OIL PUMP (w/ EGR Cooler) INSTALLATION

INSTALL OIL DIPSTICK GUIDE

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

2. Apply a small amount of clean engine oil to the O-ring.

3. Install the engine oil level dipstick guide with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

4. Install the injection pipe clamp with the bolt.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

INSTALL FUEL SUPPLY PUMP ASSEMBLY

1. Check that the injection gear in the timing gear case moves back and forth smoothly.

2. Install a new O-ring to the pump.

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

4. 

   Align the set key on the drive shaft with the groove of the injection gear.

5. 

   Install the pump with the 2 nuts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

6. Set a new O-ring.

7. 

   Using SST, hold the crankshaft pulley and install the set nut.

   SST

   09213-58013

   09330-00021

   Torque:

   64 N*m  { 653 kgf*cm, 47 ft.*lbf }

8. 

   Using a dial indicator, measure the thrust clearance of the injection pump shaft by moving the pump drive shaft pulley back and forth.

   Thrust clearance
   0.15 to 0.55 mm (0.0059 to 0.0217 in.)

   If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat step above.

9. 

   Connect the 2 connectors.

10. 

    Connect the 2 fuel hoses.

INSTALL CRANKSHAFT POSITION SENSOR

1. Install the crankshaft position sensor with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

INSTALL CAMSHAFT POSITION SENSOR

1. Install the camshaft position sensor with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

INSTALL CRANKSHAFT PULLEY

1. Align the pulley set key with the key groove of the crankshaft pulley.

2. Using SST, install the pulley bolt.

   SST

   09213-58014

   09330-00021

   Torque:

   365 N*m  { 3722 kgf*cm, 269 ft.*lbf }

INSTALL VANE PUMP ASSEMBLY

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

2. Install the vane pump assembly with the 2 nuts.

   Torque:

   41 N*m  { 418 kgf*cm, 30 ft.*lbf }

INSTALL VACUUM PUMP ASSEMBLY

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

2. Install the vacuum pump assembly with the 2 nuts.

   Torque:

   21 N*m  { 210 kgf*cm, 15 ft.*lbf }

INSTALL TIMING GEAR COVER INSULATOR

1. Install the gear cover insulator with the bolt.

   Torque:

   13 N*m  { 133 kgf*cm, 10 ft.*lbf }

INSTALL WATER PUMP ASSEMBLY

INSTALL CYLINDER BLOCK INSULATOR

1. Install the cylinder block insulator to the cylinder head.

INSTALL NO. 2 TIMING BELT COVER

1. 

   Text in Illustration

   *1	Seal Packing

   Apply seal packing (FIPG) to the specified areas shown in the illustration.

   Seal packing
   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

   Note

   After applying seal packing, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

2. Clean the bolts and their holes.

3. Apply adhesive to 2 or 3 threads at the end of each of the 4 bolts.

   Adhesive
   Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

4. Install the No. 2 timing belt cover with the 4 bolts and nut.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL CAMSHAFT TIMING PULLEY

1. Install the camshaft timing pulley.

2. Install the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

   Torque:

   98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

INSTALL TIMING BELT

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

INSTALL NO. 4 INJECTION PIPE

INSTALL FUEL INLET PIPE SUB-ASSEMBLY

ADD ENGINE OIL

1. Wipe the oil pan and drain plug.

2. Install a new gasket and the drain plug.

   Torque:

   34 N*m  { 347 kgf*cm, 25 ft.*lbf }

3. Add new oil.

   Standard oil capacity
   Item Specified Condition Drain and refill with oil filter change 6.9 liters (7.3 US qts, 6.1 Imp. qts) Drain and refill without oil filter change 6.6 liters (7.0 US qts, 5.8 Imp. qts) Dry fill 7.4 liters (7.8 US qts, 6.5 Imp. qts)

4. Install the oil filler cap.

BLEED AIR FROM FUEL SYSTEM

INSPECT ENGINE OIL LEVEL

1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low and full level marks.

   If the oil level is low, check for leakage and add oil up to the full level mark.

   Note

   Do not fill engine oil above the full level mark.

INSPECT FOR FUEL LEAK

CAUTION:

• During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

• During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.

1. Check that there are no leaks from any part of the fuel system when the engine is stopped.

   If there is fuel leakage, repair or replace parts as necessary.

2. Start the engine and check that there are no leaks from any part of the fuel system.

   If there is fuel leakage, repair or replace parts as necessary.

3. Disconnect the return hose from the common rail.

4. Start the engine and check for fuel leaks from the return pipe.

   If there is fuel leakage, replace the common rail.

5. Connect the intelligent tester to the DLC3.

6. Start the engine and push the intelligent tester main switch ON.

7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

9. Check that there are no leaks from any part of the fuel system.

   Note

   A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

   If there is fuel leakage, repair or replace parts as necessary.

10. Reconnect the return hose to the common rail.

INSPECT FOR COOLANT LEAK