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CYLINDER HEAD GASKET (w/o DPF) INSTALLATION

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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.

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  1. Click here

    CHECK INJECTOR COMPENSATION CODE

    Note:

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

    • Fuel injector compensation codes are unique, 30 digit, alphanumeric values printed on the head portion of each fuel injector. If an incorrect fuel 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.


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

      Tip:

      • Each fuel injector 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 fuel injector.

      • When you first turn the ignition switch to ON after replacing the ECM or a fuel injector(s), DTC P1601 is set. This is to inform you that registration of a fuel injector compensation code(s) is/are required. Manually clear the DTC upon completion of the compensation code registration.


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

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

      3. Turn the tester off and turn the ignition switch off.

      4. Wait for at least 30 seconds.

      5. Turn the ignition switch to ON and turn the tester on.

      6. Clear DTC P1601 stored in the ECM using the tester (Click here).

    2. A0157BSE04

      Register compensation code.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

        Note:

        Do not start the engine.

      3. Turn the tester on.

      4. A0156CME01

        Enter the following menus: Powertrain / Engine / Utility / Injector Compensation.

      5. Press Next.

      6. A015DGLE01

        Press Next again to proceed.

      7. A0155RYE01

        Select "Set Compensation Code".

      8. Press Next.

      9. A015A0R

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

      10. Press Next.

      11. A0156MFE01

        Register compensation code.


        1. Press Input.

        2. A0158O4

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

          Tip:

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

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

      12. A015CD0E01

        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 fuel injector.

        Note:

        If an incorrect fuel 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.

        Tip:

        • 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 compensation code in the ECM.

        Tip:

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

        • If the input 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. A015AQWE01

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

      15. Turn the ignition switch off and then turn the tester off.

      16. Wait for at least 30 seconds.

      17. Turn the ignition switch to ON and then turn the tester on.

      18. Clear DTC P1601 stored in the ECM using the tester (Click here).

  2. Click here

    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.).

        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. A015AE9E01

        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.

    4. A015A4ME01

      Select a new cylinder head gasket.

      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.)
  3. Click here

    INSTALL NO. 2 CYLINDER HEAD GASKET


    1. A0159I0E01

      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. Click here

    INSTALL NO. 1 CYLINDER HEAD GASKET


    1. A015BBKE01

      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. 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. A015AS3E01

      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. A015B0JE01

      Step 3:


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

    7. A015B0JE01

      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. 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. A015AS3E01

      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. A0155Y5E01

      Step 3:


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

    7. A015B0JE01

      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. 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.

  8. Click here

    INSTALL NO. 2 VALVE LASH ADJUSTER ASSEMBLY

    Note:

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


    1. A01590A

      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.

  9. Click here

    INSTALL NO. 1 VALVE LASH ADJUSTER ASSEMBLY

    Note:

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


    1. A01585A

      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.

  10. Click here

    INSTALL NO. 2 VALVE ROCKER ARM


    1. A0157MM

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

    2. A015BZL

      Install the 16 No. 2 valve rocker arms as shown in the illustration.

      Tip:

      Install the valve rocker arm 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. 5 CAMSHAFT BEARING CAP


    1. A0157IH

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

  13. Click here

    INSTALL NO. 2 CAMSHAFT BEARING CAP


    1. A0158PF

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

  14. 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 the 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. A0157CVE01

      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
    9. A0158I9

      Tighten the 2 union bolts.

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

      Remove the bolt from the No. 4 camshaft timing gear.

      Note:

      Do not drop the bolt into the engine.

  15. Click here

    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.

        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. A0158FDE01

      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
    9. A015D9S

      Tighten the 2 union bolts.

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

      Remove the bolt from the No. 1 camshaft timing gear.

      Note:

      Do not drop the bolt into the engine.

  16. Click here

    INSTALL TIMING GEAR CASE SUB-ASSEMBLY

    A015A17E01
    Note:

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


    1. A015ARGE02

      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.

