ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note
Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block sub-
assembly, cylinder head, crankshaft, connecting rod sub-assembly, camshaft and other parts.
When replacing an injector assembly (including interchanging injector assemblies between cylinders), common rail assembly,
cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.

PROCEDURE
1. SELECT NO. 2 CYLINDER HEAD GASKET
Click here

2. INSTALL NO. 2 CYLINDER HEAD GASKET

Click here

3. INSTALL CYLINDER HEAD LH

a. Place the cylinder head LH on the No. 2 cylinder head gasket.

Note
Ensure that no oil is on the mounting surface of the cylinder head LH.
b. Inspect the cylinder head bolts Click here.
c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
d. Step 1:
i. Install and uniformly tighten the 10 cylinder
head bolts with the spacers in several steps, in
the sequence shown in the illustration.
Torque:
80 N*m { 816 kgf*cm, 59 ft.*lbf }

Tech Tips
The cylinder head bolts are tightened in 4
progressive steps.
If a cylinder head bolt is broken or deformed,
replace it.

e. Step 2:
i. Mark the cylinder head bolt heads with paint
as shown in the illustration.
 ii. Tighten the cylinder head bolts 90° in the
sequence shown in step 1.

Text in Illustration

*a Painted Mark

Front

f. Step 3:
i. Tighten the cylinder head bolts another 90° in
the sequence shown in step 1.

Text in Illustration

*a Painted Mark

Front

g. Step 4:
i. Tighten the cylinder head bolts by an
additional 90° in the sequence shown in step 1.
h. Check that the painted marks are now facing the
exhaust port side.

Text in Illustration

*a Painted Mark
 Front

4. INSTALL NO. 2 VALVE LASH ADJUSTER ASSEMBLY

Note
Be sure to inspect the valve lash No. 2 valve lash adjuster assembly before installing it Click here.
a. Install the 16 No. 2 valve lash adjuster assemblies to the cylinder head LH.

Tech Tips
Install the lash adjuster at the same place it was removed from.

5. INSTALL NO. 2 VALVE ROCKER ARM SUB-ASSEMBLY

a. Apply engine oil to the No. 2 valve lash adjuster

assembly tips and valve stem ends.
b. Install the 16 No. 2 valve rocker arm sub-assemblies
as shown in the illustration.

Tech Tips
Install the No. 2 valve rocker arm sub-assembly at the same
place it was removed from.

6. INSTALL NO. 5 CAMSHAFT BEARING CAP

a. Align the No. 5 camshaft bearing cap and the ring pins of the cylinder head LH, and install the No. 5
camshaft bearing cap.

7. SELECT NO. 1 CYLINDER HEAD GASKET

Click here

8. INSTALL NO. 1 CYLINDER HEAD GASKET

 Click here

9. INSTALL CYLINDER HEAD SUB-ASSEMBLY

a. Place the cylinder head sub-assembly on the No. 1 cylinder head gasket.

Note
Ensure that no oil is on the mounting surface of the cylinder head sub-assembly.
b. Inspect the cylinder head bolts Click here.
c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
d. Step 1:
i. Install and uniformly tighten the 10 cylinder
head bolts with the spacers in several steps, in
the sequence shown in the illustration.
Torque:
80 N*m { 816 kgf*cm, 59 ft.*lbf }

Tech Tips
The cylinder head bolts are tightened in 4
progressive steps.
If a cylinder head bolt is broken or deformed,
replace it.

e. Step 2:
i. Mark the cylinder head bolt heads with paint
as shown in the illustration.
ii. Tighten the cylinder head bolts 90° in the
sequence shown in step 1.

Text in Illustration

*a Painted Mark

Front

f. Step 3:
i. Tighten the cylinder head bolts another 90° in
the sequence shown in step 1.
 Text in Illustration

*a Painted Mark

Front

g. Step 4:
i. Tighten the cylinder head bolts by an
additional 90° in the sequence shown in step 1.
h. Check that the painted marks are now facing the
intake port side.

Text in Illustration

*a Painted Mark

Front

10. INSTALL NO. 1 VALVE LASH ADJUSTER ASSEMBLY

Note
Be sure to inspect the No. 1 valve lash adjuster assembly before installing it Click here.
a. Install the 16 No. 1 valve lash adjuster assemblies to the cylinder head sub-assembly.

Tech Tips
Install the No. 1 valve lash adjuster assembly at the same place it was removed from.

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

a. Apply engine oil to the No. 1 valve lash adjuster

assembly tips and valve stem ends.
b. Install the 16 No. 1 valve rocker arm sub-assemblies
as shown in the illustration.

Tech Tips
 Install the No. 1 valve rocker arm sub-assemblies at the
same place it was removed from.

12. INSTALL NO. 2 CAMSHAFT BEARING CAP

a. Align the No. 2 camshaft bearing cap and the ring pins of the cylinder head sub-assembly, and install the No.
2 camshaft bearing cap.

13. SET NO. 1 CYLINDER TO 45° BEFORE TDC

a. Using a bar, turn the crankshaft counterclockwise

until the No. 1 cylinder is at a position 45° before TDC.

Note
Do not turn the crankshaft again until after the timing gear
is installed.

