ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note:

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

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

PROCEDURE

  1. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    1. Apply adhesive to the cylinder block water drain cock sub-assembly.

      Seal packing

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

    2. Install the cylinder block water drain cock sub-assembly.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

  2. INSTALL ENGINE BALANCER ASSEMBLY

    1. A111301C01

      *1

      Service Bolt

      *2

      Timing Mark

      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 assembly to the engine.

    2. A273384N04

      Temporarily install the engine balancer bolts.

      Tip:

      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.

        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 assembly.

  3. INSTALL OIL BAFFLE PLATE

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

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  4. INSTALL REAR ENGINE OIL SEAL

    Click here

  5. SELECT CYLINDER HEAD GASKET

    Click here

  6. INSTALL CYLINDER HEAD GASKET

  7. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  8. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Click here

  9. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

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

    Click here

  11. INSTALL CAMSHAFT

    Click here

  12. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY

    1. Install the 2 crankshaft pulley set crankshaft keys to the crankshaft.

  13. INSTALL CAMSHAFT TIMING SPROCKET

    1. A111275C01

      *1

      Hole

      *2

      Timing Mark

      *3

      Yellow 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 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.

      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.

      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. A101303C02

      *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.

      09240-00020

      09242-00200

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

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

    4. Remove SST.

  18. INSTALL FRONT CRANKSHAFT OIL SEAL

    Click here

  19. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  20. 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. A201753N06

      Using SST, install a new crankshaft pulley bolt.

      09213-58014

      91551-80840

      09330-00021

      300 N*m

      3059 kgf*cm

      221 ft.*lbf

  21. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  22. INSTALL OIL FILTER BRACKET

    Click here

  23. INSTALL OIL FILTER ELEMENT

    Click here

  24. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  25. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  26. INSTALL NOZZLE HOLDER CLAMP SEAT

    Click here

  27. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  28. INSTALL WATER INLET HOUSING

    Click here

  29. INSTALL ENGINE OIL LEVEL SENSOR

    1. Install the engine oil level sensor with the 4 bolts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  30. INSTALL NO. 1 OIL COOLER BRACKET

    Click here

  31. INSTALL OIL COOLER ASSEMBLY

    Click here

  32. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  33. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  34. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  35. INSTALL CRANKSHAFT POSITION SENSOR

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

      8.8 N*m

      90 kgf*cm

      78 in.*lbf

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

  36. INSTALL CAMSHAFT POSITION SENSOR

    1. Install the camshaft position sensor with the bolt.

      8.8 N*m

      90 kgf*cm

      78 in.*lbf

  37. INSTALL INJECTOR ASSEMBLY

    Click here

  38. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

    Click here