БЛОК ДВИГАТЕЛЯ УСТАНОВКА


  1. INSTALL OIL PAN COVER

    A0119HI

    1. Install the oil pan cover with the bolt and washer plate.

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

  2. INSTALL NO. 2 OIL PAN COVER SILENCER

    A01176G

    1. Install the No. 2 oil pan cover silencer with the 2 washer plates and 2 bolts.

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

  3. INSTALL CYLINDER BLOCK SIDE COVER

    A0119TW

    1. Install the cylinder block side cover with the bolt and washer plate.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  4. INSTALL HARNESS BRACKET (w/o Air Conditioning System)

    A011AE6

    1. Install the harness bracket with the bolt.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

  5. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    A0117ML

    1. Install the V-ribbed belt tensioner with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  6. INSTALL IDLER PULLEY SUB-ASSEMBLY

    A01192A

    1. Install the idler pulley with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  7. INSTALL CAMSHAFT POSITION SENSOR

    A0118LM

    1. Install the camshaft position sensor with the bolt.

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

    2. Install the harness bracket with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  8. INSTALL VACUUM PUMP ASSEMBLY


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

    2. A0118TC

      Install the vacuum pump with the 2 bolts.

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

  9. INSTALL OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the oil level dipstick guide.

    2. A0119KF

      Install the oil level dipstick guide with the 2 bolts.

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

  10. INSTALL ENGINE OIL LEVEL DIPSTICK

  11. INSTALL WATER INLET PIPE

    A011BY9

    1. Install the water inlet pipe with the 2 bolts.

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

  12. INSTALL WATER INLET HOSE LH

    A011BG4E01

    1. Install the water inlet hose LH.

      Tech Tips

      The clip at the water inlet housing can be installed in any orientation, as long as it does not contact any of the surrounding parts.

  13. INSTALL WATER INLET HOSE RH

    A011BC4E01

    1. Install the water inlet hose RH.

  14. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new O-ring to the water by-pass pipe.

      Note

      Apply water to all around the O-ring's inserting hole surface of the water inlet housing before installing the water by-pass pipe sub-assembly.

    2. A011BJHE01

      Install the water by-pass pipe with the 2 bolts, as shown in the illustration.

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

  15. INSTALL WATER BY-PASS HOSE

    A0118A1E01

    1. Install the water by-pass hose.

  16. INSTALL NO. 2 WATER BY-PASS HOSE

    A0118CAE01

    1. Install the No. 2 water by-pass hose.

  17. INSTALL NO. 3 WATER BY-PASS HOSE

    A01182EE01

    1. Install the No. 3 water by-pass hose.

  18. INSTALL NO. 4 WATER BY-PASS HOSE

    A011A4OE01

    1. Install the No. 4 water by-pass hose.

  19. INSTALL OIL COOLER HOSE SUB-ASSEMBLY

    A0118WUE02

    1. Install the oil cooler hose.

  20. INSTALL NO. 2 OIL COOLER HOSE

    A01176FE02
    Text in Illustration
    *1 Paint Mark

    1. Install the No. 2 oil cooler hose.

      Note

      Align the oil cooler hose paint mark with the clamp center.

    2. A011BJSE02
      Text in Illustration
      *1 Paint Mark

      Install the hose clamp.

      Note

      Align the oil cooler hose paint mark with the clamp center.

  21. INSTALL NO. 2 CYLINDER HEAD COVER

    A011756

    1. Install the No. 2 cylinder head cover.

    2. A0118GJ

      Install the 2 harness brackets with the 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  22. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

    A01194J

    1. Install the No. 1 intake manifold insulator.

  23. INSTALL COMMON RAIL ASSEMBLY

    A0119IB

    1. Install the common rail with 2 bolts.

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

  24. INSTALL SUPPLY PUMP DRIVE COUPLING


    1. A011909E03
      Text in Illustration
      *1 Camshaft
      *2 Supply Pump Drive Coupling
      *a Correct
      *b Incorrect

      Install the supply pump drive coupling into the camshaft.

      Note

      Install the supply pump drive coupling in the correct direction.

  25. TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

    Note

    When installing, clean the seal surfaces of the fuel inlet pipe, supply pump and common rail.