Tech Tips
The No. 1 cylinder is at a position 45° before TDC if the
crankshaft counterweight is overlapping the cylinder block
sub-assembly hole as shown in the illustration.
b. Remove the 2 crankshaft pulley set bolts.
14. INSTALL NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT

a. Add more than 19 cc (1.16 cu. in.) of engine oil into

the cylinder head sub-assembly side oil holes.

b. Apply engine oil to the rollers of the No. 1 valve rocker

arm sub-assemblies and the camshaft housing of the
cylinder head sub-assembly.

c. Install the No. 1 camshaft and No. 2 camshaft.

i. Apply engine oil to the camshaft journals,
lobes, thrust portion and No. 1 camshaft timing
gear and No. 2 camshaft timing gear.
ii. Align the timing marks (2 dot marks) on the
back side of the No. 1 camshaft timing gear
and No. 2 camshaft timing gear as shown in
the illustration.
iii. Place the No. 1 camshaft and No. 2 camshaft
into the cylinder head sub-assembly.

Note
Before and after setting the No. 1 camshaft and No.
2 camshaft, firmly set the No. 1 valve rocker arm
sub-assemblies to the No. 1 valve lash adjuster
assemblies.
d. Install the No. 1 camshaft bearing cap.
i. Align the No. 1 camshaft bearing cap and the
ring pins of the No. 2 camshaft bearing cap.
ii. Temporarily install the 4 bolts by hand.

e. Install the 8 No. 3 camshaft bearing caps.

i. Confirm the marks and numbers on the No. 3
camshaft bearing caps and place them in their
proper position and direction.
ii. Temporarily install the 8 bolts, which are not
installed with the No. 1 camshaft oil feed pipe
sub-assembly and No. 2 camshaft oil feed pipe
sub-assembly, by hand.

f. Temporarily install the No. 1 camshaft oil feed pipe

sub-assembly and No. 2 camshaft oil feed pipe sub-
assembly with the 8 bolts by hand.

Note
If even one of the camshaft oil feed pipe sub-assembly bolt
holes does not match its camshaft bearing cap bolt hole,
 replace the camshaft oil feed pipe sub-assembly.

Tech Tips
The camshaft oil feed pipe sub-assembly is bent on the
intake side, and straight on the exhaust side.

g. Temporarily install the 2 union bolts by hand.

h. Uniformly tighten the 20 bolts in several steps in the

order shown in the illustration.
Torque:
for 12 mm head bolt of No. 1 camshaft bearing cap
21 N*m { 214 kgf*cm, 15 ft.*lbf }
for 10 mm head bolt of No. 3 camshaft bearing cap
10 N*m { 102 kgf*cm, 7 ft.*lbf }

Text in Illustration

*a 12 mm Head Bolt

*b 10 mm Head Bolt

i. Tighten the 2 union bolts.

Torque:
17 N*m { 173 kgf*cm, 13 ft.*lbf }
 j. Remove the service bolt from the No. 1 camshaft
timing gear.

Note
Do not drop the service bolt into the engine.

15. INSTALL NO. 3 CAMSHAFT AND NO. 4 CAMSHAFT

a. Add more than 19 cc (1.16 cu. in.) of engine oil into

the cylinder head LH side oil holes.

b. Apply engine oil to the rollers of the No. 2 valve rocker

arm sub-assemblies and camshaft housing of the
cylinder head LH.

c. Install the No. 3 camshaft and No. 4 camshaft.

i. Apply engine oil to the camshaft journals,
lobes, thrust portion and No. 3 camshaft timing
gear and No. 4 camshaft timing gear.
 ii. Align the timing marks (1 dot mark) on the
back side of the No. 3 camshaft timing gear
and No. 4 camshaft timing gear as shown in
the illustration.
iii. Place the No. 3 camshaft and No. 4 camshaft
into the cylinder head LH.

Note
Before and after setting the No. 3 camshaft and No.
4 camshaft, firmly set the No. 2 valve rocker arm
sub-assemblies to the No. 2 valve lash adjuster
assemblies.

d. Install the No. 4 camshaft bearing cap.

i. Align the No. 4 camshaft bearing cap and the
ring pins of the No. 5 camshaft bearing cap.
ii. Temporarily install the 4 bolts by hand.
e. Install the 8 No. 3 camshaft bearing caps.
i. Confirm the marks and numbers on the No. 3
camshaft bearing caps and place them in their
proper position and direction.
ii. Temporarily install the 8 bolts, which are not
installed with the No. 3 camshaft oil feed pipe
sub-assembly and No. 4 camshaft oil feed pipe
sub-assembly, by hand.

f. Temporarily install the No. 3 camshaft oil feed pipe

sub-assembly and No. 4 camshaft oil feed pipe sub-
assembly with the 8 bolts by hand.

Note
If even one of the camshaft oil feed pipe sub-assembly bolt
holes does not match its camshaft bearing cap bolt hole,
replace the camshaft oil feed pipe sub-assembly.

Tech Tips
The camshaft oil feed pipe sub-assembly is bent on the
intake side, and straight on the exhaust side.

g. Temporarily install the 2 union bolts by hand.

h. Uniformly tighten the 20 bolts in several steps in the

order shown in the illustration.
Torque:
for 12 mm head bolt of No. 4 camshaft bearing cap
21 N*m { 214 kgf*cm, 15 ft.*lbf }
for 10 mm head bolt of No. 3 camshaft bearing cap
10 N*m { 102 kgf*cm, 7 ft.*lbf }
 Text in Illustration

*a 12 mm Head Bolt

*b 10 mm Head Bolt

i. Tighten the 2 union bolts.

