ENGINE UNIT REASSEMBLY

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.


  1. INSTALL TURBO WATER HOSE UNION

    Note

    If coolant leaks from a turbo water hose union or a turbo water hose union is corroded, replace the turbo water hose union.


    1. Clean the cylinder block side hole and new turbo water hose union with non-residue solvent.

    2. A01DY19E01

      Apply adhesive onto the shaded area of a turbo water hose union as shown in the illustration.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

      Install the turbo water hose union within 3 minutes after applying adhesive.

    3. Set the turbo water hose union and tap it until the edge of the turbo water hose union fits against the chamfered part of the cylinder block as shown in the illustration.

  2. INSTALL TIGHT PLUG


    1. A01DYSYE03

      Apply adhesive to the end of a new tight plug.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      Note

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

    2. Position A:

      Using a 14 mm steel bar and hammer, tap in the tight plug as shown in the illustration.

    3. Other Positions:

      Using SST and a hammer, tap in a new tight plug as shown in the illustration.

      Position B

      SST
      09950-60010   ( 09951-00180 )
      09950-70010   ( 09951-07100 )

      Position C

      SST
      09950-60010   ( 09951-00190 )
      09950-70010   ( 09951-07100 )

      Position D

      SST
      09950-60010   ( 09951-00200 )
      09950-70010   ( 09951-07100 )

      Position E

      SST
      09950-60010   ( 09951-00350 )
      09950-70010   ( 09951-07100 )

      Position F

      SST
      09950-60010   ( 09951-00400, 09951-00450 )
      09950-70010   ( 09951-07100 )

      Position G

      SST
      09950-60010   ( 09951-00450 )
      09950-70010   ( 09951-07100 )
      A01DVSKE01

  3. INSTALL STUD BOLT

    A01DV91E01

  4. INSTALL STRAIGHT PIN

    A01E208E01

  5. INSTALL RING PIN

    A01DZDWE01

  6. INSTALL NO. 1 STRAIGHT SCREW PLUG


    1. Install a new gasket and the screw plug.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  7. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

    A01E0H9E01

    1. Align the pin of the oil nozzle with the pin hole of the cylinder block.

    2. Install the 4 oil nozzles together with the check valves.

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

  8. INSTALL PISTON PIN


    1. Assemble the piston and connecting rod.


      1. A01DVXUE01

        Using a small screwdriver, install a new snap ring on one side of the piston pin hole.

      2. A01E2FEE01

        Gradually heat the piston to about 80°C (176°F).

      3. A01DYAHE01

        Coat the piston pin with engine oil.

      4. Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb.

      5. A01DUXQE01

        Check the fit between the piston and piston pin. Try to move the piston back and forth on the piston pin.

      6. A01DVOH

        Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.

    2. A01DVO2E01

      Install the piston rings.


      1. Install the coil and oil ring by hand.

        Tech Tips

        Face the end gap of the oil ring in the opposite direction of the coil joint.

      2. A01E2SUE01

        Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

        Code mark
        Number Mark
        No. 1 w/ EGR Cooler NAA
        w/EGR System without EGR Cooler NKD
        w/o EGR System NAB
        No. 2 w/ EGR System N
        w/o EGR System KD1
      3. A01E17AE01

        Position the piston rings so that the ring ends are as shown.

        Note

        Do not align the ring ends.

  9. INSTALL CONNECTING ROD BEARING

    A01DZS0E01

    1. Align the bearing claw with the groove of the connecting rod or connecting cap.

    2. Install the bearings to the connecting rod and connecting rod cap.

  10. INSTALL CRANKSHAFT BEARING

    A01E213E01

    Tech Tips

    Upper bearings have an oil groove and oil hole. Lower bearings do not.


    1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

    2. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

  11. INSTALL CRANKSHAFT

    A01E1TUE02

    1. Place the crankshaft on the cylinder block.

    2. Install the 2 upper thrust washers to the No. 5 journal position of the cylinder block.


      1. Push the crankshaft toward the front (rear) side.

      2. Install the 2 thrust washers with the oil grooves facing outward.

    3. A01DVC3E03

      Install the 2 thrust washers on the No. 5 bearing cap with the grooves facing outward.

    4. A01DZCNE01

      Install the 5 crankshaft bearing caps in their proper locations.

    5. A01DVTVE02

      Install the crankshaft bearing cap bolts.

      Tech Tips


      • The main bearing cap bolts are tightened in 2 progressive steps.

      • If a main bearing cap bolt is broken or deformed, replace it.


      1. Apply a light coat of engine oil to the threads and under the bolt heads of the main bearing caps.

      2. Install and uniformly tighten the 10 bolts of the main bearing caps in several passes in the sequence shown in the illustration.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

        If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.