    2. A0155WUE01

      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. A015B60E02

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

      for 14 mm head bolt (case is dry)
      46 N*m 469 kgf*cm 34 ft.*lbf
      for 14 mm head bolt (case is wet)
      42 N*m 428 kgf*cm 31 ft.*lbf
      for 12 mm head bolt A and B
      29 N*m 296 kgf*cm 21 ft.*lbf
      for nut
      29 N*m 296 kgf*cm 21 ft.*lbf
      Note:

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

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

      Table 1. Bolt Length
      Item Quantity Length
      A 4 20 mm (0.787 in.)
      B 8 45 mm (1.77 in.)
  17. Click here

    INSTALL V-BANK SILENCER


    1. A0159OE

      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. 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. A015A1NE01

      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. A0156ZYE01

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

    4. A015AH6

      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
  19. Click here

    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.

  20. 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 nut.

  21. 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.

  22. 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. A0155P3

      Install the idle gear shaft to the cylinder block.

  23. Click here

    INSTALL IDLE GEAR ASSEMBLY


    1. A0159YZE01

      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. A0156OHE01

      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.

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

    5. A015DZSE01

      Install the idle gear thrust plate with the 2 bolts.

      47 N*m 479 kgf*cm 35 ft.*lbf
    6. A015E4V

      w/ Intercooler:

      Remove the service bolt.

  24. Click here

    TIGHTEN FUEL SUPPLY PUMP DRIVE GEAR NUT


    1. A015CQOE01

      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
  25. 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.

  26. 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. A015AR8E01

      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.

      09960-10010 09962-01000 09963-01000
      25 N*m 250 kgf*cm 18 ft.*lbf
  27. 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. A015DHEE01

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

  28. 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
  29. Click here

    INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. A015943

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

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

    INSTALL NO. 2 CHAIN TENSIONER SLIPPER

  31. Click here

    INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


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

    2. A015BK9

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

    3. A0155BH

      Install the No. 2 chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench.

  32. Click here

    INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. A0157D9

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

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

    INSTALL NO. 1 CHAIN TENSIONER SLIPPER

  34. Click here

    INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


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

    2. A015BK9

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

    3. A0156GR

      Install the No. 1 chain tensioner with the 2 bolts.

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

    4. Remove the hexagon wrench.

  35. Click here

    INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. A01589Z

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

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    3. A015AJD

      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.

  36. Click here

    CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


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

    2. A0157BOE01

      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.

    3. Remove the 2 crankshaft pulley set bolts.

  37. 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.)
  38. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    A015B9GE01
    Note:

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


    1. A0157K4E01

      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.

      A0155Q9E02
      Tip:

      • The FIPG line is shown below.

      • Apply packing to the 6 seal surface areas.

    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.

      25 N*m 250 kgf*cm 18 ft.*lbf
      A0157DPE01
      Tip:

      If the stud bolts are loose, tighten them before performing this procedure.


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

        6.0 N*m 61 kgf*cm 53 in.*lbf
    5. A0159IYE01

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

  39. 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. A0159HSE01

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

      Table 2. Bolt Length
      Item Length
      Bolt A 70 mm (2.76 in.)
      Bolt B 25 mm (0.984 in.)
  40. Click here

    TEMPORARILY INSTALL COMMON RAIL ASSEMBLY RH


    1. Install the common rail with the 2 bolts.

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

    TEMPORARILY INSTALL COMMON RAIL ASSEMBLY LH


    1. Install the common rail with the 2 bolts.

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

    INSTALL FUEL INJECTOR RH

    Note:

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


    1. A0155RO

      Install 4 new injection nozzle seats to the cylinder head.

    2. A0158MYE04

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

      Table 3. 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.

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

      Note:
      • A0159Q5E07

        The fork portion of the nozzle holder clamp must be set on 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, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Table 4. Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *a Downward
    7. A015DOI

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

    8. 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 5. Text in Illustration
      *1 Nozzle Leakage Pipe

    9. Set the leakage pipe and 5 new gaskets in place.

    10. A015DUS

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

      Table 6. Text in Illustration
      A015CC1 Union Bolt
      Tip:

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

    11. Tighten the 4 holder clamp bolts.

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

    12. Remove the 4 injection pipes.

    13. 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 together with the nozzle leakage pipe.