Torque:
17 N*m { 173 kgf*cm, 13 ft.*lbf }

j. Remove the service bolt from the No. 4 camshaft

timing gear.

Note
Do not drop the service bolt into the engine.

16. INSTALL NO. 2 TIMING GEAR CASE INSULATOR

17. INSTALL NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

a. Install the No. 2 vacuum transmitting pipe sub-assembly with the 3 bolts.
Torque:
6.0 N*m { 61 kgf*cm, 53 in.*lbf }
18. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

a. Install the No. 1 vacuum transmitting pipe sub-assembly with the 2 bolts.
Torque:
6.0 N*m { 61 kgf*cm, 53 in.*lbf }

19. CONNECT NO. 3 VACUUM TRANSMITTING HOSE

20. CONNECT NO. 2 VACUUM TRANSMITTING HOSE

21. INSTALL TIMING GEAR CASE SUB-ASSEMBLY

Note
When the contact surfaces shown below are wet, wipe them with an oil-free cloth before applying seal packing.

Text in Illustration

*a Cylinder Block Sub-assembly *b Timing Gear Case Sub-assembly

a. Apply seal packing to the timing gear case sub-assembly as shown in the following illustration.

Standard seal diameter

4 to 5 mm (0.157 to 0.197 in.)

Seal packing

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

Note
After applying seal packing, align the timing gear case sub-assembly with the engine within 3 minutes and
tighten the bolts and nuts within 15 minutes.
Apply the seal packing in a continuous line.

Tech Tips
The FIPG line is shown below.
Apply packing to the 5 seal surface areas.
 Text in Illustration

*a Seal Diameter: 4 to 5 mm *b A-A

*c 2.5 mm (0.0984 in.) *d 2.0 mm (0.0787 in.)

b. Install a new timing gear case gasket.

c. Apply engine oil to 2 new O-rings and install them to
the timing gear case sub-assembly.

Text in Illustration

*1 Timing Gear Case Gasket

*2 O-Ring

d. Install the timing gear case sub-assembly with the 22

bolts and 2 nuts.
Torque:
for 14 mm head bolt (When "dry")
46 N*m { 469 kgf*cm, 34 ft.*lbf }
for 14 mm head bolt (When "wet")
 42 N*m { 428 kgf*cm, 31 ft.*lbf }
for 12 mm head bolt A and B
29 N*m { 296 kgf*cm, 21 ft.*lbf }
for nut
29 N*m { 296 kgf*cm, 21 ft.*lbf }

Note
The timing gear case sub-assembly is "dry" when
there is absolutely no engine oil on the 14 mm head
bolts and cylinder head bolt holes.
The timing gear case sub-assembly is "wet" when
there is engine oil on the 14 mm head bolts and
cylinder head bolt holes.
Bolt Length

Item Quantity Length

A 4 20 mm (0.787 in.)

B 8 45 mm (1.77 in.)

Text in Illustration

*1 Nut

*a 14 mm Head Bolt

*b 12 mm Head Bolt A

*c 12 mm Head Bolt B

22. INSTALL V-BANK SILENCER

a. Align the alignment areas of the V-bank silencer and cylinder block sub-assembly, and install the V-bank
silencer.

Note
Verify that the V-bank silencer is below the top surface of the intake port of the cylinder head sub-assembly and
cylinder head LH.

23. INSTALL FUEL SUPPLY PUMP ASSEMBLY

a. Using an 8 mm x 1.25 pitch tap, remove the adhesive

from the timing gear case sub-assembly side bolt hole.
 b. Apply adhesive to 2 or more threads of the timing gear
case sub-assembly bolt hole.

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or

equivalent

Text in Illustration

*a Adhesive

c. Apply engine oil to a new O-ring and install it to the

fuel supply pump assembly.
d. Install the fuel supply pump assembly to the timing
gear case sub-assembly.

Note
When installing the fuel supply pump assembly, do not hold
the fuel pipe to prevent fuel leaks.
i. Temporarily install the 2 nuts.
ii. Using a 6 mm hexagon wrench, install the
hexagon bolt, and then tighten the 2 nuts.
Torque:
21 N*m { 214 kgf*cm, 15 ft.*lbf } Text in Illustration

*1 O-Ring

24. INSTALL STRAIGHT PIN

a. Install the straight pin.

Standard protrusion height

4.5 to 7.0 mm (0.177 to 0.276 in.)

25. ASSEMBLE FUEL SUPPLY PUMP DRIVE GEAR AND FUEL SUPPLY PUMP SHAFT SPROCKET

a. Align the fuel supply pump drive gear to the fuel supply pump shaft sprocket straight pin and temporarily
install it with the 4 bolts.
b. Hold the fuel supply pump shaft sprocket in a vise between aluminum plates.

Note
Be careful not to damage the gears.
c. Tighten the 4 bolts.
Torque:
25 N*m { 250 kgf*cm, 18 ft.*lbf }

26. INSTALL RADIAL BALL BEARING

a. Using SST and a press, press in the radial ball bearing

to the fuel supply pump shaft sprocket.
SST
09316-12010
 09950-60010 ( 09951-00580 )

Note
Make sure to press in the radial ball bearing until the
radial ball bearing contacts the fuel supply pump
shaft sprocket, as shown in A in the illustration.
Make sure the fuel supply pump shaft sprocket outer
edge is further outward than the radial ball bearing
outer edge, as shown in B in the illustration.