    1. A0118J9

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

    2. Install the O-ring onto the supply pump.

    3. A0119GH

      Temporarily tighten the supply pump with the 3 bolts.

  26. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A011ADSE01

    Note


    • When replacing the supply pump. the fuel inlet pipe must also be replaced.

    • Replace the fuel inlet pipe with a new one when the fuel inlet pipe has been removed and reinstalled more than 5 times.


    1. A011B6L

      Temporarily tighten the fuel inlet pipe onto the supply pump and common rail.

      Note

      Install the pipe and union nut vertically. not at a tilt.

    2. Fully tighten the supply pump with the 3 bolts.

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

    3. Using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the common rail side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Using a wrench (17 mm), hold the supply pump nut, and using a union nut wrench (17 mm), tighten the fuel inlet pipe union nut on the supply pump side.

      Torque:
      28 N*m  { 286 kgf*cm, 20 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  27. INSTALL NO. 2 FUEL HOSE

    A0118ZU

    1. Install the No. 2 fuel hose.

  28. INSTALL INJECTION NOZZLE SEAT

    A01177OE02
    Text in Illustration
    *1 Injector
    *2 Sealing Surface
    *3 Nozzle
    *4 Cylinder Head
    *5 Cloth

    Note


    • When installing, clean the sealing surface of the injector, injection pipe and common rail.

    • When replacing the injectors, the injection pipes must also be replaced.

    • Replace the injection pipe with a new one when the injection pipe has been removed and reinstalled more than 5 times.

    • Replace the injector with one with the same part number and install it onto the cylinder.


    1. Using a cloth and solvent, wipe away any carbon from the sealing surface of the injector and injector installation hole, as shown in the illustration.

      Note


      • Do not damage the sealing surface.

      • Do not touch the injector nozzle.

    2. Install 4 new nozzle seats onto the cylinder head.

  29. INSTALL INJECTOR ASSEMBLY


    1. Install the 4 injectors onto the cylinder head.

      Tech Tips

      Fit the injectors into the seats.

  30. INSTALL NOZZLE HOLDER CLAMP SEAT


    1. A0118Z0E02
      Text in Illustration
      *1 Nozzle holder clamp seat
      *2 Concave
      A0117XZ Upper Direction

      Install the 4 nozzle holder clamp seats onto the cylinder head.

      Note

      Install the nozzle holder clamp seats with the concave end facing up.

  31. INSTALL NO. 1 NOZZLE HOLDER CLAMP


    1. A0119U6E02
      Text in Illustration
      *1 Washer
      *2 Nozzle holder clamp
      *3 Nozzle holder clamp seat
      A0117XZ Upper Direction

      Install the 4 nozzle holder clamps onto the injectors.

    2. Set the washer on the nozzle holder clamp, as shown illustration.

      Note

      Install the washer in the correct direction.

    3. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  32. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    A011BDO

    1. Install the nozzle leakage pipe into each injector.


      1. Make sure the lock bush is at top position.

        A0119C7E01
        Text in Illustration
        *1 Lock Bush
        *2 Return Plug
        *3 Rest Arm
        *4 Injector

      2. Insert the rest arm into the injector and push both sides of the return plug until the rest arm engages with the injector, as shown in the illustration.

        Tech Tips

        Push the nozzle leakage pipe until it makes a click sound.

      3. Push the lock bush until the it fits with the return plug, as shown in the illustration.

    2. A0118JV

      Connect the nozzle leakage pipe and install new retainer spring onto the supply pump.

  33. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP

    A011927

    1. Install the 3 nozzle leakage pipe set clamps.

  34. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR


    1. Install the No. 2 intake manifold insulator.

  35. INSTALL GLOW PLUG ASSEMBLY


    1. Clean the glow plug installation holes in the cylinder head.

    2. A0118CE

      Install the 4 glow plugs.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  36. INSTALL NO. 1 GLOW PLUG CONNECTOR

    A011B7B

    1. Install the No. 1 glow plug connector with the 4 nuts.

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

    2. Install the 4 screw grommets.

  37. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY


    1. A011ADSE02
      Text in Illustration
      *a Correct
      *b Incorrect

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

      Note

      Install the pipe and union nut vertically, not at a tilt.

    2. Using a union nut wrench (17 mm), tighten the injection pipe union nut on the common rail, and then tighten the union nut on the injector.

      Torque:
      28 N*m  { 286 kgf*cm, 20 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  38. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  39. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Tech Tips

    Perform the same procedure as for injection pipe No. 1.

  40. INSTALL NO. 1 INJECTION PIPE CLAMP


    1. A011970

      Install both sides of the No. 1 injection pipe clamp with the 2 nuts as shown in the illustration.

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

  41. INSTALL NO. 2 INJECTION PIPE CLAMP


    1. A0118JH

      Install both sides of the No. 2 injection pipe clamp with the nut as shown in the illustration.

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

  42. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY


    1. Install the new gasket to the cylinder head.

    2. A0119J6

      Install the intake air connector with the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  43. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. Install a new gasket.

    2. A0116YRE10
      Text in Illustration
      *1 Adhesive

      Apply adhesive to the 2 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
    3. A011BT6E02
      Text in Illustration
      *1 EGR Control Valve

      Install the electric EGR control valve with the 2 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    4. Connect the No. 3 water by-pass hose.

    5. Connect the No. 4 water by-pass hose.

  44. INSTALL HARNESS BRACKET

    A011AOS

    1. Install the harness bracket with the bolt.

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

    2. Connect the vacuum hose to the vacuum pump.

  45. INSTALL NO. 1 EGR COOLER BRACKET

    A01197G

    1. Install the No. 1 EGR cooler bracket with the 2 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    2. Connect the vacuum hose.

  46. INSTALL NO. 5 ENGINE COVER


    1. Align the hook and install the No. 5 engine cover onto the No. 1 EGR cooler bracket.

    2. Engage the 2 claws.

  47. INSTALL EGR WITH COOLER PIPE ASSEMBLY


    1. Install 2 new gaskets.

    2. A0119M3

      Install the EGR with cooler pipe assembly with the 4 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A011747E01

      Connect the No. 2 water by-pass hose.

    4. Connect the No. 2 oil cooler hose.

    5. Connect the 2 vacuum hoses and No. 1 oil hose.

    6. A0119C5E01

      Connect the No. 1 vacuum transmitting hose.

    7. Connect the vacuum transmitting hose.

  48. INSTALL GENERATOR BRACKET

    A011866

    1. Install the No. 1 generator bracket with the bolt.

      Torque:
      40 N*m  { 407 kgf*cm, 30 ft.*lbf }

  49. INSTALL GENERATOR ASSEMBLY

    A011BVOE01

    1. Install the generator with the 2 bolts and nut.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt B, Nut
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  50. INSTALL TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD

    A0117E1E01
    Text in Illustration
    *1 Compressor Side

    1. Install a new gasket to the turbocharger.

    2. A0119LI

      Temporarily tighten the turbo oil inlet pipe with the 2 nuts to the turbocharger.

    3. Install 2 new gaskets to the cylinder head and cylinder block.

    4. A01185T

      Install the turbocharger with the exhaust manifold with the 9 nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
    5. A011AFJ

      Temporarily tighten the turbo oil inlet pipe with the 2 nuts to the cylinder block.

    6. A01196N

      Fully tighten the 4 nuts.

      Tech Tips

      Fully tighten the nuts on the turbocharger side before tightening the nuts on the cylinder block.

      Torque:
      Turbocharger Side
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Cylinder Block Side
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  51. INSTALL TURBOCHARGER STAY

    A0117OT

    1. Temporarily tighten the turbocharger stay with the 2 bolts and nut.

    2. Fully tighten the nut on the turbocharger side before tightening the bolts on the cylinder head side.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  52. INSTALL NO. 2 TURBOCHARGER STAY

    A0119B0

    1. Temporarily tighten the No. 2 turbocharger stay with the bolt and nut.

    2. Fully tighten the nut on the turbocharger side before tightening the bolt on the cylinder head side.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  53. INSTALL MANIFOLD STAY

    A011AXJ

    1. Install the manifold stay with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  54. INSTALL NO. 1 TURBO INSULATOR

    A01186N

    1. Install the No. 1 turbo insulator with the 2 bolts.

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