    14. 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 together with the nozzle leakage pipe.

  43. Click here

    INSTALL FUEL INJECTOR LH

    Note:

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


    1. A0155RO

      Install 4 new injection nozzle seats to the cylinder head.

    2. A0158MYE04

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

      Table 7. 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.

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

      Note:
      • A0159Q5E07

        The fork portion of the nozzle holder clamp must be set on 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, be careful not to tilt the bolt and clamp.

      • Do not reuse the washer.

      Table 8. Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp
      *a Downward
    7. A01587D

      Temporarily install the common rail LH with the 2 bolts.

    8. A015DOI

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

    9. A0159P5E05

      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 9. Text in Illustration
      *1 Nozzle Leakage Pipe

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

    11. A015CZW

      Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

      Table 10. Text in Illustration
      A015CC1 Union Bolt
      Tip:

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

    12. Tighten the 4 holder clamp bolts.

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

    13. Remove the 4 injection pipes.

    14. 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 together with the nozzle leakage pipe.

    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 together with the nozzle leakage pipe.

  44. Click here

    REMOVE COMMON RAIL ASSEMBLY RH


    1. A0157DVE01

      Remove the 2 bolts and common rail.

      Table 11. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      Note:

      Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.

  45. Click here

    REMOVE COMMON RAIL ASSEMBLY LH


    1. A015BWVE01

      Remove the 2 bolts and common rail.

      Table 12. Text in Illustration
      *A w/ DPF
      *B w/o DPF
      Note:

      • Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

      • w/ DPF:

        Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

  46. Click here

    REMOVE INTAKE MANIFOLD


    1. A0159HS

      Remove the 16 bolts, 2 gaskets and intake manifold.

    2. A0159XZ

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

    3. A0156RZ

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

  47. Click here

    INSTALL NOZZLE HOLDER GASKET LH


    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 13. Text in Illustration
      *1 Nozzle Holder Gasket
  48. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A0157H8

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 14. 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.

  49. Click here

    INSTALL NOZZLE HOLDER SEAL LH


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

  50. 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
  51. Click here

    INSTALL NOZZLE HOLDER GASKET RH


    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 15. Text in Illustration
      *1 Nozzle Holder Gasket
  52. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


    1. A015BYJ

      Apply seal packing as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Table 16. 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.

  53. Click here

    INSTALL NOZZLE HOLDER SEAL RH


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

  54. Click here

    INSTALL CYLINDER HEAD COVER SILENCER LH (w/ Intercooler)


    1. Install the cylinder head cover silencer with the 3 bolts.

      5.0 N*m 51 kgf*cm 44 in.*lbf
  55. Click here

    INSTALL CYLINDER HEAD COVER SILENCER RH (w/ Intercooler)


    1. Install the cylinder head cover silencer with the 3 bolts.

      5.0 N*m 51 kgf*cm 44 in.*lbf
  56. Click here

    INSTALL VACUUM PUMP ASSEMBLY (w/ Intercooler)


    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.

      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.

  57. Click here

    INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the vacuum transmitting pipe with the 3 bolts.

      6.0 N*m 61 kgf*cm 53 in.*lbf

    2. w/ Intercooler:

      Connect the 2 vacuum hoses.

  58. Click here

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


    1. Install the vacuum switching valve with the bolt.

      6.0 N*m 61 kgf*cm 53 in.*lbf

    2. Connect the 2 vacuum hoses.

  59. Click here

    INSTALL GLOW PLUG ASSEMBLY


    1. Clean the glow plug and glow plug hole.

    2. A01558XE02

      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
      Table 17. Text in Illustration
      *a 12 Thread Roots

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

      12 N*m 125 kgf*cm 9 ft.*lbf
  60. Click here

    INSTALL NO. 1 GLOW PLUG CONNECTOR


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

      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.