Text in Illustration

*1 Radial Ball Bearing

*2 Fuel Supply Pump Shaft Sprocket

27. TEMPORARILY INSTALL FUEL SUPPLY PUMP DRIVE GEAR

a. Align the cutout of the fuel supply pump drive gear

and key of the fuel supply pump assembly, and
temporarily install the fuel supply pump drive gear
nut.

28. SET NO. 1 AND NO. 2 CAMSHAFTS TO TDC

a. Using a wrench, turn the No. 1 camshaft and align the

timing marks (1 dot mark) on the back side of the No.
1 camshaft timing gear and No. 2 camshaft timing
gear as shown in the illustration.
29. INSTALL NO. 1 IDLE GEAR SHAFT

a. Apply engine oil to the contact surface of the No. 1 idle

gear shaft and the back side of the protrusion.
b. Install the No. 1 idle gear shaft to the cylinder block
sub-assembly.

30. ASSEMBLE SUB GEAR, IDLE GEAR SPRING AND IDLE GEAR

a. Hold the idle gear in a vise between aluminum plates.

Note
Be careful not to damage the idle gears.

b. Align the right end of the idle gear spring to the notch
of the idle gear and set it to the idle gear.
c. Install the sub idle gear.
i. Align the notch of the sub idle gear protrusion
with the left end of the idle gear spring and
install the sub idle gear to the idle gear.

ii. Using SST, turn the sub idle gear

counterclockwise, and install an 8 mm x 1.25
pitch bolt with a length of 15 mm or more to
the service hole.
SST
09960-10010 ( 09962-01000, 09963-00700
)
Torque:
13 N*m { 133 kgf*cm, 10 ft.*lbf }
 Text in Illustration

*1 Service Bolt

31. INSTALL IDLE GEAR ASSEMBLY

a. Temporarily install the 2 crankshaft pulley set bolts to

the crankshaft.
b. Using a bar, turn the crankshaft clockwise to the No. 1
cylinder TDC position.

Text in Illustration

*1 Key

c. Align the timing marks of the fuel supply pump drive

gear and idle gear assembly, and the timing marks of
the crankshaft timing gear and idle gear as shown in
the illustration.
d. Apply engine oil to the idle gear thrust plate and
gears.
e. Install the idle gear thrust plate with the 2 bolts.
Torque:
47 N*m { 479 kgf*cm, 35 ft.*lbf }
f. Remove the service bolt.

32. TIGHTEN FUEL SUPPLY PUMP DRIVE GEAR NUT

a. Using SST, hold the idle gear assembly and tighten the
nut.
SST
09960-10010 ( 09962-01000, 09963-00700 )
Torque:
68 N*m { 693 kgf*cm, 50 ft.*lbf }
33. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

a. Check that the timing marks of the following pairs of parts are aligned: 1) supply pump drive gear and idle
gear: 2) crankshaft timing gear and idle gear: 3) RH and LH camshaft timing gears.
34. INSTALL NO. 2 CAMSHAFT TIMING SPROCKET AND NO. 2 TIMING CHAIN

a. Align the 2 mark plates (yellow) on the No. 2 timing chain with the timing mark (1 dot mark) of the No. 2
camshaft timing sprocket as shown in the illustration.
 b. Align the No. 2 timing chain mark plate (yellow) with
the supply pump drive gear timing mark, and
temporarily install the No. 2 camshaft timing sprocket
with the 4 bolts.
c. Using SST, hold the No. 2 camshaft timing sprocket,
and tighten the 4 bolts.
SST
09960-10010 ( 09962-01000, 09963-01000 )
Torque:
25 N*m { 250 kgf*cm, 18 ft.*lbf }

Text in Illustration

*a Timing Mark

35. INSTALL NO. 1 CAMSHAFT TIMING SPROCKET AND NO. 1 TIMING CHAIN

a. Align the 2 mark plates (yellow) on the No. 1 timing

chain with the timing mark (1 dot mark) of the No. 1
camshaft timing sprocket as shown in the illustration.
 b. Align the No. 1 timing chain mark plate (yellow) with
the supply pump drive gear timing mark, and
temporarily install the No. 1 camshaft timing sprocket.

Text in Illustration

*a Timing Mark

36. INSTALL PUMP DRIVE SHAFT GEAR

a. Temporarily install the pump drive shaft gear with the 4 bolts.
b. Using SST, hold the pump drive shaft gear and tighten the 4 bolts.
SST
09960-10010 ( 09962-01000, 09963-01000 )
Torque:
25 N*m { 250 kgf*cm, 18 ft.*lbf }

37. INSTALL NO. 2 CHAIN VIBRATION DAMPER

a. Install the No. 2 chain vibration damper with the 2 bolts.

Torque:
21 N*m { 214 kgf*cm, 15 ft.*lbf }
38. INSTALL NO. 2 CHAIN TENSIONER SLIPPER

39. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

a. Move the stopper plate clockwise to release the lock,

and push the plunger into the No. 2 chain tensioner
assembly.
b. Move the stopper plate counterclockwise to set the
lock, and insert a hexagon wrench into the stopper
plate hole.
c. Install the No. 2 chain tensioner assembly with the 2
bolts.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }
d. Remove the hexagon wrench.

40. INSTALL NO. 1 CHAIN VIBRATION DAMPER

a. Install the No. 1 chain vibration damper with the 2 bolts.

