ENGINE UNIT REASSEMBLY

PROCEDURE


  1. INSTALL STRAIGHT PIN

    Note

    It is not necessary to remove the straight pin unless it is being replaced.


    1. for Timing Chain Cover Sub-assembly Side:


      1. B00276RC01
        *a Protrusion Height

        Using a plastic-faced hammer, tap in 2 new straight pins to the timing chain cover sub-assembly.

        Standard protrusion height
        5.0 to 7.0 mm (0.197 to 0.276 in.)

    2. for Timing Chain Case Assembly Side:


      1. B002900C01
        *a Protrusion Height

        Using a plastic-faced hammer, tap in a new straight pin to the timing chain case assembly.

        Standard protrusion height
        18 to 20 mm (0.709 to 0.787 in.)

  2. INSTALL STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. for Timing Chain Cover Sub-assembly Side:


      1. B0028JAC01
        *a 16 mm (0.630 in.)
        *b 9.0 mm (0.354 in.)
        *c 27 mm (1.06 in.)

        Using an E6 "TORX" socket wrench, install the stud bolts to the timing chain cover sub-assembly.

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

    2. for Timing Chain Case Assembly Side:


      1. B0024SSC01
        *a 19 mm (0.748 in.)
        *b 16 mm (0.630 in.)
        *c 44 mm (1.73 in.)

        Using an E8 "TORX" socket wrench, install the stud bolts to the timing chain case assembly.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. B0024GFC02
        *a 9.0 mm (0.354 in.)
        *b 19 mm (0.748 in.)

        Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain case assembly.

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

  3. INSTALL LOCK PLATE


    1. B0025SSC01
      *a Cylinder Block Sub-assembly Side
      *b Oil Jet

      Install the lock plate with the bolt to the cylinder block sub-assembly.

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

      Tech Tips


      • Make sure the lock plate is facing the direction shown in the illustration.

      • Make sure the end of the lock plate is holding the oil jet as shown in the illustration.

  4. INSTALL CYLINDER HEAD GASKET

    Click here

  5. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  6. INSTALL VALVE LASH ADJUSTER ASSEMBLY


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

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


    1. B0024T7C01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem Cap
      *3 Valve Lash adjuster assembly

      Check that the No. 1 valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.

    2. Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

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

  8. INSTALL NO. 2 CAMSHAFT

    Tech Tips

    Glove is at the rear end of the No. 2 camshaft.

    B002494C01
    *a Glove
    B0068HS Engine Front Side

    1. Clean the No. 2 camshaft journals.

    2. Apply a light coat of engine oil to the No. 2 camshaft journals of the cylinder head sub-assembly and the thrust portion of the No. 2 camshaft.

  9. INSTALL CAMSHAFT


    1. Clean the camshaft journals.

    2. Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

    3. B0028C1C01
      *a Knock Pin

      Make sure the knock pins of the camshaft and No. 2 camshaft are facing the direction shown in the illustration.

  10. INSTALL NO. 1 AND NO. 2 CAMSHAFT BEARING CAP


    1. B0026VB

      Set the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps to the cylinder head sub-assembly as shown in the illustration.

    2. Temporarily install the 20 camshaft bearing cap bolts.

    3. B0026JYC01
      B0068HS Camshaft Bearing Cap Bolt A
      B006964 Camshaft Bearing Cap Bolt B

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

      Torque:
      for camshaft bearing cap bolt A (No. 1 camshaft bearing)
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for camshaft bearing cap bolt B (No. 2 camshaft bearing)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  11. INSTALL NO. 3 CAMSHAFT BEARING CAP


    1. Clean and degrease the contact surfaces of the No. 3 camshaft bearing cap and cylinder head sub-assembly.

    2. B0027A7C01
      *a Engine Front Side
      B00285T Seal Packing Application Area

      Apply seal packing to the No. 3 camshaft bearing cap in the areas indicated in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 mm (0.118 in.)