      4.0 N*m 41 kgf*cm 35 in.*lbf
  61. Click here

    INSTALL WATER OUTLET PIPE


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

      21 N*m 214 kgf*cm 15 ft.*lbf
      Tip:

      The gasket claw should face toward the water outlet pipe.

  62. Click here

    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.

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

    INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET


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

      43 N*m 438 kgf*cm 32 ft.*lbf
  64. Click here

    INSTALL CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)


    1. A0157L4

      Install the clutch flexible hose bracket with the 2 bolts.

      20 N*m 204 kgf*cm 15 ft.*lbf
  65. Click here

    INSTALL STARTER HOSE BRACKET


    1. A0158Q5

      Install the starter hose bracket with the 2 bolts.

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

    INSTALL STARTER ASSEMBLY


    1. Install the starter with the 2 bolts.

      80 N*m 816 kgf*cm 59 ft.*lbf
    2. A015CSYE01

      Connect the 2 starter hoses.

      Table 18. Text in Illustration
      *1 Yellow Mark

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

    4. Connect the starter wire with the nut.

      20 N*m 200 kgf*cm 14 ft.*lbf

    5. Connect the starter connector.

  67. 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 19. 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.

  68. Click here

    CONNECT INLET WATER HOSE

  69. Click here

    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.

      49 N*m 495 kgf*cm 36 ft.*lbf
  70. Click here

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


    1. A0159CU

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

      49 N*m 495 kgf*cm 36 ft.*lbf
  71. Click here

    INSTALL FAN BRACKET SUB-ASSEMBLY


    1. A015AIZE01

      Install the fan bracket with the 4 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
      Table 20. Bolt Length
      Item Length
      Bolt A 30 mm (1.18 in.)
      Bolt B 80 mm (3.15 in.)
  72. Click here

    INSTALL TIMING GEAR COVER INSULATOR (w/ Intercooler)


    1. w/o Viscous Heater:

      Install the timing gear cover insulator with the 2 bolts.

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

    2. w/ Viscous Heater:

      Install the timing gear cover insulator.

  73. Click here

    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.

      Tip:

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

  74. Click here

    INSTALL WATER INLET


    1. A015E4IE01

      Install the water inlet with the 4 bolts.

      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.

  75. Click here

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


    1. A0155QF

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

      49 N*m 495 kgf*cm 36 ft.*lbf
  76. Click here

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


    1. Install the heater assembly with the 2 bolts.

      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.

  77. 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.

  78. 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.

  79. 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 21. 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.)
  80. 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
  81. 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
  82. 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
  83. Click here

    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.

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

    3. Connect the 2 wire harness clamps.

  84. 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
  85. 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
  86. 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 22. 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.

  87. 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.

  88. Click here

    CONNECT NO. 1 OIL COOLER HOSE

  89. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01597PE01

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

      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
      Table 23. 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.

      43 N*m 438 kgf*cm 32 ft.*lbf

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

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

    INSTALL STIFFENER INSULATOR RH (w/ Intercooler)


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

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

    INSTALL COMPRESSOR BRACKET


    1. Install the compressor bracket with the bolt.

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

    INSTALL NO. 2 CYLINDER BLOCK INSULATOR

  93. Click here

    INSTALL ENGINE MOUNTING BRACKET LH


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

      80 N*m 816 kgf*cm 59 ft.*lbf
  94. Click here

    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.

      for union bolt
      35 N*m 357 kgf*cm 26 ft.*lbf
      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf
  95. Click here

    INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


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

      6.0 N*m 61 kgf*cm 53 in.*lbf

    2. w/ Intercooler:

      Connect the vacuum hose.

