Engine Unit Installation

Install 2 new fuel injector seals.

Install 2 new gaskets, the 2 exhaust fuel addition injectors, 2 nozzle holder clamps and 2 new washers with the 2 bolts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

HINT:

Align the nozzle holder clamp with the cutouts of the injector as shown in the illustration.

Install the compressor bracket with the bolt.

Torque:

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

Install the V-ribbed belt tensioner with the 5 bolts.

Torque:

for bolt A and C:

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

for bolt B:

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

Install the No. 1 idler pulley with the bolt.

Torque:

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

Install the V-ribbed belt tensioner bracket with the 3 bolts.

Torque:

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

Install the stiffener insulator RH with the 2 bolts.

Torque:

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

Hold the oil pressure regulator body in a vise between aluminum plates.

Apply a light coat of engine oil to the oil pump relief valve labeled C.

Install the oil pump relief valve labeled C to the oil pressure regulator body.

Install the 2 springs labeled B to the oil pressure regulator body.

Using a 10 mm hexagon wrench, install a new gasket and the oil pump relief valve plug labeled A.

Torque:

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

Apply a light coat of engine oil to a new O-ring, and install it to the oil pressure regulator body.

Using a 26 mm wrench, install a new gasket and the oil pressure regulator.

Torque:

86 N*m{877 kgf*cm, 63 ft.*lbf}

Install the drain cock.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Using a 17 mm wrench, rotate the drain cock clockwise (360°) and align the position of the drain hole so that it is within the range shown in the illustration after tightening the drain cock to the specified torque.

NOTICE:

1. As the oil filter bracket may be damaged, the maximum tightening torque should be 80 N*m (816 kgf*cm, 59 ft.*lbf) or less.
   
2. Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock with the specified torque.
   
3. Do not expose the drain cock to coolant within 1 hour after installation.
   

Install the oil filter drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Install the oil tank bracket with the bolt.

Torque:

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

Install the engine mounting bracket LH with the 4 bolts.

Torque:

80 N*m{816 kgf*cm, 59 ft.*lbf}

Temporarily install a new gasket and No. 2 water by-pass pipe with the union bolt and 2 bolts.

Tighten the union bolt and 2 bolts of the No. 2 water by-pass pipe in the order shown in the illustration.

Torque:

for union bolt:

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

for bolt:

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

Install the No. 3 vacuum transmitting pipe with the 2 bolts.

Torque:

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

w/ Intercooler:
Connect the vacuum hose.

Install the turbocharger wire with the 2 bolts.

Torque:

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

Attach the 3 wire harness clamps.

Install the No. 2 intake air connector bracket with the bolt.

Torque:

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

Attach the 2 wire clamps.

Install the engine mounting bracket RH with the 4 bolts.

Torque:

80 N*m{816 kgf*cm, 59 ft.*lbf}

Install the No. 4 vacuum transmitting pipe with the 2 bolts.

Torque:

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

Connect the vacuum hose.

Temporarily install a new gasket and the No. 1 water by-pass pipe with the union bolt and bolt.

Tighten the union bolt and bolt of the No. 1 water by-pass pipe in the order shown in the illustration.

Torque:

for union bolt:

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

for bolt:

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

Install the air tube support with the 2 bolts.

Torque:

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

Install the No. 1 intake air connector bracket with the 2 bolts.

Torque:

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

Install a new gasket and the rear cylinder head plate LH with the 2 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

HINT:

The gasket claw should face toward the plate.

Install a new gasket and the rear cylinder head plate RH with the 2 bolts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

HINT:

The gasket claw should face toward the plate.

w/ Intercooler:
Install the cylinder head cover silencer LH with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

w/ Intercooler:
Install the cylinder head cover silencer RH with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Install the vacuum transmitting pipe with the 3 bolts.

Torque:

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

w/ Intercooler:
Connect the 2 vacuum hoses.

Install the vacuum switching valve with the bolt.

Torque:

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

Connect the 2 vacuum hoses.

Install the fan bracket with the 4 bolts.

Torque:

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

Temporarily install the No. 2 idler pulley bracket with the bolt.

Temporarily install the 2 bolts to the No. 2 idler pulley bracket bolt hole.

Uniformly tighten the 3 bolts of the No. 2 idler pulley bracket in the order shown in the illustration.

Torque:

49 N*m{495 kgf*cm, 36 ft.*lbf}

Install the collar, No. 2 idler pulley and cover with the bolt.

Torque:

49 N*m{495 kgf*cm, 36 ft.*lbf}

Install the No. 3 engine hanger with the 2 bolts.