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

41. INSTALL NO. 1 CHAIN TENSIONER SLIPPER

42. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

a. Move the stopper plate clockwise to release the lock,

and push the plunger into the No. 1 chain tensioner
assembly.
b. Move the stopper plate counterclockwise to set the
lock, and insert a hexagon wrench into the stopper
plate hole.
c. Install the No. 1 chain tensioner assembly with the 2
bolts.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }
d. Remove the hexagon wrench.

43. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

a. Remove the adhesive from the threads of the 2 screws and the bolt holes of the crankshaft.
b. Apply adhesive to 2 or 3 threads of the 2 screws.

Adhesive

Toyota Genuine Adhesive 1344, Three Bond 1344 or

equivalent

c. Using a T30 "TORX" wrench, install the No. 1

crankshaft position sensor plate with the 2 screws.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }

Note
Make sure the "F" mark on the No. 1 crankshaft position
sensor plate is facing towards the front side of the engine. Text in Illustration
Tech Tips
 When replacing the No. 1 crankshaft position sensor plate,
perform "Crank Time Compensation Reset" Click here. *a Adhesive

44. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION

a. Temporarily install the 2 crankshaft pulley set bolts to the crankshaft.

b. Rotate the crankshaft 2 revolutions or more so that the crankshaft key is 45° counterclockwise from the
top. Check that the timing marks (1 dot mark each) of the RH and LH camshaft timing gears align. If not as
specified, turn the crankshaft 1 revolution (360°) and align the timing marks. If the timing marks are
deviated, reinstall the chain and camshaft.

Text in Illustration

*1 Key - -

*a Top - -

c. Remove the 2 crankshaft pulley set bolts.

45. INSTALL FRONT CRANKSHAFT OIL SEAL

a. Place the timing chain cover sub-assembly on wooden

blocks.
 b. Using SST and a hammer, tap in a new front
crankshaft oil seal as shown in the illustration.
SST
09316-12010
09950-70010 ( 09951-07100 )
09950-60020 ( 09951-00890 )

Standard depth A

0.6 to 1.4 mm (0.0236 to 0.0551 in.)

46. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

Note
When the contact surfaces shown below are wet, wipe them with an oil-free cloth before applying seal packing.

Text in Illustration

*1 Timing Gear Case Sub-assembly *2 Timing Chain Cover Sub-assembly

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

b. Apply seal packing to the timing chain cover sub-assembly as shown in the following illustration.

Standard seal diameter

4 to 5 mm (0.157 to 0.197 in.)

Seal packing

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

Note
After applying seal packing, align the timing chain cover sub-assembly with the timing gear case sub-assembly
within 3 minutes and tighten the bolts and nuts within 15 minutes.
Apply the seal packing in a continuous line.
 Make sure the seal packing does not become thinner than 4 mm (0.157 in.) at the areas labeled "B" in the
illustration below.

Tech Tips
The FIPG line is shown below.
Apply packing to the 6 seal surface areas.

Text in Illustration

*a Seal Diameter: 4 to 5 mm *b 2.0 mm (0.0787 in.)

*c 2.5 mm (0.0984 in.) *d A-A

c. Apply engine oil to the lip of the front crankshaft oil seal.
d. Align and install the timing chain cover sub-assembly to the timing gear case knock pin and supply pump
bearing.

Note
Make sure that the lip of the front crankshaft oil seal is properly installed.
e. If the stud bolts are loose, tighten them using an E7
"TORX" wrench.
Torque:
6.0 N*m { 61 kgf*cm, 53 in.*lbf }
 Text in Illustration

*1 Stud Bolt

f. Install and uniformly tighten the 16 bolts and 4 nuts in

the order shown in the illustration.
Torque:
25 N*m { 250 kgf*cm, 18 ft.*lbf }

Text in Illustration

*1 Nut

47. INSTALL TIMING CHAIN COVER PLATE

Click here

48. INSTALL ENGINE WATER PUMP ASSEMBLY

Click here

49. TEMPORARILY INSTALL INTAKE MANIFOLD

a. Install the gasket and temporarily install the No. 2

intake manifold with the 9 bolts.
 b. Install the gasket and temporarily install the No. 1
intake manifold with the 9 bolts.

c. Install the 2 gaskets and temporarily install the No. 3

intake manifold with the 16 bolts.
Bolt Length

Item Length

Bolt A 25 mm (0.984 in.)

Bolt B 70 mm (2.76 in.)

50. INSTALL FUEL INJECTOR LH (w/o DPF)

Note
Be sure to install the fuel injector LH, nozzle holder clamp and bolt in their original positions.
Before installing the fuel injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head LH and
fuel injector. If there is foreign matter, remove it before installing the fuel injector.
a. Install 4 new injection nozzle seats to the cylinder
head LH.
b. Apply a light coat of clean engine oil to 4 new O-rings.
c. Install an O-ring to each fuel injector LH as shown in
the illustration.
d. Insert the 4 fuel injectors into the cylinder head LH.

Note
Insert the fuel injector LH until it touches the nozzle
seat surface.
After installing the fuel injector LH to the cylinder
head, the O-ring may prevent the fuel injector LH
from fully seating. If so, pull out the fuel injector LH
and reinstall it.
Always return an fuel injector LH to the same place it
was removed from.
Text in Illustration
e. For an fuel injector LH that has been replaced with a
new fuel injector LH, register the injector *1 O-Ring
compensation code Click here.

f. Temporarily install 4 new washers and the 4 nozzle

clamps with the 4 clamp bolts.