  96. Click here

    INSTALL TURBOCHARGER WIRE


    1. Install the turbocharger wire with the 2 bolts.

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

    2. Attach the 3 wire harness clamps.

  97. Click here

    INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET


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

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

    2. Attach the 2 wire clamps.

  98. Click here

    INSTALL NO. 1 CYLINDER BLOCK INSULATOR

  99. Click here

    INSTALL ENGINE MOUNTING BRACKET RH


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

      80 N*m 816 kgf*cm 59 ft.*lbf
  100. Click here

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


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

      6.0 N*m 61 kgf*cm 53 in.*lbf

    2. Connect the vacuum hose.

  101. Click here

    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.

      for union bolt
      35 N*m 357 kgf*cm 26 ft.*lbf
      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf
  102. Click here

    INSTALL AIR TUBE SUPPORT


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

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

    INSTALL NO. 1 INTAKE AIR CONNECTOR BRACKET


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

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

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


    1. Install a new gasket to the No. 2 turbocharger.

    2. Install the exhaust manifold LH to the No. 2 turbocharger with 3 new nuts.

      69 N*m 704 kgf*cm 51 ft.*lbf
      Tip:

      The gasket claw should face toward the outside of the vehicle.

    3. w/ DPF:


      1. Install 2 new gaskets to the No. 2 exhaust manifold pipe.

        Tip:

        The gasket claws should face the No. 2 exhaust manifold pipe.

      2. A015AVS

        Temporarily install the No. 2 exhaust manifold pipe with the 4 bolts.

        Tip:

        Install the No. 2 exhaust manifold pipe so that it is oriented as shown in the illustration.

      3. Tighten the 4 bolts.

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

    4. Install a new gasket to the cylinder head LH.

    5. A015AMWE01

      Install the No. 2 turbocharger with exhaust manifold LH and 10 collars to the cylinder head LH with 10 new nuts.

      36 N*m 367 kgf*cm 27 ft.*lbf
      Table 24. Text in Illustration
      *A w/ DPF *B w/o DPF
      Tip:

      Install the collars with the colored side facing the nuts.

    6. A015674

      Install a new gasket and the No. 2 inlet turbo oil pipe to the No. 1 oil pan with the union bolt.

      29 N*m 296 kgf*cm 21 ft.*lbf

    7. Connect the 2 connectors to the turbocharger.

  105. Click here

    INSTALL NO. 2 VENTILATION TUBE SUB-ASSEMBLY


    1. A0155F8E02

      Temporarily install a new gasket and the No. 2 ventilation tube with the union bolt and bolt.

      Table 25. Text in Illustration
      *A w/ DPF *B w/o DPF

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      for union bolt
      29 N*m 296 kgf*cm 21 ft.*lbf
      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf
      Note:

      Clean and remove any oil in the area labeled 1 in the illustration.

    3. Connect the hose.

  106. Click here

    INSTALL NO. 2 TURBOCHARGER STAY


    1. Install the No. 2 turbocharger stay with the 2 bolts.

      49 N*m 495 kgf*cm 36 ft.*lbf
  107. Click here

    CONNECT NO. 2 OUTLET TURBO OIL HOSE

    A0155RSE01
    Tip:

    Align the white paint marks on the oil hose and pipe, and connect the hose.

    Table 26. Text in Illustration
    *1 Painted Mark
  108. Click here

    INSTALL NO. 2 TURBO WATER PIPE SUB-ASSEMBLY


    1. A015C38E01

      Temporarily install a new gasket and the No. 2 turbo water pipe with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      for union bolt
      35 N*m 357 kgf*cm 26 ft.*lbf
      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf

    3. Connect the water hose to the pipe.

  109. Click here

    INSTALL FRONT WATER BY-PASS JOINT


    1. Install a new gasket and the front water by-pass joint.

      50 N*m 510 kgf*cm 37 ft.*lbf
  110. Click here

    INSTALL NO. 3 TURBO WATER PIPE SUB-ASSEMBLY


    1. A015D12E02

      Temporarily install a new gasket and the No. 3 turbo water pipe with the union bolt and 2 bolts.

    2. Tighten the union bolt and 2 bolts in the order shown in the illustration.

      for union bolt
      35 N*m 357 kgf*cm 26 ft.*lbf
      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf
  111. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf
  112. Click here

    CONNECT NO. 2 TURBO WATER HOSE

  113. Click here

    CONNECT BREATHER PLUG LH


    1. Install the breather plug LH.

    2. w/o DPF:

      Attach the clamp.

