Engine Unit Reassembly

for Timing Chain Cover Sub-assembly Side:

1. Using a plastic-faced hammer, tap in 2 new straight pins to the timing chain cover sub-assembly.
   

   Standard protrusion height:

   5.0 to 7.0 mm (0.197 to 0.276 in.)
   

   Text in Illustration

   *a	Protrusion Height

for Timing Chain Case Assembly Side:

1. Using a plastic-faced hammer, tap in a new straight pin to the timing chain case assembly.
   

   Standard protrusion height:

   18 to 20 mm (0.709 to 0.787 in.)
   

   Text in Illustration

   *a	Protrusion Height

for Timing Chain Cover Sub-assembly Side:

1. Using an E6 "TORX" socket wrench, install the stud bolts to the timing chain cover sub-assembly.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

   Text in Illustration

   *a	16 mm (0.630 in.)
   *b	9.0 mm (0.354 in.)
   *c	27 mm (1.06 in.)

for Timing Chain Case Assembly Side:

1. Using an E8 "TORX" socket wrench, install the stud bolts to the timing chain case assembly.
   

   Torque:

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

   Text in Illustration

   *a	19 mm (0.748 in.)
   *b	16 mm (0.630 in.)
   *c	44 mm (1.73 in.)

Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain case assembly.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

for Oil Pan Sub-assembly Side:

1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the oil pan sub-assembly.
   

   Torque:

   6.0 N*m{61 kgf*cm, 53 in.*lbf}

   Text in Illustration

   *a	9.0 mm (0.354 in.)
   *b	19 mm (0.748 in.)

Install the lock plate to the cylinder block sub-assembly with the bolt.

Torque:

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

HINT:

1. Make sure the lock plate is facing the direction shown in the illustration.
   
2. Make sure the end of the lock plate is holding the oil jet as shown in the illustration.
   

Check the piston protrusions for each cylinder.

1. Clean the cylinder block sub-assembly with solvent.
   

2. Set the piston of the cylinder to be measured to slightly before TDC.
   





3. Place a dial indicator on the cylinder block sub-assembly, and position the measuring tip as shown in the illustration.
   

   Text in Illustration

   *a	Measuring Tip
   *b	Protrusion

4. Set the dial indicator at 0 mm (0 in.)
   

   HINT:

   Make sure that the measuring tip is square to the cylinder block gasket surface and piston head when taking the measurements.

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

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

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

Standard piston protrusion:

0.355 to 0.605 mm (0.0140 to 0.0238 in.)

HINT:

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

Select a new cylinder head gasket.

HINT:

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

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

   Gasket Size

   Item	Specified Condition
   Piston protrusion	0.355 to 0.405 mm (0.0140 to 0.0159 in.)	0.405 to 0.455 mm (0.0159 to 0.0179 in.)	0.455 to 0.505 mm (0.0179 to 0.0199 in.)	0.505 to 0.555 mm (0.0199 to 0.0219 in.)	0.555 to 0.605 mm (0.0219 to 0.0238 in.)
   Gasket to be used	A	B	C	D	E

Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block sub-assembly.

Place the cylinder head gasket on the cylinder block sub-assembly.

NOTICE:

Make sure the cylinder head gasket is installed facing the proper direction.

Clean and degrease the contact surfaces of the cylinder head sub-assembly and cylinder block sub-assembly.

Place the cylinder head sub-assembly on the cylinder head gasket.

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

Install and uniformly tighten the 10 cylinder head set bolts and 6 cylinder head set bolt spacers in several passes in the sequence shown in the illustration.

Torque:

for bolt A:

150 N*m{1530 kgf*cm, 111 ft.*lbf}

for bolt B:

85 N*m{867 kgf*cm, 63 ft.*lbf}

Text in Illustration

	Bolt A
	Bolt B

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

Mark the front of each cylinder head set bolt with paint.

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

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

Check that the painted marks are now facing rearward.

Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

Check that the No. 1 valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.

Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

Install the 16 No. 1 valve rocker arm sub-assemblies to the 16 valve lash adjuster assemblies.

Clean the No. 2 camshaft journals.

Apply a light coat of engine oil to the No. 2 camshaft journals of the cylinder head sub-assembly and the thrust portion of the No. 2 camshaft.

Clean the camshaft journals.

Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

Make sure the knock pins of the camshaft and No. 2 camshaft are facing the direction shown in the illustration.

Set the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps to the cylinder head sub-assembly as shown in the illustration.

Temporarily install the 20 camshaft bearing cap bolts.

Uniformly tighten the 20 camshaft bearing cap bolts in several steps in the order shown in the illustration.

Torque:

for camshaft bearing cap bolt A (No. 1 camshaft bearing):

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

for camshaft bearing cap bolt B (No. 2 camshaft bearing):

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

Text in Illustration

	Camshaft Bearing Cap Bolt A
	Camshaft Bearing Cap Bolt B

Clean and degrease the contact surfaces of the No. 3 camshaft bearing cap and cylinder head sub-assembly.

Apply seal packing to the No. 3 camshaft bearing cap in the areas indicated in the illustration.

Seal packing:

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

Standard seal diameter:

3.0 mm (0.118 in.)

Text in Illustration

*a	Engine Front Side
	Seal Packing Application Area

NOTICE:

1. Install the No. 3 camshaft bearing cap within 3 minutes and tighten the camshaft bearing cap bolts within 15 minutes after applying seal packing.
   
2. Do not add engine oil within 2 hours of installation.
   
3. Do not start the engine for at least 2 hours after the installation.
   

Install the No. 3 camshaft bearing cap to the cylinder head sub-assembly with the 2 camshaft bearing cap bolts.

Torque:

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

Wipe off excess seal packing from between No. 3 camshaft bearing cap and cylinder head sub-assembly.

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

Install the 4 O-rings to the cylinder block sub-assembly and cylinder head sub-assembly.

Clean and degrease the contact surfaces of the timing chain case assembly, cylinder head sub-assembly and cylinder block sub-assembly.

Apply a coating of seal packing to the timing chain case assembly at the points shown in the illustration.

Seal packing:

for line area D:

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

for line area A-A, B-B, C-C and E:

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

NOTICE:

1. Using non-residue solvent, clean and remove any oil from the installation surface.
   
2. Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Temporarily install the timing chain case assembly with the 15 bolts.

Bolt Length:

Item	Length	Thread Diameter
Bolt A	30 mm (1.18 in.)	8.0 mm (0.315 in.)
Bolt B	45 mm (1.77 in.)	8.0 mm (0.315 in.)
Bolt C	65 mm (2.56 in.)	8.0 mm (0.315 in.)
Bolt D	30 mm (1.18 in.)	10 mm (0.394 in.)

Temporarily install a new gasket and the engine water pump assembly with the 8 bolts.

Tighten the 23 bolts in the order shown in the illustration.

Torque:

for bolt A, B and C:

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

for bolt D:

43 N*m{438 kgf*cm, 32 ft.*lbf}

NOTICE:

Check the torque of bolt 1 after tightening bolt 23.

Install the injection pump insulator to the cylinder block sub-assembly.

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

Install the supply pump assembly to the timing chain case assembly with the 3 nuts.

Torque:

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

Install the No. 1 fuel pump bracket to the cylinder block sub-assembly and supply pump assembly with the 2 bolts.

Torque:

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

Install the No. 1 chain tensioner slipper to the straight pin.

Temporarily install the No. 1 chain vibration damper to the cylinder block sub-assembly with the bolt.

Install the crankshaft timing sprocket to the crankshaft.

Align the crankshaft pulley set key as shown in the illustration.

Align the supply pump shaft key as shown in the illustration.

Remove the crankshaft timing sprocket from the crankshaft.

Align the 2 mark plates (pink) of the No. 1 chain sub-assembly with the 2 timing marks of the crankshaft timing sprocket and install the No. 1 chain sub-assembly to the crankshaft timing sprocket as shown in the illustration.

Align the mark plate (yellow) of the No. 1 chain sub-assembly with the timing mark of the injection pump drive gear and install the No. 1 chain sub-assembly to the injection pump drive gear as shown in the illustration.

Install the crankshaft timing sprocket, injection pump drive gear and No. 1 chain sub-assembly to the crankshaft and supply pump shaft together.

Tighten the No. 1 chain vibration damper to the cylinder block sub-assembly with the bolt.

Torque:

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

Install a new gasket and No. 1 chain tensioner assembly to the cylinder block sub-assembly with the 2 bolts.

