ENGINE UNIT REASSEMBLY

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL CYLINDER BLOCK DRAIN COCK PLUG


    1. Apply adhesive to the cylinder block drain cock plug.

      Seal packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent

    2. Install the cylinder block drain cock plug.

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

  2. INSTALL ENGINE BALANCER ASSEMBLY


    1. A00OU3VE04
      Text in Illustration
      *1 Service Bolt
      *2 Align

      Turn the crankshaft with a wrench to align the timing mark of the drive gear with that of the driven gear (1 dot mark each), and then mesh the gears and install the engine balancer to the engine.

    2. A00OT88E02

      Temporarily install the engine balancer bolts.

      Tech Tips

      The engine balancer bolts are tightened in 2 progressive steps.

    3. Step 1


      1. Uniformly tighten the 8 bolts in several passes in the sequence shown in the illustration.

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

    4. Step 2


      1. Mark the front of the engine balancer bolts with paint.

      2. Tighten the engine balancer bolts by 90°.

      3. Check that the painted marks are now at a 90° angle to the front.

    5. Remove the service bolt from the engine balancer.

  3. INSTALL OIL BAFFLE PLATE


    1. Install the oil baffle plate with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  4. INSTALL REAR CRANKSHAFT OIL SEAL


    1. Coat the lip of a new oil seal with MP grease.

    2. A00OUFHE03

      Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.

      SST
      09223-56010

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

  5. SELECT CYLINDER HEAD GASKET


    1. Check the piston protrusions for each cylinder.


      1. Clean the cylinder block with solvent.

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

      3. A00OUH8E02
        Text in Illustration
        *1 Measuring Tip
        *2 Protrusion
        *3 Measuring Point

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

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

        Tech Tips

        Make sure that the measuring tip is perpendicular to the cylinder block gasket surface and piston head when taking the measurements.

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

      6. Measure each cylinder at 2 places as shown in the illustration, making a total of 8 measurements.

      7. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

        Standard piston protrusion
        0.300 to 0.560 mm (0.0118 to 0.0220 in.)

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

    2. A00OUAWE04

      Select a new cylinder head gasket.

      New Installed Cylinder Head Gasket Thickness
      Cutout Mark Specified Condition
      A 1.00 to 1.10 mm (0.0394 to 0.0433 in.)
      B 1.05 to 1.15 mm (0.0413 to 0.0453 in.)
      C 1.10 to 1.20 mm (0.0433 to 0.0472 in.)
      D 1.15 to 1.25 mm (0.0453 to 0.0492 in.)
      E 1.20 to 1.30 mm (0.0472 to 0.0512 in.)
      Text in Illustration
      A00OV9Z Front

      Tech Tips

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


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

        Gasket Size
        Item Specified Condition
        Piston protrusion 0.300 to 0.355 mm (0.0118 to 0.0140 in.) 0.355 to 0.405 mm (0.0140 to 0.0159 in.) 0.405 to 0.455 mm (0.0159 to 0.0179 in.) 0.455 to 0.505 mm (0.0179 to 0.0199 in.) 0.505 to 0.560 mm (0.0199 to 0.0220 in.)
        Gasket to be used A B C D E

  6. INSTALL CYLINDER HEAD GASKET

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. A00OR5UE01

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

    2. Place the cylinder head gasket in position on the cylinder block.

    3. Place the cylinder head on the cylinder block.

      Note

      Be careful of the installation direction.

    4. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    5. Temporarily install the cylinder head bolts.

      Tech Tips

      If any cylinder head bolt is broken or deformed, replace it.

    6. Step 1:

      For new bolts, perform steps 1 to 3. For used bolts, perform only step 1.


      1. A00OUBVE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Uniformly tighten the 10 cylinder head bolts, in several steps in the sequence shown in the illustration.

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

        Tech Tips

        If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      2. Mark the front of the cylinder head bolts with paint.

      3. Tighten the cylinder head bolts by 90° in the sequence shown in the illustration.

      4. Perform the step above twice.

      5. A00OROEE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Check that the paint marks are positioned as shown in the illustration.

    7. Step 2:


      1. A00OUHRE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Loosen the cylinder head bolts by 90° in the sequence shown in the illustration.