Torque:

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

Install the No. 1 intercooler support bracket with the 2 bolts.

Torque:

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

Install the fuel pump wire with the bolt.

Torque:

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

HINT:

Attach the claw of the bracket to the timing gear case when installing the bracket.

Clean the glow plug and glow plug hole.

Apply adhesive to 3 or more thread roots in the area shown in the illustration.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using a 10 mm deep socket wrench, install the 8 glow plugs.

Torque:

12 N*m{125 kgf*cm, 9 ft.*lbf}

Install the 2 glow plug connectors by uniformly tightening the 8 nuts.

Torque:

2.2 N*m{22 kgf*cm, 19 in.*lbf}

Install the 8 screw grommets.

Connect the 2 wire harnesses with the 2 nuts and 2 screw grommets.

Torque:

4.0 N*m{41 kgf*cm, 35 in.*lbf}

Install the clutch flexible hose bracket with the 2 bolts.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Align the painted mark of the No. 1 water hose joint with the protrusion of the water by-pass outlet and connect the water by-pass outlet to the No. 1 water hose joint.

Align the painted mark of the No. 1 water hose joint with the painted mark of the No. 2 water outlet pipe and connect the No. 2 water outlet pipe to the No. 1 water hose joint.

Connect a new gasket and the No. 1 and No. 2 water outlet pipes with the 2 bolts.

Torque:

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

HINT:

The gasket claws can face the No. 1 or No. 2 water outlet pipe.

Install 2 new gaskets and the water outlet pipe with the 4 bolts.

Torque:

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

HINT:

The gasket claw should face toward the water outlet pipe.

Install a new gasket and the water outlet with the 2 bolts, and then connect the water outlet to the No. 2 water hose joint.

Torque:

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

Install the No. 2 intercooler support bracket with the 2 bolts.

Torque:

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

Install a new gasket to the sensor.

Using a 19 mm deep socket wrench, install the sensor.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the sensor connector.

Install the starter hose bracket with the 2 bolts.

Torque:

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

Install the starter with the 2 bolts.

Torque:

80 N*m{816 kgf*cm, 59 ft.*lbf}

Connect the 2 starter hoses.

Attach the harness clamp and connect the wire harness.

Connect the starter wire with the nut.

Torque:

20 N*m{200 kgf*cm, 14 ft.*lbf}

Connect the starter connector.

w/o Viscous Heater:
Install the timing gear cover insulator with the 2 bolts.

Torque:

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

w/ Viscous Heater:
Install the timing gear cover insulator.

Install a new gasket to the thermostat.

NOTICE:

When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the groove of the gasket is properly installed onto the thermostat, as shown in the illustration.

Insert the thermostat into the water pump with the jiggle valve facing straight upward.

HINT:

The jiggle valve may be set within 30° of either side of the prescribed position.

Install the water inlet with the 4 bolts.

Torque:

for bolt A:

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

for bolt B:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the No. 2 oil cooler hose to the clamp and water pump.

Install the No. 1 idler pulley bracket with the bolt.

Torque:

49 N*m{495 kgf*cm, 36 ft.*lbf}

Install the heater assembly with the 2 bolts.

Torque:

48.5 N*m{495 kgf*cm, 36 ft.*lbf}

Connect the 2 heater hoses.

Using pliers, grip the claws of the clips and slide the 2 clips.

Connect the connector and attach the clamp.

Install a new gasket to the No. 2 turbocharger.

Install the exhaust manifold LH to the No. 2 turbocharger with 3 new nuts.

Torque:

69 N*m{704 kgf*cm, 51 ft.*lbf}

HINT:

The gasket claw should face toward the outside of the vehicle.

w/ DPF:

1. Install 2 new gaskets to the No. 2 exhaust manifold pipe.
   

   HINT:

   The gasket claws should face the No. 2 exhaust manifold pipe.





2. Temporarily install the No. 2 exhaust manifold pipe with the 4 bolts.
   

   HINT:

   Install the No. 2 exhaust manifold pipe so that it is oriented as shown in the illustration.

3. Tighten the 4 bolts.
   

   Torque:

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

Install a new gasket to the cylinder head LH.

Install the No. 2 turbocharger with exhaust manifold LH and 10 collars to the cylinder head LH with 10 new nuts.

Torque:

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

HINT:

Install the collars with the colored side facing the nuts.

Install a new gasket and the No. 2 inlet turbo oil pipe to the No. 1 oil pan with the union bolt.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Connect the 2 connectors to the turbocharger.

Temporarily install a new gasket and the No. 2 ventilation tube with the union bolt and bolt.

Tighten the union bolt and bolt in the order shown in the illustration.

Torque:

for union bolt:

29 N*m{296 kgf*cm, 21 ft.*lbf}

for bolt:

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

NOTICE:

Clean and remove any oil in the area labeled 1 in the illustration.

Connect the hose.

Install the No. 2 turbocharger stay with the 2 bolts.

Torque:

49 N*m{495 kgf*cm, 36 ft.*lbf}

Temporarily install a new gasket and the No. 2 turbo water pipe with the union bolt and bolt.

Tighten the union bolt and bolt in the order shown in the illustration.

Torque:

for union bolt:

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

for bolt:

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

Connect the water hose to the pipe.

Install a new gasket and the front water by-pass joint.

Torque:

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

Temporarily install a new gasket and the No. 3 turbo water pipe with the union bolt and 2 bolts.

Tighten the union bolt and 2 bolts in the order shown in the illustration.

Torque:

for union bolt:

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

for bolt:

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

Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

Torque:

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

Install the breather plug LH.

w/o DPF:
Attach the clamp.

Connect the hose.

Install a new gasket to the No. 1 turbocharger.

Install the exhaust manifold RH to the No. 1 turbocharger with 2 new nuts and the bolt.

Torque:

69 N*m{704 kgf*cm, 51 ft.*lbf}

w/ DPF:

1. Install 2 new gaskets to the No. 1 exhaust manifold pipe.
   

   HINT:

   The gasket claws should face the No. 1 exhaust manifold pipe.





2. Temporarily install the No. 1 exhaust manifold pipe with the 4 bolts.
   

   HINT:

   Install the No. 1 exhaust manifold pipe so that it is oriented as shown in the illustration.

3. Tighten the 4 bolts.
   

   Torque:

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

Install a new gasket to the cylinder head RH.

Install the No. 1 turbocharger with exhaust manifold RH to the cylinder head RH with the 10 collars and 10 new nuts.

Torque:

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

HINT:

Install the collars with the colored side facing the nuts.

Install a new gasket and the No. 1 inlet turbo oil pipe to the cylinder block with the union bolt.

Torque:

When "dry":

29 N*m{296 kgf*cm, 21 ft.*lbf}

When "wet":

23 N*m{235 kgf*cm, 17 ft.*lbf}

NOTICE:

1. The parts are "dry" when there is absolutely no engine oil on the union bolt and cylinder block bolt hole.
   
2. The parts are "wet" when there is engine oil on the union bolt and cylinder block bolt hole.
   

Temporarily install a new gasket and the No. 1 ventilation tube with the union bolt and bolt.

Tighten the union bolt and bolt in the order shown in the illustration.

Torque:

for union bolt:

29 N*m{296 kgf*cm, 21 ft.*lbf}

for bolt:

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

NOTICE:

Clean and remove any oil in the area labeled 1 in the illustration.

Connect the hose.

Temporarily install the No. 1 turbocharger stay with the 2 bolts.

Tighten the 2 bolts.

Torque:

49 N*m{495 kgf*cm, 36 ft.*lbf}

Install a new gasket and the No. 1 turbo water pipe with 2 new nuts and the 3 bolts.

Torque:

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

Connect the water hose.

Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

Torque:

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

Install the breather plug RH and attach the clamp.

Connect the hose.

Temporarily install the generator with the 3 bolts and 2 nuts.

Uniformly tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque:

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

Connect the generator cable and install the nut and bolt.

Torque:

for bolt:

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

for nut (130A Type and 150A Type:):

9.8 N*m{100 kgf*cm, 87 in.*lbf}

for nut (180A Type:):

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

Install the No. 1 intake air connector pipe with the bolt. Then tighten the hose clamp.

Torque:

for bolt:

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

for hose clamp:

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

Connect the 4 connectors and attach the 5 wire harness clamps.

Apply a light coat of engine oil to a new O-ring and install it to the No. 1 engine oil level dipstick guide.

Install the No. 1 engine oil level dipstick guide with the 2 bolts.

Torque:

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

Apply engine oil to 2 new O-rings.

Install the 2 O-rings to the vacuum pump.

Install the vacuum pump so that the coupling teeth of the vacuum pump (labeled A) and the groove of the camshaft (labeled B) are aligned.

NOTICE:

Be careful not to damage the O-ring.

Install the vacuum pump with the 3 bolts.

Torque:

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

NOTICE:

Confirm that the vacuum pump is not at an angle, and that there is no clearance between the fitting surfaces.