Torque:

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

HINT:

Align the claw (lower side) of the gasket with the groove of the No. 1 chain tensioner assembly body to install the No. 1 chain tensioner assembly as shown in the illustration.

Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.

Using SST, hold the crankshaft pulley and install the supply pump shaft nut to the supply pump shaft.

SST

09213-58014(91551-80840)
09330-00021

Torque:

137 N*m{1397 kgf*cm, 101 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

NOTICE:

If the supply pump shaft nut is tightened with torque higher than the specified torque, the No. 1 chain sub-assembly may break.

Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.

Make sure that the timing marks of the crankshaft timing sprocket and injection pump drive gear are aligned with the mark plates of the No. 1 chain sub-assembly as shown in the illustration.

Remove the pin from the No. 1 chain tensioner assembly.

Temporarily install the 2 camshaft timing sprockets to the camshaft and No. 2 camshaft with the 2 camshaft timing sprocket bolts.

NOTICE:

Make sure that the timing mark of the camshaft timing sprocket faces the front side of the engine.

HINT:

Align the knock pins of the camshaft and No. 2 camshaft with the cutout of the camshaft timing sprocket to install the camshaft timing sprocket.

for Intake Side:

1. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing sprocket bolt to the camshaft.
   

   Torque:

   81 N*m{826 kgf*cm, 60 ft.*lbf}

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.

for Exhaust Side:

1. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing sprocket bolt to the No. 2 camshaft.
   

   Torque:

   81 N*m{826 kgf*cm, 60 ft.*lbf}

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.

Install the No. 2 chain vibration damper to the timing chain case assembly with the 2 bolts.

Torque:

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

Align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (intake side) and install the No. 2 chain sub-assembly to the camshaft timing sprocket (intake side) as shown in the illustration.

Align the mark plate (yellow) of the No. 2 chain sub-assembly with the timing mark of the injection pump drive gear and install the No. 2 chain sub-assembly to the injection pump drive gear as shown in the illustration.

Using a wrench, turn the hexagonal portion of the No. 2 camshaft clockwise and align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (exhaust side) to install the No. 2 chain sub-assembly to the camshaft timing sprocket (exhaust side).

Text in Illustration

*a	Mark Plate (Orange)
*a	Timing Mark
	Turn

Install the No. 2 chain tensioner slipper to the timing chain case assembly with the bolt.

Torque:

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

Install the No. 2 chain tensioner assembly to the timing chain case assembly with the 2 bolts.

Torque:

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

Remove the pin from the No. 2 chain tensioner assembly.

Install the timing chain guide to the cylinder head sub-assembly with the bolt.

Torque:

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

Make sure that the timing marks of the camshaft timing sprocket (exhaust side), camshaft timing sprocket (intake side), injection pump drive gear and crankshaft timing sprocket are at the positions shown in the illustration.

Set the engine balancer assembly to the cylinder block sub-assembly.

Install the engine balancer assembly to the cylinder block sub-assembly with the 8 bolts and tighten the bolts in the sequence shown in the illustration.

Torque:

for bolt A:

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

for bolt B:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Bolt Length:

Item	Specified Condition
Bolt A	50 mm (1.97 in.)
Bolt B	55 mm (2.17 in.)

Align the mark plate (yellow) of the No. 3 chain sub-assembly with the timing mark of the balance shaft timing sprocket and install the No. 3 chain sub-assembly to the balance shaft timing sprocket as shown in the illustration.

NOTICE:

Make sure that the timing plate of the No. 3 chain sub-assembly faces the front side of the engine.

Align the 2 mark plates (yellow) of the No. 3 chain sub-assembly with the 2 timing marks of the balance shaft timing gear sub-assembly and install the No. 3 chain sub-assembly to the balance shaft timing gear sub-assembly as shown in the illustration.

Apply engine oil to the position shown in the illustration.

Align the timing mark of the engine balancer assembly with the 2 paint marks (pink) and timing mark of the balance shaft gear sub-assembly, and then install the balance shaft timing sprocket, balance shaft gear sub-assembly with No. 3 chain sub-assembly to the crankshaft and engine balancer assembly as shown in the illustration.

Make sure that the timing marks of the balance shaft timing sprocket and balance shaft gear sub-assembly are aligned with the mark plates of the No. 3 chain sub-assembly as shown in the illustration.

Apply engine oil to the front and rear surfaces of the No. 1 balance shaft thrust plate.

Install the No. 1 balance shaft thrust plate to the crankshaft with the bolt.

Torque:

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

Install the No. 3 chain tensioner assembly to the engine balancer assembly with the 2 bolts.

Torque:

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

Remove the pin from the No. 3 chain tensioner assembly.

Install the oil pump drive gear to the crankshaft.

Install a new gasket and oil pump relief valve plug to the timing chain cover sub-assembly.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Install the timing chain cover plate and new gasket with the 3 bolts.

Torque:

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

Apply a light coat of engine oil to a new timing chain case gasket.

Install the timing chain case gasket to the timing chain case assembly.

Clean and degrease the contact surfaces of the timing chain cover sub-assembly and timing chain case assembly.

Apply a coating of seal packing to the timing chain cover sub-assembly at the points shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

2.5 to 3.5 mm (0.0984 to 0.138 in.)

NOTICE:

1. Using non-residue solvent, clean and remove any oil from the installation surface.
   
2. Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Temporarily install the timing chain cover sub-assembly with the 20 bolts.

Bolt Length:

Item	Length	Thread Diameter
Bolt A	40 mm (1.57 in.)	8.0 mm (0.315 in.)
Bolt B	25 mm (0.984 in.)	8.0 mm (0.315 in.)

Tighten the 20 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

Check the torque of bolt 1 after tightening bolt 20.

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

NOTICE:

1. Keep the lip free of foreign objects.
   
2. Do not allow MP grease to contact the dust seal.
   

Using SST and a hammer, tap in the front crankshaft oil seal.

SST

09214-76011

NOTICE:

1. The acceptable depth from the top of the timing chain cover assembly is 0 to 1.5 mm (0 to 0.0591 in.)
   
2. Keep the lip free from foreign matter.
   
3. Do not tap the front crankshaft oil seal at an angle.
   
4. Make sure that the front crankshaft oil seal is properly installed.
   

Clean and degrease the contact surfaces of the rear engine oil seal retainer and cylinder block sub-assembly.

Apply seal packing to the rear engine oil seal retainer in the areas indicated in the illustration.

Seal packing:

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

Standard seal diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

NOTICE:

1. Remove any engine oil from the contact surface.
   
2. Install the rear engine oil seal retainer within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil within 2 hours of installation.
   
4. Do not start the engine for at least 2 hours after the installation.
   

Install the rear engine oil seal retainer to the cylinder block sub-assembly, and then install the 5 bolts.

Torque:

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

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

NOTICE:

1. Keep the lip free of foreign matter.
   
2. Do not allow MP grease to contact the dust seal.
   

Using SST and a hammer, tap in the rear engine oil seal to the rear engine oil seal retainer edge.

SST

09351-40010(09351-04010,09351-04020)

NOTICE:

1. The acceptable depth from the top of the rear engine oil seal retainer is 0 to 1.0 mm (0 to 0.0394 in.)
   
2. Keep the lip free from foreign matter.
   
3. Do not tap the rear engine oil seal at an angle.
   
4. Make sure that the rear engine oil seal is properly installed.
   

Install a new gasket and oil strainer sub-assembly to the cylinder block sub-assembly with the 5 bolts in several steps in the sequence shown in the illustration.

Torque:

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

HINT:

Make sure that the claw of the gasket faces the oil strainer sub-assembly.

Clean and degrease the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

Seal Packing

Seal packing:

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

Standard seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
   
3. Do not add engine oil within 2 hours after installation.
   
4. Do not start the engine for at least 2 hours after installation.
   

Install the oil pan sub-assembly to the cylinder block sub-assembly with the 23 bolts and 2 nuts.

Torque:

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

NOTICE:

Check the torque of all nuts and bolts labeled A again.

Clean and degrease the contact surfaces of the No. 2 oil pan sub-assembly and cylinder block sub-assembly.

Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

Seal Packing

Seal packing:

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

Standard seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
   
3. Do not add engine oil within 2 hours after installation.
   
4. Do not start the engine for at least 2 hours after installation.
   

Install the No. 2 oil pan sub-assembly to the oil pan sub-assembly with the 11 bolts and 2 nuts.

Torque:

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

Install the engine oil level sensor to the oil pan sub-assembly with the 4 bolts.

Torque:

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

Connect the engine oil level sensor connector.

Apply a light coat of engine oil to the O-ring of the crankshaft position sensor.

Install the crankshaft position sensor with the bolt to the rear oil seal retainer.

Torque:

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

NOTICE:

1. When reusing the crankshaft position sensor, check the O-ring.
   
2. Make sure that the O-ring is not cracked or jammed when installing to the rear oil seal retainer.
   
3. Replace with a new part if it is dropped or if it receives a strong impact.
   

Install the crankshaft position sensor harness bracket to the cylinder block sub-assembly with the bolt.

Torque:

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

Connect the crankshaft position sensor connector.

Install the No. 1 cylinder block insulator to the cylinder block sub-assembly.

Install the No. 5 cylinder block insulator to the cylinder block sub-assembly.

Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

Install a new cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets to the cylinder head cover sub-assembly.

Clean and degrease the contact surfaces of the cylinder head cover sub-assembly and cylinder head sub-assembly.

Apply seal packing as shown in the illustration.

Seal packing:

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

Standard seal diameter:

3.0 to 6.0 mm (0.118 to 0.236 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Tighten the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and camshaft position sensor in the order shown in the illustration.

Text in Illustration

	Bolt
	Nut
	Nozzle Holder Clamp Seat

Torque:

10 N*m{107 kgf*cm, 7 ft.*lbf}

NOTICE:

1. When reusing the camshaft position sensor, check the O-rings.
   
2. Make sure that the O-ring is not cracked or jammed when installing it on the cylinder head cover sub-assembly.
   
3. Replace with a new part if it is dropped or if it receives a strong impact.
   
4. Check the torque of bolts 1 to 4 again.
   

Install the oil filler cap gasket to the oil filler cap sub-assembly.

Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly.

Install 4 new injection nozzle seats to the cylinder head sub-assembly.

Apply a light coat of engine oil to the O-ring on each injector assembly.

Install a new O-ring to each injector assembly.

Install the 4 injector assemblies to the cylinder head sub-assembly.

NOTICE:

Fit the injector assembly to the injection nozzle seats.

Install the nozzle holder clamps and washers as shown in the illustration.

NOTICE:

Pay attention to the mounting orientation (beveled edge) of the washer.

Temporarily install the nozzle holder clamp bolts.

NOTICE:

When temporarily installing the nozzle holder clamp bolt to the No. 1 nozzle holder clamp, make sure that the bolt and clamp are not at an angle.

HINT:

Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

Install 2 new O-rings to the cylinder block sub-assembly.

Install the oil filter bracket to the cylinder block sub-assembly with the 2 nuts and bolt.

Torque:

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

Using a 27 mm deep socket wrench, install the oil filter union to the oil filter bracket.

Torque:

29 N*m{300 kgf*cm, 22 ft.*lbf}

Check and clean the oil filter sub-assembly installation surface.

Apply clean engine oil to the gasket of a new oil filter sub-assembly.

Lightly screw the oil filter sub-assembly into place by hand. Tighten it until the gasket contacts the seat.

Using SST, tighten the oil filter sub-assembly.

Text in Illustration

3/4 Turn

SST

09228-07501

Depending on the space available, choose from the following.
If enough space is available, use a torque wrench to tighten the oil filter sub-assembly.

Torque:

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

If enough space is not available to use a torque wrench, tighten the oil filter sub-assembly 3/4 of a turn by hand or with a common wrench.

Apply a light coat of engine oil to the 2 new O-rings.

Install the 2 O-rings to the cylinder block sub-assembly.

Install a new water outlet pipe gasket to the cylinder block sub-assembly.

Install the oil cooler assembly to the cylinder block sub-assembly with the bolt and 5 nuts.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Install the generator bracket sub-assembly to the cylinder head sub-assembly and timing chain case assembly with the 4 bolts.

Torque:

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

Install the No. 3 cylinder block insulator to the cylinder block sub-assembly.

Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Install the No. 2 cylinder block insulator to the front No. 1 engine mounting bracket LH.

Install the No. 1 engine hanger to the cylinder head sub-assembly with the 2 bolts.

Torque:

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