Note
The fork portion of the nozzle holder clamp must be
set to the fuel injector LH.
Before tightening the bolts, check that the nozzle
holder clamps are set properly.
To tighten the clamp bolts, first tighten them by hand
until they cannot be turned further. Then, tighten the
bolts to the specified torque in a later step.
When tightening the bolts, pay attention not to tilt
the bolt and clamp.
Do not reuse the washer.

Text in Illustration

*1 Washer
 *2 Nozzle Holder Clamp

*a Downward

g. Temporarily install the common rail assembly LH with

the 2 bolts.

h. Temporarily install the 4 new injection pipes to the

common rail assembly LH and fuel injectors.

i. 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.
j. Set the nozzle leakage pipe and 5 new gaskets in
place.

Text in Illustration

*1 Nozzle Leakage Pipe

k. Temporarily install the nozzle leakage pipe with the 4

hollow screws and union bolt.

Tech Tips
To position the injectors, loosely tighten the 4 hollow screws
and union bolt.
 l. Tighten the 4 holder clamp bolts.
Torque:
25 N*m { 255 kgf*cm, 18 ft.*lbf }

m. Remove the 4 injection pipes.

n. Remove the 2 bolts and common rail assembly LH.

o. Tighten the 4 hollow screws.

Torque:
18 N*m { 184 kgf*cm, 13 ft.*lbf }

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

p. Tighten the union bolt.

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

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

51. INSTALL FUEL INJECTOR RH (w/o DPF)

Note
Be sure to install the fuel injector RH, nozzle holder clamp and bolt in their original positions.
Before installing the fuel injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head sub-
assembly and fuel injector. If there is foreign matter, remove it before installing the fuel injector.
a. Install 4 new injection nozzle seats to the cylinder
head sub-assembly.
b. Apply a light coat of clean engine oil to 4 new O-rings.

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

illustration.
d. Insert the 4 fuel injectors into the cylinder head sub-
assembly.

Note
Insert the fuel injector until it touches the injection
nozzle seat surface.
After installing the fuel injector to the cylinder head
sub-assembly, the O-ring may prevent the fuel
injector from fully seating. If so, pull out the injector
and reinstall it.
 Always return an fuel injector to the same place it Text in Illustration
was removed from.
*1 O-Ring
e. For an fuel injector that has been replaced with a new
fuel injector, register the fuel injector compensation
code Click here.
f. Temporarily install 4 new washers and the 4 nozzle
clamps with the 4 clamp bolts.

Note
The fork portion of the nozzle holder clamp must be
set to the fuel injector.
Before tightening the bolts, check that the nozzle
holder clamp is set properly.
To tighten the clamp bolts, first tighten them by hand
until they cannot be turned further. Then, tighten the
bolts to the specified torque in a later step.
When tightening the bolts, pay attention not to tilt
the bolt and clamp.
Do not reuse the washer.

Text in Illustration

*1 Washer

*2 Nozzle Holder Clamp

*a Downward

g. Temporarily install the common rail assembly RH with

the 2 bolts.

h. Temporarily install the 4 new injection pipes to the

common rail assembly RH and fuel injectors.
 i. 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.
j. Set the nozzle leakage pipe and 5 new gaskets in
place.

Text in Illustration

*1 Nozzle Leakage Pipe

k. Temporarily install the nozzle leakage pipe with the 4

hollow screws and union bolt.

Tech Tips
To position the injectors, loosely tighten the 4 hollow screws
and union bolt.

l. Tighten the 4 holder clamp bolts.

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

m. Remove the 4 injection pipes.

 n. Remove the 2 bolts and common rail assembly RH.

o. Tighten the 4 hollow screws.

Torque:
18 N*m { 184 kgf*cm, 13 ft.*lbf }

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

p. Tighten the union bolt.

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

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

52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (w/ DPF)

a. Temporarily install 2 service stud bolts (8 mm x 1.25

pitch with a length of 30 mm or more) to the 2
locations shown in the illustration.
b. Apply seal packing as shown in the illustration.

Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B

or equivalent

Text in Illustration

Seal Packing

Note
Remove any oil from the contact surface.
Install the cylinder head cover sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after
applying seal packing.
Do not start the engine for at least 2 hours after the installation.
c. Install a new cylinder head cover gasket LH and new No. 4 cylinder head cover gasket to the cylinder head
cover sub-assembly LH.

Note
Remove any oil from the contact surface.
d. Using the service stud bolts as guides, place the cylinder head cover sub-assembly LH on the cylinder head
LH.
e. Remove the 2 service stud bolts.
f. Temporarily install the cylinder head cover sub-
assembly LH with the 18 bolts and 4 nozzle holder
clamp seats. Tighten the 18 bolts and 4 nozzle holder
clamp seats in the order shown in the illustration.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }
Text in Illustration

Bolt

Nozzle Holder Clamp Seat

Tech Tips
 After tightening the bolts, check that the bolts at step 16 and 24 are tightened to the specified torque.

53. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (w/ DPF)

a. Temporarily install 2 service stud bolts (8 mm x 1.25

pitch with a length of 30 mm or more) to the 2
locations shown in the illustration.

b. Apply seal packing as shown in the illustration.