    3. Connect the hose.

  114. Click here

    CONNECT NO. 3 VENTILATION HOSE

  115. Click here

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


    1. Install a new gasket to the No. 1 turbocharger.

    2. Install the exhaust manifold RH to the No. 1 turbocharger with 2 new nuts and the bolt.

      69 N*m 704 kgf*cm 51 ft.*lbf

    3. w/ DPF:


      1. Install 2 new gaskets to the No. 1 exhaust manifold pipe.

        Tip:

        The gasket claws should face the No. 1 exhaust manifold pipe.

      2. A015D0F

        Temporarily install the No. 1 exhaust manifold pipe with the 4 bolts.

        Tip:

        Install the No. 1 exhaust manifold pipe so that it is oriented as shown in the illustration.

      3. Tighten the 4 bolts.

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

    4. Install a new gasket to the cylinder head RH.

    5. A0159UXE01

      Install the No. 1 turbocharger with exhaust manifold RH to the cylinder head RH with the 10 collars and 10 new nuts.

      36 N*m 367 kgf*cm 27 ft.*lbf
      Table 27. Text in Illustration
      *A w/ DPF *B w/o DPF
      Tip:

      Install the collars with the colored side facing the nuts.

    6. A015B3D

      Install a new gasket and the No. 1 inlet turbo oil pipe to the cylinder block with the union bolt.

      When "dry"
      29 N*m 296 kgf*cm 21 ft.*lbf
      When "wet"
      23 N*m 235 kgf*cm 17 ft.*lbf
      Note:

      • The parts are "dry" when there is absolutely no engine oil on the union bolt and cylinder block bolt hole.

      • The parts are "wet" when there is engine oil on the union bolt and cylinder block bolt hole.

  116. Click here

    INSTALL NO. 1 VENTILATION TUBE SUB-ASSEMBLY


    1. A0156CBE01

      Temporarily install a new gasket and the No. 1 ventilation tube with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      for union bolt
      29 N*m 296 kgf*cm 21 ft.*lbf
      for bolt
      10 N*m 102 kgf*cm 7 in.*lbf
      Note:

      Clean and remove any oil in the area labeled 1 in the illustration.

    3. Connect the hose.

  117. Click here

    INSTALL NO. 1 TURBOCHARGER STAY


    1. Temporarily install the No. 1 turbocharger stay with the 2 bolts.

    2. Tighten the 2 bolts.

      49 N*m 495 kgf*cm 36 ft.*lbf
  118. Click here

    INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. A01596NE02

      Install a new gasket and the No. 1 turbo water pipe with 2 new nuts and the 3 bolts.

      10 N*m 102 kgf*cm 7 ft.*lbf
      Table 28. Text in Illustration
      *1 New Nut

    2. Connect the water hose.

  119. Click here

    CONNECT NO. 1 OUTLET TURBO OIL HOSE

  120. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

      25 N*m 255 kgf*cm 18 ft.*lbf
  121. Click here

    CONNECT NO. 2 TURBO WATER HOSE

  122. Click here

    CONNECT BREATHER PLUG RH


    1. Install the breather plug RH and attach the clamp.

    2. Connect the hose.

  123. Click here

    CONNECT NO. 2 VENTILATION HOSE

  124. Click here

    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.

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

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

      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
  125. Click here

    INSTALL NO. 1 INTAKE AIR CONNECTOR PIPE


    1. Install the No. 1 intake air connector pipe with the bolt. Then tighten the hose clamp.

      for bolt
      21 N*m 214 kgf*cm 15 ft.*lbf
      for hose clamp
      6.0 N*m 61 kgf*cm 53 in.*lbf

    2. Connect the 4 connectors and attach the 5 wire harness clamps.

  126. Click here

    INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring, and install it to the No. 1 engine oil level dipstick guide.

    2. Install the No. 1 engine oil level dipstick guide with the 2 bolts.

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

    INSTALL ENGINE ASSEMBLY


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

  128. Click here

    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.