      Note


      • Install the No. 3 camshaft bearing cap within 3 minutes and tighten the camshaft bearing cap bolts within 15 minutes after applying seal packing.

      • Do not add engine oil within 2 hours of installation.

      • Do not start the engine for at least 2 hours after the installation.

    3. Install the No. 3 camshaft bearing cap with the 2 camshaft bearing cap bolts to the cylinder head sub-assembly.

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

    4. Wipe off excess seal packing from between No. 3 camshaft bearing cap and cylinder head sub-assembly.

  12. INSTALL TIMING CHAIN CASE ASSEMBLY AND ENGINE WATER PUMP ASSEMBLY

    Click here

  13. INSTALL INJECTION PUMP INSULATOR


    1. Install the injection pump insulator to the cylinder block sub-assembly.

  14. INSTALL SUPPLY PUMP ASSEMBLY

    Note

    Do not hold the supply pump assembly by the parts indicated by the arrows in the illustration.

    B0024BVC01
    *A w/ Pressurised Fuel Filter
    *B w/o Pressurised Fuel Filter

    1. Install a new O-ring to the supply pump assembly.

    2. Install the supply pump assembly with the 3 nuts to the timing chain case assembly.

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

    3. w/ Pressurised Fuel Filter:

      Install the No. 1 fuel pump bracket with the 2 bolts to the cylinder block sub-assembly and supply pump assembly.

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

  15. INSTALL NO. 1 CHAIN TENSIONER SLIPPER


    1. Install the No. 1 chain tensioner slipper to the straight pin.

  16. TEMPORARILY INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Temporarily install the No. 1 chain vibration damper with the bolt to the cylinder block sub-assembly.

  17. INSTALL CRANKSHAFT TIMING SPROCKET, INJECTION PUMP DRIVE GEAR WITH NO. 1 CHAIN SUB-ASSEMBLY


    1. B0027K9C01
      *1 Crankshaft Pulley Set Key
      *a Timing Mark
      *b Upper Side

      Install the crankshaft timing sprocket to the crankshaft.

    2. Align the crankshaft pulley set key as shown in the illustration.

    3. B0024E8C01
      *a Supply Pump Shaft Key
      *b Upper Side

      Align the supply pump shaft key as shown in the illustration.

    4. Remove the crankshaft timing sprocket from the crankshaft.

    5. B0027KUC01
      *1 Crankshaft Timing Sprocket
      *2 Injection Pump Drive Gear
      *a Mark Plate (Pink)
      *b Mark Plate (Yellow)
      *c Timing Mark

      Align the 2 mark plates (pink) of the No. 1 chain sub-assembly with the 2 timing marks of the crankshaft timing sprocket and install the No. 1 chain sub-assembly to the crankshaft timing sprocket as shown in the illustration.

    6. Align the mark plate (yellow) of the No. 1 chain sub-assembly with the timing mark of the injection pump drive gear and install the No. 1 chain sub-assembly to the injection pump drive gear as shown in the illustration.

    7. Install the crankshaft timing sprocket, injection pump drive gear and No. 1 chain sub-assembly to the crankshaft and supply pump shaft together.

  18. TIGHTEN NO. 1 CHAIN VIBRATION DAMPER


    1. Tighten the No. 1 chain vibration damper with the bolt to the cylinder block sub-assembly.

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

  19. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Note

    B0026F8C01
    *a No. 1 Chain Tensioner Assembly Body
    *b Spring
    *c Plunger

    • When the pin is removed from the No. 1 chain tensioner assembly, the plunger and spring may come off of the No. 1 chain tensioner assembly body, but this is not a malfunction.

    • Before installing the plunger and spring to the No. 1 chain tensioner assembly body, check that they are free of foreign matter and not damaged.


    1. Install a new gasket and No. 1 chain tensioner assembly with the 2 bolts to the cylinder block sub-assembly.

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

      Tech Tips

      Align the claw (lower side) of the gasket with the groove of the No. 1 chain tensioner assembly body to install the No. 1 chain tensioner assembly as shown in the illustration.

