bolts.

      Torque:
      48.5 N*m  { 495 kgf*cm, 36 ft.*lbf }

    2. Connect the 2 heater hoses.

    3. Using pliers, grip the claws of the clips and slide the 2 clips.

    4. Connect the connector and attach the clamp.

  70. INSTALL CRANKSHAFT POSITION SENSOR

    A0155XF

    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.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the sensor wire harness clamp.

  71. INSTALL CAMSHAFT POSITION SENSOR

    A01572C

    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.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the sensor connector.

  72. 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.

    A015874

    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.

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

  73. 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.

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

  74. 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.

    A0158VR

    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.

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

  75. INSTALL ENGINE OIL LEVEL SENSOR

    A015CS5

    1. Install a new gasket to the sensor.

    2. Install the sensor with the 4 bolts.

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

    3. Connect the sensor connector.

  76. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. A015CNAE01

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

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

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

    3. Connect the 2 wire harness clamps.

  77. 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.

      SST
      09228-06501
      Torque:
      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.

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

  78. INSTALL TIMING GEAR COVER SPACER


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

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

  79. 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
      Text in Illustration
      *1 Service Hole
      *2 Protrusion

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

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

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

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

    5. A015CV2E01

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

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

    6. Remove the service bolt.

  80. 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.

  81. 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.

  82. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01597PE01

      Install the V-ribbed belt tensioner with the 5 bolts.

      Torque:
      for bolt A and C
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Quantity Length
      Bolt A 1 116 mm (4.57 in.)
      Bolt B 2 40 mm (1.58 in.)
      Bolt C 2 95 mm (3.74 in.)

    2. Install the No. 1 idler pulley with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    3. Install the V-ribbed belt tensioner bracket with the 3 bolts.

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

  83. INSTALL STIFFENER INSULATOR RH


    1. Install the stiffener insulator RH with the 2 bolts.

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

  84. INSTALL COMPRESSOR BRACKET


    1. Install the compressor bracket with the bolt.

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

  85. INSTALL NO. 2 CYLINDER BLOCK INSULATOR

  86. INSTALL ENGINE MOUNTING BRACKET LH


    1. Install the engine mounting bracket LH with the 4 bolts.

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

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


    1. A015CRLE01

      Temporarily install a new gasket and No. 2 water by-pass pipe with the union bolt and 2 bolts.

    2. Tighten the union bolt and 2 bolts of the No. 2 water by-pass pipe in the order shown in the illustration.

      Torque:
      for union bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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


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

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

    2. w/ Intercooler:

      Connect the vacuum hose.

  89. INSTALL TURBOCHARGER WIRE


    1. Install the turbocharger wire with the 2 bolts.

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

    2. Attach the 3 wire harness clamps.

  90. INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET


    1. Install the No. 2 intake air connector bracket with the bolt.

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

    2. Attach the 2 wire clamps.

  91. INSTALL NO. 1 CYLINDER BLOCK INSULATOR

  92. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 4 bolts.

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

  93. INSTALL NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 4 vacuum transmitting pipe with the 2 bolts.

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

    2. Connect the vacuum hose.

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


    1. Temporarily install a new gasket and the No. 1 water by-pass pipe with the union bolt and bolt.

    2. A015CMGE01

      Tighten the union bolt and bolt of the No. 1 water by-pass pipe in the order shown in the illustration.

      Torque:
      for union bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  95. INSTALL AIR TUBE SUPPORT


    1. Install the air tube support with the 2 bolts.

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

  96. INSTALL NO. 1 INTAKE AIR CONNECTOR BRACKET


    1. Install the No. 1 intake air connector bracket with the 2 bolts.

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

  97. INSTALL GENERATOR ASSEMBLY


    1. A015E66E02

      Temporarily install the generator with the 3 bolts and 2 nuts.

    2. Uniformly tighten the 3 bolts and 2 nuts in the order shown in the illustration.

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

    3. Connect the generator cable and install the nut and bolt.

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for nut (130A Type and 150A Type:)
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      for nut (180A Type:)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  98. INSTALL NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH AND NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH

    Click here

  99. 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.