      2. Perform the step above again.

      3. A00ORLFE03
        Text in Illustration
        *1 Paint Mark
        *a Front

        Check that the paint marks are positioned as shown in the illustration.

    8. Step 3:


      1. A00OSGLE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.

      2. Perform the above step twice.

      3. A00OSO0E02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Check that the paint marks are positioned as shown in the illustration.

    9. A00OUF0E02
      Text in Illustration
      *1 Cylinder Head
      *2 Cylinder Block
      *3 Seal Packing
      *a 15 mm or more

      Apply seal packing between the cylinder head and cylinder block in the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing application length
      15 mm (0.591 in.) or more

      Note


      • Before applying seal packing, clean the cylinder head and cylinder block surfaces near the head gasket. Be sure to remove any oil that has seeped in between the gasket and cylinder head or cylinder block.

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

      • Wipe off any seal packing that seeps out from the groove in the cylinder head.

      • Do not start the engine for at least 4 hours after installation.

  8. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free from dirt and foreign objects.

    • Use only clean engine oil.


    1. Place the lash adjuster into a container full of new engine oil.

    2. Insert SST tip into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      A00E859E01
      SST
      09276-75010

    3. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed air.

      OK
      Plunger moves up and down.

      Note

      When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding air, remove SST. Then quickly and firmly press the plunger repeatedly with your fingers.

      OK
      Plunger can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the lash adjuster with a new one.

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Install the 16 valve lash adjusters to the cylinder head.

      Note

      Install the lash adjusters to their original positions.

  10. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Install the 16 No. 1 valve rocker arms to the lash adjusters.

  11. INSTALL CAMSHAFT


    1. Install the No. 2 camshaft bearing cap.

    2. A00OQQ7E08
      Text in Illustration
      *a Apply Engine Oil

      Apply clean engine oil to the cam of each camshaft, journals of the cylinder head and No. 1 valve rocker arms.

    3. A00OTCKE07
      Text in Illustration
      *1 No. 3 Cylinder Cam Lobe
      *2 No. 1 Cylinder Cam Lobe

      Place the No. 2 camshaft on the cylinder head as shown in the illustration so that the No. 1 and No. 3 cylinder cam lobes face upward.

      Note

      A00OTOIE05

      Before and after setting the camshaft and No. 2 camshaft on the cylinder head, check that the No. 1 valve rocker arm is firmly set to the valve lash adjuster.

    4. A00OSE2E02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm
      *2 Valve Stem
      *3 Valve Lash Adjuster
      *a CORRECT
      *b INCORRECT

      Align the camshaft and No. 2 camshaft timing mark (1 dot mark each).

    5. Place the camshaft on the cylinder head.

    6. A00OUAQ
      Text in Illustration
      *1 Dot Mark

      Set the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap on the camshafts as shown in the illustration.

      Tech Tips

      Make sure of the marks and numbers on the camshaft bearing caps and place them in the proper position and direction.

    7. Partially tighten the 20 bolts.

    8. A00OTVGE02
      Text in Illustration
      *1 Oil Pipe Seat

      Uniformly tighten the bolts in several steps, in the sequence shown in the illustration.

      Torque:
      for 1 to 16
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for 17 to 20
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    9. Install the 2 oil pipe seats.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  12. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY


    1. Install the 2 keys to the crankshaft.

  13. INSTALL CAMSHAFT TIMING SPROCKET


    1. A00OTJSE02
      Text in Illustration
      *1 Straight Pin
      *2 Timing Mark
      *3 Yellow Paint Mark

      Install the crankshaft timing sprocket and camshaft timing sprocket to the chain so that the timing marks of the sprockets and paint marks of the chain are aligned.

    2. Install the camshaft timing sprocket to the No. 2 camshaft by fitting the straight pin of the No. 2 camshaft into the hole on the camshaft timing sprocket.

    3. Install the crankshaft timing sprocket to the crankshaft.

    4. While holding the hexagon portion of the No. 2 camshaft, install and uniformly tighten the 4 bolts of the No. 2 camshaft.