      B00247YC01
      *a Claw (Lower Side)
      *b Groove

  20. INSTALL SUPPLY PUMP SHAFT NUT


    1. Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.

    2. B00293CC01
      *a Hold
      B0068HS Turn

      Using SST, hold the crankshaft pulley and install the supply pump shaft nut to the supply pump shaft.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }

      Note

      If the supply pump shaft nut is tightened with torque higher than the specified torque, the No. 1 chain sub-assembly may break.

    3. Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.

    4. B0027KUC01
      *1 Crankshaft Timing Sprocket
      *2 Injection Pump Drive Gear
      *a Mark Plate (Pink)
      *b Mark Plate (Yellow)
      *c Timing Mark

      Make sure that the timing marks of the crankshaft timing sprocket and injection pump drive gear are aligned with the mark plates of the No. 1 chain sub-assembly as shown in the illustration.

    5. Remove the pin from the No. 1 chain tensioner assembly.

  21. INSTALL CAMSHAFT TIMING SPROCKET


    1. B0024QBC01
      *a Engine Front Side
      *b Timing Mark
      *c Knock Pin
      *d Cutout

      Temporarily install the 2 camshaft timing sprockets with the 2 camshaft timing sprocket bolts to the camshaft and No. 2 camshaft.

      Note

      Make sure that the timing mark of the camshaft timing sprocket faces the front side of the engine.

      Tech Tips

      Align the knock pins of the camshaft and No. 2 camshaft with the cutout of the camshaft timing sprocket to install the camshaft timing sprocket.

    2. for Intake Side:


      1. B0024EUC01
        *a Hold
        B0068HS Turn

        Use a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing sprocket bolt to the camshaft.

        Torque:
        81 N*m  { 826 kgf*cm, 60 ft.*lbf }

        Note

        Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.

    3. for Exhaust Side:


      1. B0025QVC01
        *a Hold
        B0068HS Turn

        Use a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing sprocket bolt to the No. 2 camshaft.

        Torque:
        81 N*m  { 826 kgf*cm, 60 ft.*lbf }

        Note

        Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.

  22. INSTALL NO. 2 CHAIN VIBRATION DAMPER


    1. Install the No. 2 chain vibration damper with the 2 bolts to the timing chain case assembly.

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

  23. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. B0024ZEC01
      *a Mark Plate (Orange)
      *b Timing Mark

      Align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (intake side) and install the No. 2 chain sub-assembly to the camshaft timing sprocket (intake side) as shown in the illustration.

    2. B0026I7C01
      *a Mark Plate (Yellow)
      *b Timing Mark

      Align the mark plate (yellow) of the No. 2 chain sub-assembly with the timing mark of the injection pump drive gear and install the No. 2 chain sub-assembly to the injection pump drive gear as shown in the illustration.

    3. B0027FCC01
      *a Mark Plate (Orange)
      *b Timing Mark
      B0068HS Turn

      Using a wrench, turn the hexagonal portion of the No. 2 camshaft clockwise and align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (exhaust side) to install the No. 2 chain sub-assembly to the camshaft timing sprocket (exhaust side).

  24. INSTALL NO. 2 CHAIN TENSIONER SLIPPER


    1. Install the No. 2 chain tensioner slipper with the bolt to the timing chain case assembly.

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

  25. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


    1. Install the No. 2 chain tensioner assembly with the 2 bolts to the timing chain case assembly.

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

    2. Remove the pin from the No. 2 chain tensioner assembly.

  26. INSTALL TIMING CHAIN GUIDE

    Click here

  27. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Make sure that the timing marks of the camshaft timing sprocket (exhaust side), camshaft timing sprocket (intake side), injection pump drive gear and crankshaft timing sprocket are at the positions shown in the illustration.