Seal packing

Toyota Genuine Seal Packing Black, Three Bond 1207B

or equivalent

Text in Illustration

Seal Packing

Note
Remove any oil from the contact surface.
Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after
applying seal packing.
Do not start the engine for at least 2 hours after the installation.
c. Install a new cylinder head cover gasket RH and new No. 3 cylinder head cover gasket to the cylinder head
cover sub-assembly.

Note
Remove any oil from the contact surface.
d. Using the service stud bolts as guides, place the cylinder head cover sub-assembly on the cylinder head sub-
assembly.
e. Remove the 2 service stud bolts.
f. Temporarily install the cylinder head cover RH with
the 19 bolts and 4 nozzle holder clamp seats. Tighten
the 19 bolts and 4 nozzle holder clamp seats in the
order shown in the illustration.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }
Text in Illustration

Bolt
 Nozzle Holder Clamp Seat

Tech Tips
After tightening the bolts, check that the bolts at step 16
and 25 are tightened to the specified torque.

54. INSTALL FUEL INJECTOR LH (w/ DPF)

Note
Be sure to install the fuel injector, nozzle holder clamp and bolt to their original positions.
Before installing the fuel injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head LH and
fuel injector. If there is foreign matter, remove it before installing the fuel injector.
a. Install 4 new injection nozzle seats to the cylinder
head LH.

b. Install 4 new fuel injector seals to each fuel injector as

shown in the illustration.

Text in Illustration

*1 Fuel Injector Seal

c. Apply a light coat of clean engine oil to 4 new O-rings.

d. Install the O-rings to each fuel injector as shown in
the illustration.
e. Insert the 4 fuel injectors into the cylinder head LH.

Note
Insert the fuel injector until it touches the injection
nozzle seat surface.
After installing the fuel injector to the cylinder head
LH, the O-ring may prevent the fuel injector from
fully seating. If so, pull out the fuel injector and
reinstall it.
Always return an fuel injector to the same place it
was removed from. Text in Illustration
f. For an fuel injector that has been replaced with a new
*1 O-Ring
fuel injector, register the fuel injector compensation
code Click here.
g. Temporarily install 4 new washers, 4 nozzle holder
clamps and 4 new nozzle holder seals with the 4 clamp
bolts.

Note
When temporarily installing the nozzle holder clamp bolt to
the nozzle holder clamp, make sure that the bolt and nozzle
holder clamp are not at an angle.

Text in Illustration

*1 New Washer

h. Temporarily install the common rail assembly LH with

the 2 bolts.

i. Temporarily install 4 new injection pipes to the common rail assembly LH and fuel injector.
 j. Temporarily install the No. 2 nozzle leakage pipe and 4
used gaskets with the 4 injector hollow screws and 2
bolts.
Text in Illustration

Injector Hollow Screw

Bolt

k. Tighten the 4 holder clamp bolts.

Torque:
25 N*m { 255 kgf*cm, 18 ft.*lbf }
l. Remove the 4 injection pipes.
m. Remove the 2 bolts and common rail assembly LH.
n. Remove the 4 fuel injector hollow screws and 4 gaskets.
o. Remove the 2 bolts and No. 2 nozzle leakage pipe.

55. INSTALL FUEL INJECTOR RH (w/ DPF)

Note
Be sure to install the fuel injector, nozzle holder clamp and bolt to their original positions.
Before installing the fuel injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head sub-
assembly and fuel injector. If there is foreign matter, remove it before installing the fuel injector.
a. Install 4 new injection nozzle seats to the cylinder
head sub-assembly.

b. Install 4 new fuel injector seals to each fuel injector as

shown in the illustration.
 Text in Illustration

*1 Fuel Injector Seal

c. Apply a light coat of clean engine oil to 4 new O-rings.

d. Install the O-rings to each fuel injector as shown in
the illustration.
e. Insert the 4 fuel injectors into the cylinder head sub-
assembly.

Note
Insert the fuel injector until it touches the injection
nozzle seat surface.
After installing the fuel injector to the cylinder head
sub-assembly, the O-ring may prevent the fuel
injector from fully seating. If so, pull out the fuel
injector and reinstall it.
Text in Illustration
Always return an fuel injector to the same place it
was removed from. *1 O-Ring
f. For an fuel injector that has been replaced with a new
fuel injector, register the fuel injector compensation
code Click here.
g. Temporarily install 4 new washers, 4 nozzle holder
clamps and 4 new nozzle holder seals with the 4 clamp
bolts.

Note
When temporarily installing the nozzle holder clamp bolt to
the nozzle holder clamp, make sure that the bolt and nozzle
holder clamp are not at an angle.

Text in Illustration

*1 Washer

h. Temporarily install the common rail assembly RH with

the 2 bolts.
 i. Temporarily install 4 new injection pipes to the
common rail assembly RH and fuel injector.

j. Temporarily install the No. 1 nozzle leakage pipe and 4

used gaskets with the 4 injector hollow screws and
union bolt.
Text in Illustration

Injector Hollow Screw

Union Bolt

k. Tighten the 4 holder clamp bolts.

Torque:
25 N*m { 255 kgf*cm, 18 ft.*lbf }
l. Remove the 4 injection pipes.
m. Remove the 2 bolts and common rail assembly RH.
n. Remove the 4 fuel injector hollow screws and 4 gaskets.
o. Remove the union bolt and No. 1 nozzle leakage pipe.