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

  14. INSTALL OIL PUMP DRIVE GEAR


    1. Install the oil pump drive gear to the crankshaft.

  15. 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 }

  16. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  17. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A00OTH9E05
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      SST
      09240-00020   ( 09242-00200 )

    3. Install the chain tensioner with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Remove SST.

  18. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A00OTOVE01
      Text in Illustration
      *1 Oil Seal
      *2 Timing Chain Cover

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

      SST
      09223-50010
      Standard depth
      0 to 0.6 mm (0 to 0.236 in.)

      Note


      • Keep the lip of the oil seal free from foreign matter.

      • Do not tap in the oil seal at an angle.

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

      Note


      • Do not allow foreign matter to contact the lip of the oil seal.

      • Do not allow MP grease to contact the dust seal.

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install a new gasket and O-ring to the timing chain cover.

    2. Remove any old seal packing material.

    3. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

      A00OTGBE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter (Round) Seal Packing Dimension (Flat) Seal Packing Application Length
      A - A 2.0 to 4.0 mm (0.0787 to 0.157 in.) - -
      B - B 8.0 to 10 mm (0.315 to 0.394 in.) - 30 mm (1.18 in.)
      C - C - 13 mm (0.512 in.) or more wide and 6.0 mm (0.236 in.) or more thick 15 mm (0.591 in.)

      Note


      • Be sure to clean and degrease the contact surfaces, especially the 4 areas indicated by the arrows in the illustration.

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

      • When applying seal packing to area C - C, apply it in the direction of the white arrows in the illustration.

      • Install the timing chain cover within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    4. A00OT47E01
      Text in Illustration
      *1 Adhesive
      A00OVAR Bolt and New Seal Washer

      Apply adhesive to the 4 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Temporarily install the timing chain cover and a new seal washer with the 13 bolts.

      Bolt Length
      Item Specified Condition
      Bolt A 60 mm (2.36 in.)
      Bolt B 30 mm (1.18 in.)
      Bolt C 30 mm (1.18 in.)

      Tech Tips

      Bolt B and C are identical.

    6. Tighten the 12 bolts labeled B and C.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    7. Tighten the bolt labeled A.

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

  20. INSTALL CRANKSHAFT PULLEY


    1. Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

    2. A00OQDQE01

      Using SST, install a new pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  21. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new O-ring to the oil strainer.

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

    3. Install the oil strainer with the 3 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  22. INSTALL OIL FILTER BRACKET


    1. Install a new gasket to the oil filter bracket.

    2. Install the oil filter bracket with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  23. INSTALL OIL FILTER ELEMENT


    1. 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.

    6. A00OULPE01

      Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      for Aluminum Oil Filter Cap
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
      for Resin Oil Filter Cap
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A00OQN9E01
      Text in Illustration
      *a 4.0 to 7.0 mm

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

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Seal Packing Diameter Seal Packing Application Length
      A - A 4.0 to 7.0 mm (0.157 to 0.276 in.) 12 mm (0.472 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the oil pan within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    3. Install the oil pan with the 18 bolts and 2 nuts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A00OQYAE01

      Apply seal packing to the cylinder head as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Seal Packing Diameter Seal Packing Application Length
      A 6.0 mm (0.236 in.) 8.0 mm (0.315 in.)
      B 6.0 mm (0.236 in.) 10 mm (0.394 in.)

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


      1. Install the cylinder head cover gasket so that the triangle tabs of the cylinder head cover gasket are aligned with the protrusions of the cylinder head cover as shown in the parts of the illustration labeled A and B.

      2. Install the cylinder head cover gasket to the groove of the cylinder head cover moving from C and D in the direction of the black arrows shown in the illustration.

      3. Install the cylinder head cover gasket to the groove of the cylinder head cover moving from C and D towards E as shown by the white arrows in the illustration.

      4. Install the cylinder head gasket to the groove of the cylinder head cover moving from D towards F as shown by the striped arrow in the illustration.

      5. Install the cylinder head cover gasket to the cylinder head cover pins and cutouts as shown in the parts of the illustration labeled G and H.

        A00OV6ME01
        Text in Illustration
        *1 Triangle Tab of Cylinder Head Cover Gasket *2 Protrusion of Cylinder Head Cover
        *3 Cylinder Head Cover Pin *4 Cutout of Cylinder Head Cover

        Note

        Make sure that the rib of the cylinder head cover gasket is securely inserted into the groove of the cylinder head cover.