      3. A01DW4ZE06

        Mark the front of the main bearing cap bolts with paint.

      4. Retighten the main bearing cap bolts 90° in the numerical order shown above.

      5. Check that the painted marks are now at a 90° angle to the front.

    6. Check that the crankshaft turns smoothly.

    7. Check the crankshaft thrust clearance.

  12. INSTALL PISTON AND CONNECTING ROD

    A01E0TME01

    1. Using a piston ring compressor, push the correctly numbered piston and connecting rod assembly into the cylinder with the front mark of the piston facing forward.

    2. A01DVAWE01

      Place the connecting rod cap on the connecting rod.


      1. Match the numbered connecting rod cap with the connecting rod.

      2. Align the pins of the connecting rod cap with the pin holes of the connecting rod, and install the connecting rod cap.

      3. A01DX3JE01

        Check that the front mark of the connecting rod cap is facing forward.

    3. A01DW42E01

      Install the connecting rod cap bolts.

      Tech Tips


      • The connecting rod cap bolts are tightened in 2 progressive steps.

      • If any connecting rod bolt is broken or deformed, replace it.


      1. Apply a light of engine oil on the threads and under the heads of the connecting rod cap bolts.

      2. Install and alternately tighten the bolts of the connecting rod cap in several passes.

        Torque:
        35 N*m  { 357 kgf*cm, 26 ft.*lbf }

        If any one of the connecting rod cap bolts does not meet the torque specification, replace the cap bolts.

      3. A01DYYDE02

        Mark the front of the connecting rod cap bolts with paint.

      4. Retighten the connecting rod cap bolts 90° as shown.

      5. Check that the painted marks are now at a 90° angle to the front.

    4. Check that the crankshaft turns smoothly.

    5. Check the connecting rod thrust clearance Click here.

  13. INSTALL CYLINDER BLOCK OIL ORIFICE

  14. INSTALL ENGINE REAR OIL SEAL RETAINER

    A01E2JNE01

    1. Remove any old packing (FIPG) material.

    2. Apply seal packing to the specific places described in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3 to 5 mm (0.12 to 0.20 in.)

      Note

      After applying FIPG, install the engine rear oil seal retainer within 3 minutes and tighten its bolts within 15 minutes.

    3. A01DW0I

      Install the retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

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

  15. INSTALL NO. 2 BALANCE SHAFT DRIVEN GEAR

    A01DVXKE01

    1. Mount the balance shaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balance shaft.

    2. Align the balance shaft knock pin with the knock pin hole. Then install the balance shaft thrust washer and balance shaft driven gear.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  16. INSTALL NO. 2 BALANCE SHAFT SUB-ASSEMBLY

    A01DZWPE01

    1. Install the balance shaft with the 2 bolts.

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

  17. INSTALL NO. 1 BALANCE SHAFT DRIVEN GEAR

    A01DYJBE01

    1. Mount the balance shaft between aluminum plates in a vise.

      Note

      Be careful not to damage the balance shaft.

    2. Align the balance shaft knock pin with the knock pin hole. Then install the balance shaft thrust washer and balance shaft driven gear.

    3. Install the bolt.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  18. INSTALL NO. 1 BALANCE SHAFT SUB-ASSEMBLY

    A01DY6DE01

    1. Install the balance shaft with the 2 bolts.

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

  19. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old packing (FIPG) material.

    2. A01DW8HE02

      Apply seal packing to the timing gear case as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      5 mm (0.20 in.)

      Note

      Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

    3. A01DYNME01

      Install a new gasket to the groove of the timing gear case.

    4. A01DZBXE01

      Install 2 new O-rings to the cylinder block groove of the timing gear case.

    5. A01DYNJE01

      Align the "2" marks of the balance shaft driven gear No. 1 and oil pump drive gear.

    6. Align the mark on the oil pump drive gear with the mark on the timing gear case.

    7. A01DW4JE02

      Install the timing gear case with the union bolt and 8 bolts.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf, for union bolt (A) }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for bolt }
    8. A01E2YEE01

      Remove the screw plug.

    9. Pour in approximately 20 cc (0.12 cu in.) of engine oil into the oil pump.

    10. Install a new gasket and the screw plug.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  20. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  21. INSTALL OIL PAN SUB-ASSEMBLY

    A01E0W7E01

    1. Remove any old packing (FIPG) material.

    2. Apply seal packing to the oil pan as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note

      Install the oil pan within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

    3. Install the oil pan with the 22 bolts and 2 nuts.

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

    4. Install the oil level gauge sensor with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  22. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

    A01DVITE01

    1. Face the crankshaft timing gear with timing mark 1 facing forward.

    2. Align the set key on the crankshaft with the key groove of the crankshaft timing gear.

    3. Using SST and a hammer, tap in the timing gear.

      SST
      09223-00010

  23. INSTALL SUPPLY PUMP GEAR


    1. Install the supply pump with the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01E0Z5E01

      Align the "3" marks of the balance shaft driven gear No. 2 and supply pump gear.

    3. A01DVCYE01

      Install a new O-ring to the supply pump gear.

    4. A01DZIAE01

      Install the supply pump gear set nut.

    5. Using SST, tighten the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  24. INSTALL NO. 2 IDLE SUB GEAR

    A01DXWWE01

    1. Mount the No.1 idle gear in a vise.

      Tech Tips

      The cut-off mark of the idle gear faces down.

      Note

      Be careful not to damage the gear.

    2. A01DVE0E01

      Install the idle gear spring.

    3. Install the No. 2 idle sub-gear.

    4. Install the wave washer.

      Tech Tips

      Fit the pins on the gears to the spring ends.

    5. A01E1X4E01

      Using snap ring pliers, install the snap ring.

    6. A01DVQQE01

      Using SST, align the holes of the No. 1 idle gear and No. 2 idle sub gear by turning the No. 2 idle sub gear clockwise, and install a service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    7. Remove the No. 1 idle gear from the vise and turn it upside down.

  25. INSTALL NO. 1 IDLE SUB GEAR

    A01E0WOE01

    1. Mount the No. 1 idle gear and No. 2 idle sub gear in a vise.

      Note

      Be careful not to damage the gears.

    2. A01DXW3E01

      Remove the service bolt.

    3. A01DZ33E01

      Install the idle gear spring.

    4. Install the No. 1 idle sub gear.

    5. Install the wave washer.

      Tech Tips

      Fit the pins on the gears to the spring ends.

    6. A01DYSVE01

      Using a snap ring pliers, install the snap ring.

    7. A01E1I6E01

      Using SST, align the holes of the No. 1 idler gear and No. 1 idle sub gear by turning the No. 1 idle sub gear clockwise, and install the service bolt.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

  26. INSTALL NO. 1 IDLE GEAR

    A01DVPDE01

    1. Install the gear shaft as shown in the illustration.

    2. A01DW82E01

      Align the "5" timing marks of the idle gear and crankshaft timing gear.

    3. Using SST, turn the supply pump gear, and align the "4" timing marks of the idle gear and supply pump gear, and mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    4. A01DZ74E02

      Face the thrust plate with the protrusion facing forward.

    5. Align the bolt holes, and install the thrust plate with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

    6. Remove the service bolt.

  27. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    A01DW5HE01

    1. Align the set key with the key groove of the sensor plate.

    2. Install the sensor plate, facing the cup side outward.

  28. INSTALL TIMING GEAR CASE ASSEMBLY


    1. Remove any old packing (FIPG) material.

    2. A01DVM3E01

      Apply seal packing to the timing gear cover as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      3 to 5 mm (0.12 to 0.20 in.)

      Note

      Install the timing gear case within 3 minutes and tighten its bolts within 15 minutes as soon as applying FIPG is completed.

    3. A01DYKIE01

      Install a new O-ring to the timing gear case.

    4. A01E28YE01

      Install the timing gear cover with the 14 bolts and 2 nuts.

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

  29. INSTALL WATER PUMP ASSEMBLY

    A01DWA8

    1. Install a new gasket and the water pump with the 5 bolts and 2 nuts.

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

  30. INSTALL CYLINDER HEAD GASKET


    1. A01E1XTE01

      Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

    2. A01DWGGE01

      Measure the piston protrusion of each cylinder at 2 points as shown in the illustration.

    3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

      Piston protrusion
      0.005 to 0.255 mm (0.0002 to 0.0100 in.)

      Tech Tips

      When removing the piston and connecting rod assembly: If the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01DXBTE01

      Select a new cylinder head gasket.

      Tech Tips

      New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

      New installed cylinder head gasket thickness
      Mark Thickness
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)

      1. Select the largest piston protrusion value from the measurements made. Then select a new appropriate gasket according to the table below.

        Use gasket size
        Gasket Size Piston Protrusion
        Use A 0.005 to 0.054 mm (0.0002 to 0.0021 in.)
        Use B 0.055 to 0.104 mm (0.0022 to 0.0041 in.)
        Use C 0.105 to 0.154 mm (0.0041 to 0.0061 in.)
        Use D 0.155 to 0.204 mm (0.0061 to 0.0080 in.)
        Use E 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
    5. A01E1R6E01

      Place the cylinder head on the cylinder block.


      1. Place the cylinder head gasket on the cylinder block.

        Note

        Be careful of the installation direction.

  31. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • If any bolt is broken or deformed, replace it.


    1. Place the cylinder head on the cylinder head gasket.

    2. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

    3. A01E12RE01

      Install and uniformly tighten the 18 cylinder head bolts, in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt length A
      110 mm (4.33 in.)
      Bolt length B
      167 mm (6.57 in.)

      If any of the cylinder head bolts does not meet the torque specification, replace it.

    4. A01DYXOE02

      Mark the front of the cylinder head bolts with paint.

    5. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

    6. Finally, tighten the cylinder head bolts by an additional 90°.

    7. Check that the painted marks are now facing rearward.

  32. INSTALL CAMSHAFT

    A01E2S9E01

    1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    2. A01DXL7E01

      Install the camshaft.


      1. Apply MP grease to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head, facing the key groove upward.

      3. A01DV15E01

        Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

    3. A01DYANE02

      Remove any old packing (FIPG) material from the camshaft bearing cap.

    4. Apply seal packing to the specified areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note


      • Do not allow FIPG to contact the oil passage of the bearing cap.

      • After applying FIPG, install the camshaft bearing caps within 3 minutes and fasten the bolts within 15 minutes.

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


      1. A01E2XHE01

        Install the 5 bearing caps in their proper locations.

      2. A01E0JJE02

        Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

      3. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

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

    5. Install the camshaft oil seal.

  33. INSPECT VALVE CLEARANCE


    1. Remove the injector.

    2. Remove the timing belt.

    3. Remove the camshaft timing pulley.

    4. Remove the No. 2 timing belt cover.

    5. Remove the camshafts.

    6. Remove the valve lifters.

    7. A01DVS9E01

      Using a micrometer, measure the thickness of the removed lifter.

    8. Calculate the thickness of a new lifter so that the valve clearance is within the specified range.

      A B C
      New lifter thickness Used lifter thickness Measured valve clearance
      New lifter thickness
      Intake A = B + (C - 0.25 mm (0.0098 in.))
      Exhaust A = B + (C - 0.40 mm (0.00158 in.))

    9. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips

      Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

      A01DWV3E01
      A01DZ1SE01
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a No. 40 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
      A01DUZHE01
      A01DYK2E01
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) lifter with a No. 42 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -

    10. Install the selected valve lifter.

    11. Install the camshaft.

    12. Install the No. 2 timing belt cover.

    13. Install the camshaft timing pulley.

    14. Install the timing belt.

    15. Install the fuel injector.

  34. ADJUST VALVE CLEARANCE


    1. Remove the injector.

    2. Remove the timing belt.

    3. Remove the camshaft timing pulley.

    4. Remove the No. 2 timing belt cover.

    5. Remove the camshafts.

    6. Remove the valve lifters.

    7. A01DVS9E01

      Using a micrometer, measure the thickness of the removed lifter.

    8. Calculate the thickness of a new lifter so that the valve clearance is within the specified range.

      A B C
      New lifter thickness Used lifter thickness Measured valve clearance
      New lifter thickness
      Intake A = B + (C - 0.25 mm (0.0098 in.))
      Exhaust A = B + (C - 0.40 mm (0.00158 in.))

    9. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips

      Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

      A01DWV3E01
      A01DZ1SE01
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      A 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) lifter with a No. 40 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -
      A01DUZHE01
      A01DYK2E01
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      A 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) lifter with a No. 42 lifter.
      New Lifter Thickness
      Lifter No. Specified Condition Lifter No. Specified Condition Lifter No. Specified Condition
      06 5.060 mm (0.1992 in.) 30 5.300 mm (0.2087 in.) 54 5.540 mm (0.2181 in.)
      08 5.080 mm (0.2000 in.) 32 5.320 mm (0.2094 in.) 56 5.560 mm (0.2189 in.)
      10 5.100 mm (0.2008 in.) 34 5.340 mm (0.2102 in.) 58 5.580 mm (0.2197 in.)
      12 5.120 mm (0.2016 in.) 36 5.360 mm (0.2110 in.) 60 5.600 mm (0.2205 in.)
      14 5.140 mm (0.2024 in.) 38 5.380 mm (0.2118 in.) 62 5.620 mm (0.2213 in.)
      16 5.160 mm (0.2031 in.) 40 5.400 mm (0.2126 in.) 64 5.640 mm (0.2220 in.)
      18 5.180 mm (0.2039 in.) 42 5.420 mm (0.2134 in.) 66 5.660 mm (0.2228 in.)
      20 5.200 mm (0.2047 in.) 44 5.440 mm (0.2142 in.) 68 5.680 mm (0.2236 in.)
      22 5.220 mm (0.2055 in.) 46 5.460 mm (0.2150 in.) 70 5.700 mm (0.2244 in.)
      24 5.240 mm (0.2063 in.) 48 5.480 mm (0.2157 in.) 72 5.720 mm (0.2252 in.)
      26 5.260 mm (0.2071 in.) 50 5.500 mm (0.2165 in.) 74 5.740 mm (0.2260 in.)
      28 5.280 mm (0.2079 in.) 52 5.520 mm (0.2173 in.) - -

    10. Install the selected valve lifter.

    11. Install the camshaft.

    12. Install the No. 2 timing belt cover.

    13. Install the camshaft timing pulley.

    14. Install the timing belt.

    15. Install the fuel injector.

  35. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install the injector, No. 1 nozzle holder clamp, washer and bolt in their original positions.


    1. A01DYB9E01

      Install 4 new injection nozzle seats to the cylinder head.

    2. Apply a small amount of clean engine oil to 4 new O-rings.

    3. A01E0HXE07

      Install an O-ring to each injector as shown in the illustration.

    4. Insert the 4 injectors into the cylinder head.

      Note


      • Insert the injector until it touches the injection nozzle seats surface.

      • After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.

      • Always return an injector to the same place it was removed from.

    5. For an injector that has been replaced with a new injector, register the injector compensation code Click here.

    6. A01DWZ6E05

      Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

      Tech Tips

      Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.

      Note


      • A01DV3XE04

        The fork portion of the nozzle holder clamp must be set to the injector.

      • Before tightening the bolts, check that the No. 1 nozzle holder clamp is set properly.

      • To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at the following step.

      • When tightening the bolts, pay attention not to tilt the bolt and the clamp.

      • Do not reuse the washer.

      • If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

    7. Temporarily install the 4 injection pipes with the union nuts.

      Tech Tips

      To position the injectors, loosely tighten the union nut.

    8. A01E2T3E01

      Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.

      If scratches or dents are present, replace the nozzle leakage pipe.

    9. A01DVA2E04

      Set the leakage pipe and 5 new gaskets in place.

    10. Apply a small amount of oil to the 4 injector hollow screws and union bolt.

    11. A01DZ37E03

      Temporarily install the leakage pipe with the 4 injector hollow screws and union bolt.

    12. Tighten the 4 holder clamp bolts.

      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    13. A01DVZRE04

      Tighten the 4 injector hollow screws in order from 1 to 4.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note

      If an injector hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

    14. Tighten the union bolt.

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

      Note

      If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

    15. Remove the 4 injection pipes.

  36. CHECK FOR FUEL LEAKS


    1. A01E0SLE03

      Check that there are no leaks from the nozzle leakage pipe connection.


      1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

        Part No.
        23762-27010 (No. 2 nozzle leakage pipe)
        SST
        09280-00010
        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.

      3. A01DX5HE02

        Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 100 kPa (1.0 kgf/cm2, 14.5 psi) of pressure for 60 seconds to check that no bubbles form.

        SST
        09992-00242

        Note

        Before checking the leakage, be sure to remove the ball and spring in the check valve.

      4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

      5. Remove SST, No. 2 nozzle leakage pipe and gasket.

        Note

        Never reinstall the disassembled check valve on the engine.

  37. INSTALL CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


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

  38. INSTALL NO. 2 TIMING BELT COVER


    1. A01E1J8E01

      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 FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

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

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

  39. INSTALL CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      Install the camshaft timing pulley.

    2. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

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

  40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DZAXE01

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover in the directions shown in the illustration.

      Note


      • Do not install the No. 3 cylinder head cover gaskets at an angle.

      • Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.

    2. Remove any old seal packing (FIPG) material from the cylinder head.

    3. A01E1YSE03

      Apply seal packing to the specific areas shown in the illustration.

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

      Note


      • Remove any oil from the contact surface.

      • Install the head cover within 3 minutes after applying seal packing.

      • Do not start the engine for at least 2 hours after installing the seal packing.

    4. Install a new cylinder head cover gasket and the cylinder head cover with the 10 bolts and 2 nuts.

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

    5. Install 4 new nozzle holder seals.

    6. Connect the ventilation hose.

    7. Connect the 4 connectors and install the 3 bolts.

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

  41. INSTALL NOZZLE HOLDER SEAL


    1. Install 4 new nozzle holder seals.

  42. INSTALL OIL FILLER CAP SUB-ASSEMBLY