ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

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  2. INSTALL OIL FILTER SUB-ASSEMBLY

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  3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  4. INSTALL EXHAUST MANIFOLD

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  5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  6. INSTALL VACUUM PUMP OIL OUTLET HOSE


    1. Install the vacuum pump oil outlet hose to the oil pan sub-assembly and slide the clip to secure the hose.

  7. INSTALL UNION


    1. Clean the threads of the union and hole.

    2. Apply adhesive to 2 or 3 threads at the end of union.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    3. Install the union to the cylinder block sub-assembly.

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

  8. INSTALL VACUUM PUMP OIL INLET HOSE

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  9. INSTALL PUMP BRACKET


    1. B0026EFN01

      Install the pump bracket with the 6 bolts.

      Torque:
      for bolt A
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      for bolt B
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }
      Bolt Length
      Item Length Thread Diameter
      Bolt A 26 mm (1.02 in.) 18 mm (0.709 in.)
      Bolt B 29 mm (1.14 in.) 19 mm (0.748 in.)

  10. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. Install the No. 1 front engine mounting bracket RH with the 4 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  11. INSTALL WATER HOSE JOINT


    1. Clean the threads of the water hose joint and hole.

    2. Apply adhesive to 2 or 3 threads at the end of the water hose joint.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    3. B0026T7C01
      *a LH Side

      Install the water hose joint.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Install the water hose joint within 3 minutes after applying adhesive.

    4. Rotate the water hose joint clockwise to the position shown in the illustration.

      Note


      • Do not rotate the water hose joint by more than 1 revolution (360°) after tightening the water hose joint to the specified torque.

      • Do not loosen the water hose joint after setting it correctly.

  12. INSTALL WATER OUTLET HOUSING


    1. Install a new gasket to the cylinder head sub-assembly.

    2. Install the water outlet hosing with the 3 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  13. INSTALL IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)


    1. Temporarily install the idle pulley assembly with bracket with the 3 bolts.

    2. Tighten the 3 bolts.

      Torque:
      46.6 N*m  { 475 kgf*cm, 34 ft.*lbf }

  14. INSTALL INTAKE MANIFOLD

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  15. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  16. INSTALL CRANKSHAFT POSITION SENSOR

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  17. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  18. INSTALL INJECTION PUMP ASSEMBLY

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  19. INSTALL INJECTION PUMP DRIVE PULLEY

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  20. INSTALL GLOW PLUG ASSEMBLY

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  21. INSTALL NOZZLE HOLDER AND NOZZLE SET

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  22. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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  23. INSTALL NO. 1 GLOW PLUG CONNECTOR

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  24. INSTALL INJECTION PIPE SUB-ASSEMBLY

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  25. INSTALL VENTURI ASSEMBLY

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  26. INSTALL INTAKE FLANGE

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  27. INSTALL CRANKSHAFT TIMING PULLEY

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  28. INSTALL TIMING BELT GUIDE

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  29. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  30. INSTALL TIMING BELT

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  31. INSTALL TIMING BELT COVER

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  32. INSTALL CRANKSHAFT PULLEY

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  33. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

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