ENGINE UNIT INSTALLATION


  1. INSTALL VACUUM PUMP OUTLET UNION


    1. Install a new gasket and the outlet union.

  2. INSTALL VACUUM PUMP INLET UNION


    1. Clean the threads of the inlet union apply adhesive there.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

    2. Install the inlet union.

  3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Clean the threads of the oil pressure switch, apply adhesive there.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

    2. Install the oil pressure switch.

      Torque:
      15 N*m  { 155 kgf*cm, 11 ft.*lbf }

  4. INSTALL ENGINE OIL LEVEL SENSOR

    Torque:
    7.0 N*m  { 71.4 kgf*cm, 62 ft.*lbf }

  5. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Clean the threads of the coolant temperature sensor, apply adhesive there.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

    2. Install the coolant temperature sensor.

      Torque:
      20 N*m  { 200 kgf*cm, 15 ft.*lbf }

  6. INSTALL WATER BY-PASS HOSE UNION


    1. Clean the threads of the water by-pass hose union, apply adhesive there.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent

    2. Install the water by-pass hose union.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  7. INSTALL INTAKE MANIFOLD


    1. A01KFMXE01
      Text in Illustration
      *a Upward
      *b Protrusion

      Install a new gasket to the cylinder head, facing the protrusion upward.

    2. Install the intake manifold, 2 engine wire brackets, oil dipstick guide bracket with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

      Torque:
      24.5 N*m  { 250 kgf*cm, 17 ft.*lbf }

    3. Install the accelerator link and hose clamp (w/ ACSD) with the bolt and nut.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

    4. Connect the accelerator link to the injection pump.

    5. w/ ACSD:

      Connect the 2 water by-pass hoses to the hose clamp.

  8. INSTALL WATER OUTLET HOUSING


    1. Install a new gasket, the water outlet and outlet housing assembly with the 3 bolts.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

    2. Connect the water temperature sender gauge connector.

    3. w/ ACSD:

      Connect the water by-pass hose to the water housing.

  9. INSTALL NOZZLE HOLDER AND NOZZLE SET


    1. Install a new nozzle sheet gasket and nozzle sheet to the cylinder head.

    2. Using SST, install the set of holder and nozzle.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }
      SST
      09268-64010   ( 09268-64020 )

  10. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Using a new washer, install the nozzle leakage pipe assembly.

      Torque:
      29.5 N*m  { 300 kgf*cm, 22 ft.*lbf }

  11. INSTALL GLOW PLUG ASSEMBLY

    Click here

  12. INSTALL GLOW PLUG NO.1 CONNECTOR

  13. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install a new gasket and oil filter bracket.

      Torque:
      29.5 N*m  { 300 kgf*cm, 22 ft.*lbf }

  14. INSTALL OIL FILTER SUB-ASSEMBLY

    A01KHPEE01
    Text in Illustration
    *a 3/4 Turn

    1. Check and clean the oil filter installation surface.

    2. Apply clean engine oil to the rubber gasket of a new oil filter.

    3. Lightly screw the oil filter into place, and tighten it by hand until the rubber gasket contacts the installation surface.

    4. Using SST, tighten it by an additional 3/4 turn to seat the filter.

      SST
      09228-10002

  15. INSTALL EXHAUST MANIFOLD


    1. A01KEG0E01
      Text in Illustration
      *a Front Mark

      Install a new gasket to the cylinder head.

      Tech Tips

      The direction of a new gasket is in the illustration.

    2. Install the exhaust manifold with the 6 bolts and 2 new nuts. Uniformly tighten the bolts and nuts in several passes.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  16. INSTALL EXHAUST PIPE ASSEMBLY FRONT


    1. Install a new gasket to the exhaust pipe.

    2. Install the exhaust pipe with the 3 new nuts. Uniformly tighten the nuts.

      Torque:
      62 N*m  { 630 kgf*cm, 46 ft.*lbf }

  17. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR)


    1. A01KF6R

      Install a new gasket and EGR pipe to the intake manifold with the 2 bolts.

    2. Install a new gasket, EGR valve and EGR pipe with the 2 bolts, 4 nuts and union nut.

      Torque:
      Bolt
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Nut
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }
      Union nut
      108 N*m  { 110 kgf*cm, 79 ft.*lbf }

  18. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A01KFQME01

      Install the heat insulator with the 3 bolts.

      Torque:
      A
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
      B
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  19. INSTALL PUMP BRACKET


    1. A01KEOSE01

      Install the pump bracket with the 6 bolts.

      Torque:
      A
      78.5 N*m  { 800 kgf*cm, 58 ft.*lbf }
      B
      57 N*m  { 580 kgf*cm, 42 ft.*lbf }

  20. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH

    Torque:
    39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  21. INSTALL INJECTION PUMP ASSEMBLY

    Click here

  22. INSTALL INJECTION PUMP DRIVE PULLEY


    1. Using SST, install the injection pump drive pulley.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021   ( 09330-00030 )

  23. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.1

    Click here

  24. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.2

    Click here

  25. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.3

    Click here

  26. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.4

    Click here

  27. INSTALL INJECTION PIPE CLAMP

    Click here

  28. INSTALL FAN BELT ADJUSTING BAR (W/ AIR CONDITIONER)

    Torque:
    45 N*m  { 460 kgf*cm, 33 ft.*lbf }

  29. INSTALL GENERATOR ASSEMBLY

    Click here

  30. REMOVE IDLE PULLEY BRACKET (W/ AIR CONDITIONER)

    Torque:
    46.6 N*m  { 466 kgf*cm, 34 ft.*lbf }

  31. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONER)

    Torque:
    85.6 N*m  { 876 kgf*cm, 63 ft.*lbf }

  32. INSTALL CYLINDER HEAD COVER NO.2 (w/ Cylinder Head Cover No.2)


    1. Install the cylinder head cover with the 4 plate washers and nuts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  33. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  34. INSTALL INTAKE AIR CONNECTOR BRACKET

    Torque:
    12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  35. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Install a new gasket to the intake manifold.

    2. Install the intake air connector with the 3 nuts and bolt.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  36. INSTALL TIMING BELT

    Tech Tips

    If re-using the timing belt, align the points marked during removal, and install the timing belt with the arrow pointing in the direction of engine revolution.


    1. A01KERN

      Install the timing belt Click here.

  37. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY


    1. Install the collar to the timing pointer.

    2. Install the 2 gaskets to the timing belt cover.

    3. Install the timing belt cover with the 11 bolts.

      Torque:
      10.5 N*m  { 105 kgf*cm, 8 ft.*lbf }

  38. INSTALL CRANKSHAFT PULLEY


    1. A01KHPKE01

      Align the pulley set key with the key groove of the pulley, and slide the pulley to the crankshaft.

    2. Using SST, install the new pulley bolt.

      Torque:
      235 N*m  { 2400 kgf*cm, 173 ft.*lbf }

  39. INSTALL VANE PUMP DRIVE PULLEY


    1. Install the vane pump drive pulley and vane pump pulley spacer with the 4 bolts.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

    2. w/ A/C

      Install the vane pump drive pulley and crankshaft pulley No.2 with the 4 bolts.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  40. INSTALL ENGINE ASSEMBLY

    Click here