        A00OUL3E01
        Text in Illustration
        *a CORRECT
        *b INCORRECT
        A00OQR6 Rib of Cylinder Head Cover Gasket
    4. A00OSPQE01

      Install the cylinder head cover with the 14 bolts and nut, and tighten the bolts and nut in the order shown in the illustration.

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

      Tech Tips

      Partially tighten the bolt indicated by the number 6 in the illustration until the cylinder head cover contacts the cylinder head, and then tighten the bolts and nut in the order shown in the illustration.

  26. INSTALL NOZZLE HOLDER CLAMP SEAT


    1. A00OV5L

      Install the 4 nozzle holder clamp seats.

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

  27. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  28. INSTALL WATER INLET HOUSING


    1. Install a new gasket and the water inlet housing with the 3 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  29. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install the sensor with the 4 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  30. INSTALL NO. 1 OIL COOLER BRACKET


    1. A00OUNIE02

      Apply engine oil to the 2 new O-rings labeled B in the illustration.

      Note

      Do not apply engine oil to the new O-ring labeled A in the illustration.

    2. Install 3 new O-rings to the oil cooler bracket.

    3. Install the No. 1 oil cooler bracket with the 6 bolts and nut.

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

  31. INSTALL OIL COOLER ASSEMBLY


    1. A00OREWE01

      Apply engine oil to the 2 new O-rings labeled B in the illustration.

      Note

      Do not apply engine oil to the new O-ring labeled A in the illustration.

    2. Install 3 new O-rings to the oil cooler bracket.

    3. Install the oil cooler with the 5 bolts.

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

  32. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


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

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

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

    3. A00OTCOE02
      Text in Illustration
      *1 Fulcrum Length

      Using SST, install the engine oil pressure switch.

      SST
      09224-00010
      Torque:
      without SST
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      with SST
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Tech Tips


      • Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).

      • Make sure SST and the wrench are connected in a straight line.

      Note

      Do not start the engine for at least 1 hour after installation.

    4. Connect the engine oil pressure switch connector.

  33. INSTALL WATER PUMP ASSEMBLY


    1. Remove the adhesive from the threads of the bolt and the bolt hole of the timing chain cover.

    2. A003CYU

      Install a new gasket to the timing chain cover so that the protrusions indicated by the arrows in the illustration are aligned.

    3. A003EEXE01
      Text in Illustration
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt labeled A shown in the illustration.

      Standard Bolt Length
      Item Specified Condition
      Bolt A and C 45 mm (1.77 in.)
      Bolt B 30 mm (1.18 in.)
      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    4. A003BJB

      Install the water pump with the 2 bolts indicated by the arrows in the illustration.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }
    5. A003CR0

      Install the 5 bolts.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

  34. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Install a new gasket to the sensor.

    2. A00OVCUE01

      Using SST, install the sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  35. INSTALL CRANKSHAFT POSITION SENSOR


    1. Install the sensor with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Connect the sensor harness and install the clip.

  36. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  37. INSTALL INJECTOR ASSEMBLY

    Note

    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. Install 4 new nozzle seats to the cylinder head.

    2. A00OR6DE01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to each injector.

    3. Apply a light coat of engine oil to the O-ring on each injector.

    4. Install the 4 injectors to the cylinder head.

      Note

      Fit the injectors to the nozzle seats.

    5. A00OQLDE01
      Text in Illustration
      *1 Washer

      Install the nozzle holder clamps and washers as shown in the illustration.

      Note

      Pay attention to the mounting orientation (beveled edge) of the washer.

    6. Temporarily install the nozzle holder 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.

      Tech Tips

      Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

    7. Temporarily install the 4 injection pipes.

    8. Temporarily install the No. 1 leakage pipe and 4 new gaskets with the 4 union bolts and bolt.

    9. Tighten the 4 nozzle holder clamp bolts.

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

  38. INSTALL NO. 1 NOZZLE LEAKAGE PIPE


    1. A00OV7LE01
      Text in Illustration
      *1 Union Bolt

      Install 4 new gaskets and the No. 1 nozzle leakage pipe with the 4 union bolts and bolt.

      Torque:
      for union bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for bolt
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  39. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. Temporarily install the No. 2 nozzle leakage pipe and a new gasket with the check valve and bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the bolt.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }