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 OIL BAFFLE PLATE


    1. Install the oil baffle plate with the 4 bolts.

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

  3. INSTALL REAR CRANKSHAFT OIL SEAL


    1. Apply MP grease to the lip of a new rear crankshaft oil seal.

    2. A01IR14E01

      Using SST and a hammer, tap in the rear crankshaft oil seal as shown in the illustration.

      SST
      09223-56010
      Standard depth
      0 to 0.9 mm (0 to 0.0354 in.)

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the rear crankshaft oil seal at an angle.

      • Make sure that the rear crankshaft oil seal is properly installed.

  4. SELECT CYLINDER HEAD GASKET


    1. Check the piston protrusions for each cylinder.


      1. Clean the cylinder block sub-assembly with solvent.

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

      3. A01IT5OE02
        Text in Illustration
        *1 Measuring Tip
        *2 Protrusion
        *3 Measuring Point

        Place a dial indicator on the cylinder block sub-assembly, 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. A01IONIE04

      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
      A01ISM9 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

  5. INSTALL CYLINDER HEAD GASKET

  6. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. A01INX8E01

      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 sub-assembly.

    3. Place the cylinder head sub-assembly on the cylinder head gasket.

      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. A01IORYE02
        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. A01IUSOE02
        Text in Illustration
        *1 Paint Mark
        *a Front

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

    7. Step 2:


      1. A01IO47E02
        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. A01IQP3E03
        Text in Illustration
        *1 Paint Mark
        *a Front

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

    8. Step 3:


      1. A01ISDIE02
        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. A01IRI5E02
        Text in Illustration
        *1 Paint Mark
        *a Front

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

    9. A01INQYE02
      Text in Illustration
      *1 Cylinder Head Sub-assembly
      *2 Cylinder Block Sub-assembly
      *3 Seal Packing
      *a 15 mm or more

      Apply seal packing between the cylinder head sub-assembly and cylinder block sub-assembly 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 sub-assembly and cylinder block sub-assembly surfaces near the head gasket. Be sure to remove any oil that has seeped in between the cylinder head gasket and cylinder head sub-assembly or cylinder block sub-assembly.

      • 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 sub-assembly.

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

  7. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


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

    • Use only clean engine oil.


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

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

      SST
      09276-75010
      A01ITY2E01
      Text in Illustration
      *1 Taper Port *2 Plunger
      *3 Lower Pressure Chamber *4 Check Ball
      *5 High Pressure Chamber - -
      *a CORRECT *b INCORRECT

    3. Squeeze SST and the valve 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 valve lash adjuster assembly with a new one.

  8. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

      Install the valve lash adjuster assemblies to their original positions.

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


    1. Install the 16 No. 1 valve rocker arm sub-assemblies to the valve lash adjuster assemblies.

  10. INSTALL CAMSHAFT


    1. Install the No. 2 camshaft bearing cap.

    2. A01INVVE08
      Text in Illustration
      *a Apply Engine Oil

      Apply clean engine oil to the cam of each camshaft, journals of the cylinder head sub-assembly and No. 1 valve rocker arm sub-assemblies.

    3. A01IRBQE07
      Text in Illustration
      *1 No. 3 Cylinder Cam Lobe
      *2 No. 1 Cylinder Cam Lobe

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

      Note

      A01IT84E05

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

    4. A01IQRUE02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem
      *3 Valve Lash Adjuster Assembly
      *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 sub-assembly.

    6. A01IOMC
      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. A01ITINE02
      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 }

  11. INSTALL KEY


    1. Install the 2 keys to the crankshaft.

  12. INSTALL CAMSHAFT TIMING SPROCKET


    1. A01IOQBE01
      Text in Illustration
      *A CCo
      *B DPF
      *1 Straight Pin
      *2 Timing Mark
      *3 Yellow Paint Mark
      *4 Pink Paint Mark

      Install the crankshaft timing sprocket and camshaft timing sprocket to the chain sub-assembly so that the timing marks of the sprockets and paint marks of the chain sub-assembly 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 }

  13. INSTALL OIL PUMP DRIVE GEAR


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

  14. 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 }

  15. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01ITESE05
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    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 No. 1 chain tensioner assembly with the 2 bolts.

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

    4. Remove SST.

  17. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01IUP6E01
      Text in Illustration
      *1 Front Crankshaft Oil Seal
      *2 Timing Chain Cover Sub-assembly

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

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

      Note


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

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

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

      Note


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

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

  18. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


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

    2. Remove any old seal packing material.

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

      A01IP1EE01
      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 sub-assembly 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. for CCo:

      Apply adhesive to the 4 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      A01ITU1E01
      Text in Illustration
      *A for CCo *B for DPF
      *1 Adhesive - -
      A01ISER Bolt and New Seal Washer - -

    5. for DPF:

      Apply adhesive to the 3 bolts labeled B and bolt labeled D.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Temporarily install the timing chain cover sub-assembly 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.)
      Bolt D 45 mm (1.77 in.)

      Tech Tips

      Bolt B and C are identical.

    7. for CCo:

      Tighten the 12 bolts labeled B and C.

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

    8. for DPF:

      Tighten the 12 bolts labeled B, C and D.

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

    9. Tighten the bolt labeled A.

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

  19. INSTALL CRANKSHAFT PULLEY


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

    2. A01IPB5E01

      Using SST, install a new pulley bolt.

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

  20. INSTALL OIL STRAINER SUB-ASSEMBLY


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

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

    3. A01IPZEE02

      Install the oil strainer sub-assembly with the 3 bolts.

      Torque:
      for bolt A
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
      for bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  21. 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 }

  22. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY (for DPF)

  23. INSTALL OIL FILTER ELEMENT


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

    2. A01IN35E01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

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

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    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. Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      A01ITSEE01
      *A for CCo *B for DPF
      *1 Oil Filter Cap *2 O-Ring
      *3 Oil Filter Bracket - -
      *a No Gap - -

      Note

      After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.

  24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A01INH3E01
      Text in Illustration
      *A for CCo
      *B for DPF
      *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 Acceptable Seal Packing Application Range
      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 No. 2 oil pan sub-assembly 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 No. 2 oil pan sub-assembly 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. A01IOYBE01

      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 sub-assembly.


      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 sub-assembly 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 sub-assembly 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 sub-assembly 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 sub-assembly 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 sub-assembly pins and cutouts as shown in the parts of the illustration labeled G and H.

        A01IOK1E01
        Text in Illustration
        *1 Triangle Tab of Cylinder Head Cover Gasket *2 Protrusion of Cylinder Head Cover Sub-assembly
        *3 Cylinder Head Cover Sub-assembly Pin *4 Cutout of Cylinder Head Cover Sub-assembly

        Note

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

        A01INFME01
        Text in Illustration
        *a CORRECT
        *b INCORRECT
        A01IOJV Rib of Cylinder Head Cover Gasket
    4. A01IN1EE01

      Install the cylinder head cover sub-assembly 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 }
      Text in Illustration
      A01ISER Nut

      Tech Tips

      Partially tighten the bolt indicated by the number 6 in the illustration until the cylinder head cover sub-assembly 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. A01IOCF

      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 engine oil level sensor with the 4 bolts.

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

  30. INSTALL NO. 1 OIL COOLER BRACKET


    1. for CCo:


      1. A01INIOE02

        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 No. 1 oil cooler bracket.

    2. for DPF:


      1. A01IRZME01

        Apply engine oil to the 2 new gaskets labeled B in the illustration.

        Note

        Do not apply engine oil to the new gasket labeled A in the illustration.

      2. Install 3 new gaskets to the No. 1 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. for CCo:


      1. A01IT2UE01

        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 No. 1 oil cooler bracket.

    2. for DPF:


      1. A01IOY3E01

        Apply engine oil to the 2 new gaskets labeled B in the illustration.

        Note

        Do not apply engine oil to the new gasket labeled A in the illustration.

      2. Install 3 new gaskets to the No. 1 oil cooler bracket.

    3. Install the oil cooler assembly with the 5 bolts.

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

  32. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (for CCo)


    1. Remove the adhesive from the threads of the oil pressure switch assembly and the bolt hole of the No. 1 oil cooler bracket.

    2. A01IQK9E01
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Do not apply adhesive to the oil inlet port of the engine oil pressure switch assembly.

    3. Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

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

    4. Connect the engine oil pressure switch connector.

  33. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (for DPF)


    1. Remove the adhesive from the threads of the oil pressure sender gauge assembly and the bolt hole of the No. 1 oil cooler bracket.

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Do not apply adhesive to the oil inlet port of the oil pressure sender gauge assembly.

    3. Using a 27 mm deep socket wrench, install the oil pressure sender gauge assembly.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note

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

    4. Connect the oil pressure sender gauge connector.

  34. INSTALL WATER PUMP ASSEMBLY


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

    2. A01IS5B

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

    3. A01IQBME04
      Text in Illustration
      *a 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. A01IPB4

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

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }
    5. A01IQ7I

      Install the 5 bolts.

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

  35. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Install a new gasket to the engine coolant temperature sensor.

    2. A01IN8AE01

      Using SST, install the engine coolant temperature sensor.

      SST
      09817-33190
      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

  36. INSTALL CRANKSHAFT POSITION SENSOR


    1. Install the crankshaft position sensor with the 2 bolts.

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

    2. Connect the crankshaft position sensor harness and install the clip.

  37. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the camshaft position sensor with the bolt.

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

  38. 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 injection nozzle seats to the cylinder head.

    2. A01IT2HE01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to each injector assembly.

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

    4. Install the 4 injectors to the cylinder head.

      Note

      Fit the injectors to the injection nozzle seats.

    5. A01IOSXE01
      Text in Illustration
      *1 Washer

      Install the 4 No. 1 nozzle holder clamps and 4 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 No. 1 nozzle holder clamp, make sure that the nozzle holder clamp bolt and No. 1 nozzle holder 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 }

    10. Connect the 4 injector connectors.

  39. INSTALL NO. 1 NOZZLE LEAKAGE PIPE


    1. 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 }

  40. 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 }