56. REMOVE INTAKE MANIFOLD

a. Remove the 16 bolts, 2 gaskets and intake manifold.

b. Remove the 9 bolts, No. 1 intake manifold and gasket.
c. Remove the 9 bolts, No. 2 intake manifold and gasket.

57. INSTALL CYLINDER HEAD COVER INSULATOR LH (w/ DPF)

58. INSTALL CYLINDER HEAD COVER INSULATOR RH (w/ DPF)

59. INSTALL NO. 2 FUEL PUMP BRACKET (w/ DPF)

a. Install the No. 2 fuel pump bracket with the bolt.

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

60. INSTALL NOZZLE HOLDER GASKET LH (w/o DPF)

Click here

61. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (w/o DPF)

Click here

62. INSTALL NOZZLE HOLDER SEAL LH (w/o DPF)

Click here

63. INSTALL OIL SEPARATOR ASSEMBLY

Click here

64. INSTALL NOZZLE HOLDER GASKET RH (w/o DPF)

Click here

65. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (w/o DPF)

Click here

66. INSTALL NOZZLE HOLDER SEAL RH (w/o DPF)

Click here

67. INSTALL OIL FILLER CAP GASKET

68. INSTALL OIL FILLER CAP SUB-ASSEMBLY

69. INSTALL SCAVENGING PUMP ASSEMBLY

Click here

70. INSTALL OIL PUMP ASSEMBLY

Click here

71. INSTALL REAR CRANKSHAFT OIL SEAL

a. Place the rear engine oil seal retainer on wooden

blocks.
b. Using SST and a hammer, tap in a new rear crankshaft
oil seal as shown in the illustration.
SST
09223-56010

Standard depth A

2.7 to 3.7 mm (0.106 to 0.147 in.)

Note
Keep the lip free from foreign matter.
Do not tap on the seal at an angle.
72. INSTALL REAR ENGINE OIL SEAL RETAINER
Click here

73. INSTALL OIL REGULATOR ASSEMBLY

Click here

74. INSTALL INLET OIL PUMP PIPE

a. Apply a light coat of engine oil to a new O-ring, and install it to the inlet oil pump pipe.
b. Install the inlet oil pump pipe with the 3 bolts.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }

75. INSTALL NO. 1 OIL PAN BAFFLE PLATE

a. Install the No. 1 oil pan baffle plate with the 5 bolts.
Torque:
10 N*m { 102 kgf*cm, 7 ft.*lbf }

76. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY

Click here

77. INSTALL OIL STRAINER SUB-ASSEMBLY

Click here

78. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

Click here

79. INSTALL OIL PAN DRAIN PLUG

a. Install a new gasket and the oil pan drain plug.

Torque:
38 N*m { 387 kgf*cm, 28 ft.*lbf }

80. INSTALL ENGINE OIL LEVEL SENSOR

Click here

81. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

 a. Apply a light coat of engine oil to 2 new O-rings, and set them to the oil filter bracket sub-assembly.
b. Install the oil filter bracket sub-assembly with the 3 bolts and 2 nuts.
Torque:
21 N*m { 214 kgf*cm, 15 ft.*lbf }

82. INSTALL OIL FILTER ELEMENT

Click here

83. INSTALL OIL COOLER RELIEF VALVE ASSEMBLY

a. Install a new gasket and the oil cooler relief valve assembly.
Torque:
25 N*m { 250 kgf*cm, 18 ft.*lbf }

84. INSTALL OIL COOLER ASSEMBLY

Click here

85. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY

Click here

86. INSTALL TIMING GEAR COVER SPACER

Click here

87. INSTALL CRANKSHAFT PULLEY

Note
This procedure is intended for removal/installation of the crankshaft pulley only. Do not use this procedure for
removal/installation of the flywheel or the drive plate and ring gear.
a. Align the crankshaft pulley and the crankshaft knock
pin, and temporarily install the crankshaft pulley with
the 3 bolts.
b. Install the 2 bolts to the bolt holes of the crankshaft
rear side.
c. Using a bar, turn the crankshaft until the crankshaft
pulley service hole is a little to the right of bottom
dead center.
d. Install a 14 mm x 1.5 pitch service bolt with a length
of 70 mm or more to the crankshaft pulley service
hole, and hold the crankshaft using the timing chain
cover sub-assembly protrusion.

Text in Illustration

*a Crankshaft Pulley Service Hole

*b Protrusion

e. Uniformly tighten the 3 bolts in 2 passes in the order

shown in the illustration.
Torque:
115 N*m { 1168 kgf*cm, 84 ft.*lbf }
 f. Remove the service bolt.

88. CONNECT NO. 2 OIL COOLER HOSE

a. Align the white paint marks on the No. 2 oil cooler hose and oil filter bracket sub-assembly and connect the
hose. Then connect the other side to the water pump assembly and attach the No. 2 oil cooler hose to the
clamp.

Note
Make sure to maintain a space between the oil cooler hose and crankshaft pulley, and the oil cooler hose and V-ribbed
belt idler pulley.

89. CONNECT NO. 1 OIL COOLER HOSE

a. Face the pink paint mark on the No. 1 oil cooler hose toward the front side of the engine and connect the
hose to the oil filter bracket sub-assembly. Then connect the other side to the water pump assembly.

Note
Make sure to maintain a space between the No. 1 oil cooler hose and crankshaft pulley.

90. INSTALL CRANKSHAFT POSITION SENSOR

Click here

91. INSTALL CAMSHAFT POSITION SENSOR

Click here