ENGINE UNIT (for DPF) 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.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. INSTALL STUD BOLT

    Tech Tips

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


    1. Install the stud bolts.

      A01E23VE01
      Text in Illustration
      *a Front Side *b Left Side
      *c Oil Pan Side *d Right Side

  2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


    1. A01E0H9E01

      Align the pin of the No. 1 oil nozzle with the pin hole of the cylinder block.

    2. Install the 4 No. 1 oil nozzles with the 4 check valves.

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

  3. INSTALL PISTON WITH PIN SUB-ASSEMBLY


    1. A01DVXUE01

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

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

    3. Coat the piston pin with engine oil.

    4. A01DYFUE01
      Text in Illustration
      *1 Front Mark (Arrow)
      *2 Front Mark (Protrusion)

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

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

    6. A01E2PE

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

  4. INSTALL PISTON RING SET


    1. A01E2AOE01
      Text in Illustration
      *1 Coil Joint
      *2 Oil Ring End Gap

      Install the coil and oil ring by hand.

      Tech Tips

      Make sure the end gap of the oil ring and the coil joint are on opposite sides.

    2. A01DZUNE01
      Text in Illustration
      *1 No. 1 Piston Ring
      *2 No. 2 Piston Ring

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

      Code Mark
      Ring Code Mark
      No. 1 Piston Ring 1VN
      No. 2 Piston Ring N2
    3. A01E248E01
      Text in Illustration
      *1 No. 1 Piston Ring
      *2 Oil Ring
      *3 Coil
      *4 No. 2 Piston Ring
      *5 Front Mark (Arrow)

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

      Note

      Do not align the ring ends.

  5. 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. A01DV1HE01

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

  6. INSTALL CRANKSHAFT

    A01E1TUE02

    1. Place the crankshaft on the cylinder block.

    2. Push the crankshaft in one direction and install one thrust washer to the No. 5 journal position with the oil groove facing outward.

    3. Push the crankshaft in the opposite direction and install the other thrust washer to the No. 5 journal position with the oil groove facing outward.

    4. A01DVC3E03

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

    5. A01DZCNE01

      Install the 5 crankshaft bearing caps to their proper locations.

    6. A01DVTVE07

      Install the crankshaft bearing cap bolts.

      Tech Tips


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

      • If a crankshaft 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 crankshaft bearing cap bolts.

      2. Install and uniformly tighten the 10 bolts of the crankshaft 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. A01DW4ZE08
        Text in Illustration
        *1 Painted Mark
        *a Front

        Mark the front of each crankshaft bearing cap bolt with paint.

      4. Tighten the crankshaft bearing cap bolts by 90° in the numerical order shown in the previous illustration.

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

    7. Check that the crankshaft turns smoothly.

    8. Check the crankshaft thrust clearance.

  7. INSTALL CONNECTING ROD BEARING


    1. A01DZS0E01

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

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

  8. INSPECT CRANKSHAFT THRUST CLEARANCE

    A01DWAFE01

    1. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

      Standard thrust clearance
      0.04 to 0.24 mm (0.0016 to 0.0094 in.)
      Maximum thrust clearance
      0.3 mm (0.0118 in.)

      If the thrust clearance is more than the maximum, replace the thrust washers as a set.

      Standard Thrust Washer Thickness
      Item Specified Condition
      STD 2.430 to 2.480 mm (0.0957 to 0.0976 in.)
      O/S 0.125 2.555 to 2.605 mm (0.1006 to 0.1026 in.)
      O/S 0.250 2.680 to 2.730 mm (0.1055 to 0.1074 in.)

  9. INSTALL PISTON AND CONNECTING ROD


    1. Apply engine oil to the cylinder walls, the pistons and the surfaces of the connecting rod bearings.

    2. Check the positions of the piston ring ends.

    3. A01DYKQE01
      Text in Illustration
      *1 Front Mark (Arrow)

      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.

    4. A01DVAWE01

      Place the connecting rod cap on the connecting rod.


      1. Match each numbered connecting rod cap with the correct 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. A01DX3JE02
        Text in Illustration
        *1 Front Mark (Protrusion)
        A01E2TX Front

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

    5. 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 coat of engine oil to 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 }

        Tech Tips

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

      3. A01DYYDE05
        Text in Illustration
        *1 Painted Mark
        *a Front

        Mark the front of each connecting rod cap bolt with paint.

      4. Tighten the connecting rod cap bolts by 90° as shown in the illustration.

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

    6. Check that the crankshaft turns smoothly.

  10. INSPECT CONNECTING ROD THRUST CLEARANCE

    A01DX8YE01

    1. Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth.

      Standard thrust clearance
      0.100 to 0.300 mm (0.0039 to 0.0118 in.)
      Maximum thrust clearance
      0.40 mm (0.0157 in.)

      If the thrust clearance is more than the maximum, replace the connecting rod assembly. If necessary, replace the crankshaft.

  11. INSTALL CYLINDER BLOCK OIL ORIFICE

  12. INSTALL REAR CRANKSHAFT OIL SEAL


    1. A01DZ7VE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear engine oil seal retainer edge.

      SST
      09518-36030
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

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

  13. INSTALL SUPPLY PUMP OIL SEAL


    1. A01DVQ3E02

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST
      09223-15020
      09502-12010
      09950-70010   ( 09951-07100 )

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

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

  14. INSTALL FRONT CRANKSHAFT OIL SEAL


    1. A01E15ZE01

      Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing gear cover edge.

      SST
      09214-76011

      Note


      • Keep the lip free from foreign matter.

      • Do not tap the oil seal at an angle.

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

  15. INSTALL REAR ENGINE OIL SEAL RETAINER


    1. Remove any old seal packing (FIPG material) from the oil pan and cylinder block.

    2. A01E22OE01
      Text in Illustration
      *1 Seal Packing

      Apply seal packing to the places shown in the illustration.

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

      Note

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

    3. Install the rear engine oil seal retainer with the 5 bolts. Alternately tighten the 5 bolts in several passes.

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

  16. INSTALL TIMING GEAR CASE ASSEMBLY


    1. A01E2GZE04
      Text in Illustration
      *1 New O-Ring

      Install 2 new O-rings to the cylinder block.

    2. A01E1H1E01
      Text in Illustration
      *1 New Gasket

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

    3. Remove any old seal packing (FIPG material).

    4. A01E2ASE05
      Text in Illustration
      *1 Seal Packing

      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
      4 mm (0.157 in.)

      Note

      After applying seal packing, install the timing gear case assembly within 3 minutes and tighten the bolts within 15 minutes.

    5. A01DXR2E01

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

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

  17. 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 }

  18. INSTALL OIL PAN SUB-ASSEMBLY


    1. A01E0W7E03

      Remove any old seal 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 packing diameter
      4 mm (0.157 in.)

      Note

      After applying seal packing, install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes.

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

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

  19. INSTALL ENGINE OIL LEVEL SENSOR


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

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

  20. INSTALL INJECTION GEAR


    1. Install a new O-ring and the fuel supply pump with the 2 nuts.

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

    2. Temporarily install the injection gear with the nut.

      Tech Tips

      Fit the key (protrusion) of the fuel supply pump into the key slot of the injection gear.

    3. A01DWZSE02
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the injection gear.

    4. A01DZIAE02

      Install the injection gear set nut.

    5. Using SST, tighten the set nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  21. INSTALL CRANKSHAFT TIMING GEAR

    A01DVITE01

    1. Position the crankshaft timing gear with the "1" timing marks facing forward.

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

    3. Using SST and a hammer, tap on the timing gear to install it.

      SST
      09223-00010

  22. INSTALL NO. 1 IDLE GEAR SHAFT


    1. A01DWZ3E01
      Text in Illustration
      *1 Engine Oil

      Apply a coat of engine oil to the No. 1 idle gear shaft.

    2. A01DVPDE07
      Text in Illustration
      *1 Oil Hole

      Install the gear shaft as shown in the illustration.

  23. INSTALL NO. 2 IDLE SUB GEAR


    1. A01E12GE01

      Using a cloth or equivalent, mount the No. 1 idle gear in a vise as shown in the illustration.

      Note

      Be careful not to damage the gear.

    2. A01DXLPE02
      Text in Illustration
      *1 Wave Washer
      *2 No. 2 Idle Sub Gear
      *3 Gear Spring
      *4 Pin

      Install the gear spring.

    3. Install the No. 2 idle sub gear.

      Tech Tips

      Align the pins on the gears with the spring ends.

    4. Install the wave washer.

    5. Using snap ring pliers, install the snap ring.

    6. A01E16CE03
      Text in Illustration
      *1 Service Bolt
      *2 No. 1 Idle Gear
      *3 No. 2 Idle Sub Gear
      A01E2TX Turn

      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 temporarily install a service bolt.

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

    7. Align the gear teeth of the No. 1 idle gear and No. 2 idle sub gear and tighten the service bolt.

  24. INSTALL NO. 1 IDLE GEAR


    1. A01DW82E04
      Text in Illustration
      *a Turn

      Align the "4" and "5" timing marks of the idle gear and crankshaft timing gear.

    2. Using SST, turn the injection gear and align the "4" timing marks of the idle gear and injection gear, and then mesh the gears.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
    3. A01DZQ6E02
      Text in Illustration
      *1 Service Bolt

      Position the idle gear thrust plate with the protrusion facing forward.

    4. Align the bolt holes and install the idle gear thrust plate with the 2 bolts.

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

    5. Remove the service bolt.

  25. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    1. Align the key groove of the No. 1 crankshaft position sensor plate with the set key.

    2. Install the No. 1 crankshaft position sensor plate with the cupped side facing outward.

  26. INSTALL TIMING GEAR COVER


    1. Remove any old seal packing (FIPG material).

    2. A01DWHEE01
      Text in Illustration
      *1 Seal Packing

      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
      4 mm (0.157 in.)

      Note

      After applying seal packing, install the timing gear cover within 3 minutes and tighten the bolts within 15 minutes.

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

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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    5. A01E1MW

      Remove the screw plug and gasket.

    6. Pour approximately 50 cc (3.05 cu. in.) of engine oil into the oil pump.

    7. Install a new gasket and the screw plug.

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

    8. Install the vacuum transmitting pipe with the bolt.

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

  27. INSTALL WATER PUMP ASSEMBLY


    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 }

  28. INSTALL CYLINDER HEAD GASKET


    1. A01E1XTE02
      Text in Illustration
      *1 Measuring Tip
      *2 Protrusion

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

    2. A01DWGGE02
      Text in Illustration
      *1 Measuring Point

      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

      After installing the piston and connecting rod assembly, if the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01DXBTE02
      Text in Illustration
      *1 Cutout Mark
      A01E2TX Front

      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 Cylinder Head Gasket Thickness
      Mark Specified Condition
      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 gasket according to the table below.

        Gasket Size
        Item Specified Condition
        Piston protrusion 0.005 to 0.054 mm (0.0002 to 0.0021 in.) 0.055 to 0.104 mm (0.0022 to 0.0041 in.) 0.105 to 0.154 mm (0.0041 to 0.0061 in.) 0.155 to 0.204 mm (0.0061 to 0.0080 in.) 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
        Gasket to be used A B C D E
    5. A01E1R6E02

      Place the cylinder head gasket on the cylinder block.

      Text in Illustration
      A01E2TX Front

      Note

      Make sure the gasket is installed facing the proper direction.

  29. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01E12RE01

    Tech Tips


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

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


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

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

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

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

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

    4. A01DYXOE03
      *1 Painted Mark
      *a Front

      Mark the front of each cylinder head bolt with paint.

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

    6. Tighten the cylinder head bolts by an additional 90°.

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

  30. INSTALL VALVE LIFTER


    1. Install the valve lifters.

    2. Check that each valve lifter rotates smoothly by hand.

  31. INSTALL CAMSHAFT


    1. A01E2S9E02
      Text in Illustration
      *1 Key

      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 prevent the top of the piston from hitting against the valve head.

    2. A01DXL7E04

      Install the camshaft.


      1. Apply engine oil to the thrust portion of the camshaft.

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

        Text in Illustration
        *1 Key Groove
        *a Upward
      3. A01DV15E01

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

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

    4. A01DYANE05
      Text in Illustration
      *1 Seal Packing
      *2 Oil Passage

      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 seal packing to contact the oil passage of the bearing cap.

      • After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

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

    5. A01E2XHE01

      Install the 5 bearing caps to their proper locations.

    6. A01E0JJE02

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

    7. 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 }
    8. A01DV44E01

      Install a new camshaft oil seal.


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

      2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.

        SST
        09608-06041

  32. INSTALL CYLINDER BLOCK INSULATOR


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

  33. INSTALL NO. 2 TIMING BELT COVER


    1. A01E1J8E02
      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 }

  34. 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 }

  35. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  36. INSTALL INJECTOR ASSEMBLY

    Note

    Be sure to install each injector, No. 1 nozzle holder clamp, washer and bolt in its original position.


    1. A01E0TP

      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. A01DYU7E01
      Text in Illustration
      *1 New O-Ring

      Install one of the O-rings 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 seat surface.

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

      • Always reinstall 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. A01DV1AE02
      Text in Illustration
      *1 Washer
      *a Downward

      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.

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

      Tech Tips

      To position the injectors, loosely tighten the union nuts.

    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. A01DWSME03
      Text in Illustration
      *1 Union Bolt

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

    12. Tighten the 4 nozzle holder clamp bolts.

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

    13. Remove the 4 injection pipes.

    14. A01DZ18E05
      Text in Illustration
      *1 Union Bolt

      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.

    15. 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.

  37. INSPECT FOR FUEL LEAK


    1. A01DVWLE01

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


      1. Install a new gasket and the 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. A01DWUUE01

        Install SST (turbocharger pressure gauge) to the fuel return side of the nozzle leakage pipe, maintain 100 kPa (1.0 kgf/cm2, 15 psi) of pressure for 60 seconds and check that no bubbles form.

        SST
        09992-00242

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

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

        Note

        Never reinstall the disassembled union bolt to the engine.

  38. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DX5RE01
      Text in Illustration
      *1 No. 3 Cylinder Head Cover Gasket
      *2 Cylinder Head Cover

      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. A01E2KS

      Apply seal packing to the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Text in Illustration
      A01DWGY Seal Packing

      Note


      • Remove any oil from the contact surface.

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

      • Do not start the engine for at least 2 hours after installing the cylinder head cover.

    4. Install a new cylinder head cover gasket to the cylinder head cover.

    5. A01DYWGE01

      Temporarily install the cylinder head cover with the 10 bolts and 2 nuts in the order shown in the illustration. Then, tighten the 10 bolts and 2 nuts in the order shown in the illustration in 2 progressive steps.

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

    6. Connect the ventilation hose.

    7. Install 4 new nozzle holder seals.

  39. INSTALL OIL FILLER CAP SUB-ASSEMBLY