      B0024Z5C01
      *a Camshaft Timing Sprocket (Exhaust Side) *b Camshaft Timing Sprocket (Intake Side)
      *c Injection Pump Drive Gear *d Crankshaft Timing Sprocket
      *e Mark Plate (Orange) *f Mark Plate (Yellow)
      *g Mark Plate (Pink) *h Timing Mark

  28. INSTALL OIL PUMP DRIVE GEAR

    Click here

  29. INSTALL OIL PUMP RELIEF VALVE PLUG


    1. Install a new gasket and oil pump relief valve plug to the timing chain cover sub-assembly.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  30. INSTALL TIMING CHAIN COVER PLATE

    Click here

  31. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  32. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  33. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Clean and degrease the contact surfaces of the rear engine oil seal retainer and cylinder block sub-assembly.

    2. B00258KC01
      *a Seal Packing

      Apply seal packing to the rear engine oil seal retainer in the areas indicated in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3.0 to 4.0 mm (0.118 to 0.157 in.)

      Note


      • Remove any engine oil from the contact surface.

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

      • Do not add engine oil within 2 hours of installation.

      • Do not start the engine for at least 2 hours after the installation.

    3. Install the rear engine oil seal retainer to the cylinder block sub-assembly, and then install the 5 bolts.

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

  34. INSTALL REAR ENGINE OIL SEAL

    Click here

  35. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. B00255IN01

      Install a new gasket and oil strainer sub-assembly with the 4 bolts to the cylinder block sub-assembly in several steps in the sequence shown in the illustration.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Tech Tips

      Make sure that the claw of the gasket faces the oil strainer sub-assembly.

  36. INSTALL OIL PAN SUB-ASSEMBLY

    Click here

  37. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  38. INSTALL OIL PAN COVER SILENCER

    Click here

  39. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  40. INSTALL CRANKSHAFT POSITION SENSOR HARNESS BRACKET


    1. Install the crankshaft position sensor harness bracket with the bolt to the cylinder block sub-assembly.

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

    2. Connect the crankshaft position sensor connector.

  41. INSTALL NO. 1 CYLINDER BLOCK INSULATOR


    1. Install the No. 1 cylinder block insulator to the cylinder block sub-assembly.

  42. INSTALL NO. 5 CYLINDER BLOCK INSULATOR


    1. Install the No. 5 cylinder block insulator to the cylinder block sub-assembly.

  43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  44. INSTALL OIL FILLER CAP GASKET


    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.

  45. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  46. INSTALL NOZZLE HOLDER GASKET

    Click here

  47. TEMPORARILY INSTALL INJECTOR ASSEMBLY

    Click here

  48. INSTALL OIL FILTER BRACKET


    1. Install 2 new O-rings to the cylinder block sub-assembly.

    2. Install the oil filter bracket with the 2 nuts and bolt to the cylinder block sub-assembly.

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

  49. INSTALL OIL FILTER UNION


    1. Using a 27 mm deep socket wrench, install the oil filter union to the oil filter bracket.

      Torque:
      29.4 N*m  { 300 kgf*cm, 22 ft.*lbf }

  50. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  51. INSTALL OIL COOLER ASSEMBLY

    Click here

  52. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH with the 4 bolts to the cylinder block sub-assembly.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  53. INSTALL GENERATOR BRACKET SUB-ASSEMBLY


    1. Install the generator bracket sub-assembly with the 4 bolts to the cylinder head sub-assembly and timing chain case assembly.

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

  54. INSTALL NO. 3 CYLINDER BLOCK INSULATOR


    1. Install the No. 3 cylinder block insulator to the cylinder block sub-assembly.

  55. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH with the 4 bolts to the cylinder block sub-assembly.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  56. INSTALL NO. 2 CYLINDER BLOCK INSULATOR


    1. Install the No. 2 cylinder block insulator to the front No. 1 engine mounting bracket LH.

  57. INSTALL NO. 1 ENGINE HANGER


    1. Install the No. 1 engine hanger with the 2 bolts to the cylinder head sub-assembly.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }