ENGINE UNIT INSTALLATION


  1. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Clean the threads of the oil pressure switch and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      Note

      Do not apply adhesive to the oil inlet port of the oil pressure switch.

    2. Using a 24 mm deep socket wrench, install the oil pressure switch.

      Torque:
      15 N*m  { 150 kgf*cm, 11 ft.*lbf }

      Note

      Do not start the engine within 1 hour of installation.

  2. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. A00JUOBE01
      Text in Illustration
      *1 Nut

      Install a new gasket and the oil filter bracket with the 10 bolts and 2 nuts.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

  3. INSTALL EXHAUST MANIFOLD


    1. A0097W7E01
      Text in Illustration
      *a Front Mark

      Install a new gasket to the cylinder head.

      Tech Tips

      Be sure to install a new gasket in the correct direction as shown in the illustration.

    2. A009BTKE01
      Text in Illustration
      *1 Nut

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

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

  4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A0096YME01

      Install the insulator with the 3 bolts.

      Torque:
      for bolt A
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
      for bolt B
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  5. INSTALL VACUUM PUMP OIL OUTLET HOSE


    1. A00JZVDE01

      Install the vacuum pump oil outlet hose with the bolt and 2 new gaskets.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  6. INSTALL UNION


    1. Clean the threads of the union and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Install the union to the cylinder block.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  7. INSTALL VACUUM PUMP OIL INLET HOSE


    1. A00JWVQE03

      Connect the vacuum pump oil inlet hose with a new gasket and the union bolt.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }

      Tech Tips

      When tightening the inlet hose, hang the stopper-bar of the inlet hose on the filter bracket to prevent the inlet hose from rotating.

      Text in Illustration
      *1 Stopper-bar

  8. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket with the 4 bolts.

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

  9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the dipstick guide.

    3. Install the dipstick guide with the 2 bolts.

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

    4. Install the dipstick.

  10. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. Install the engine mounting bracket with the 4 bolts.

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

  11. INSTALL PUMP BRACKET


    1. A00JVPHE01

      Install the pump bracket with the 3 bolts.

      Torque:
      for bolt A
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      except bolt A
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  12. INSTALL NO. 1 GENERATOR BRACKET


    1. Install the generator bracket with the 3 bolts.

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

  13. INSTALL WATER BY-PASS HOSE UNION


    1. Clean the threads of the water by-pass hose union and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the water by-pass hose union.

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

  14. INSTALL INTAKE MANIFOLD


    1. A0099ANE02
      Text in Illustration
      *a Protrusion
      *b Upward

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

    2. A0099VAE01
      Text in Illustration
      *1 Nut

      Install the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.

      Torque:
      24 N*m  { 240 kgf*cm, 17 ft.*lbf }

    3. Install the wire harness bracket with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

  15. INSTALL WATER OUTLET HOUSING


    1. Install a new gasket to the cylinder head.

    2. Install the outlet hosing with the 3 bolts

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

  16. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. Install a new gasket and the engine coolant temperature sensor with the bolt.

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

    2. Connect the engine coolant temperature sensor connector.

  17. INSTALL CRANKSHAFT POSITION SENSOR


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

    2. Install the crankshaft position sensor with the bolt.

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

    3. Connect the crankshaft position sensor connector.

  18. INSTALL INJECTION PUMP ASSEMBLY


    1. Temporarily install the injection pump to the timing gear case with the 2 nuts.

    2. Temporarily install the injection pump stay to the injection pump rear end with the 3 bolts.

    3. A00JWU4E01

      Rotate the pump body to align the marks on the pump flange and timing gear case.

    4. Tighten the 2 nuts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

    5. Tighten the 3 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
    6. A00K1ZY

      Connect the 3 fuel hoses.

    7. Connect the 5 connectors and attach the wire harness clamp.

  19. INSTALL INJECTION PUMP DRIVE PULLEY


    1. A00K1PUE01

      Using SST, install the injection pump drive pulley with the nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  20. INSTALL GLOW PLUG ASSEMBLY


    1. Using a 12 mm deep socket wrench, install the 4 glow plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  21. INSTALL NOZZLE HOLDER & NOZZLE SET


    1. A00JWYSE01

      Install 4 new injection nozzle seat gaskets and the 4 injection nozzle seats to the injection nozzle holes of the cylinder head.

    2. Using SST, install the 4 nozzle holder and nozzle sets.

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

  22. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Install 4 new ring packing washers and the leakage pipe with the 4 nuts.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

    2. Connect the fuel hose to the leakage pipe.

  23. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Install the No. 1 glow plug resistor insulator and No. 1 glow plug connector.

    2. A009A2KE01
      Text in Illustration
      *1 Nut
      *2 Washer
      *3 No. 2 Glow Plug Resistor Insulator
      *4 Engine Wire
      *5 No. 1 Glow Plug Connector
      *6 No. 1 Glow Plug Resistor Insulator
      *7 Bolt

      Install the glow plug connector with the 4 nuts. Uniformly tighten the nuts.

      Torque:
      1.0 N*m  { 10 kgf*cm, 9 in.*lbf }

    3. Install the 4 screw grommets.

    4. Connect the engine wire and install the No. 2 glow plug resistor insulator and washer with the bolt.

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

  24. INSTALL INJECTION PIPE SET


    1. Install the 2 lower clamps to the intake manifold.

    2. A00JV8HE01
      Text in Illustration
      *a for Injection Nozzle Side
      *b for Injection Pump Side

      Install the 4 injection pipes.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Install the 2 upper pipe clamps with the 2 nuts.

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

  25. INSTALL DIESEL THROTTLE BODY


    1. Install a new gasket and the diesel throttle body.

    2. Connect the throttle control motor connector.

    3. Install the bracket with the 2 bolts.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

    4. Connect the throttle open switch connector.

  26. INSTALL INTAKE FLANGE


    1. Install a new gasket and the intake flange with the 3 nuts.

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

    2. Connect the manifold absolute pressure sensor connector.

    3. Install the heater hose bracket with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

    4. Connect the PCV hose.

  27. INSTALL CRANKSHAFT TIMING PULLEY


    1. A00JVXNE04
      Text in Illustration
      *a Inside

      Align the key groove of the timing pulley with the pulley set key.

    2. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.

      SST
      09223-46011

  28. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A00O6RAE03
      Text in Illustration
      *1 Timing Mark
      A00O9VA Turn

      Using the crankshaft pulley bolt, align the groove of the crankshaft pulley with the timing pointer by turning the crankshaft clockwise.

      Note

      Do not turn the crankshaft pulley counterclockwise.

    2. A00O7JOE01

      Set the timing and drive pulleys at each position.

      Note


      • Make sure the engine is cold.

      • When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.

  29. INSTALL TIMING BELT

    A00O4FCE01

    Tech Tips

    If reusing the timing belt, align the points marked during removal, and install the timing belt with the arrow pointing in the direction the belt moves when the engine is running.


    1. Remove any oil or water on each pulley, and keep them clean.

    2. Install the timing belt to the crankshaft timing and timing belt idlers.

    3. A00O8POE01
      Text in Illustration
      *1 Timing Mark

      Using SST, slightly turn the injection pump drive pulley clockwise. Install the timing belt to the pulley, and align the timing marks of the drive pulley and timing belt case.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    4. A00O64HE01
      Text in Illustration
      *1 Timing Mark

      Using SST, slightly turn the camshaft timing pulley clockwise. Install the timing belt to the timing pulley, and align the timing marks of the timing pulley and timing belt case.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    5. Check that the timing belt has tension between the injection pump drive and camshaft timing pulleys.

    6. Install the timing belt to the No. 1 timing belt idler.

    7. A00OBI4E01

      Loosen the No. 1 timing belt idler bolt (A), and stretch the timing belt.

    8. Slowly turn the crankshaft pulley.

      Note

      Always turn the crankshaft clockwise.

    9. Tighten the No. 1 timing belt idler bolt.

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  30. INSTALL TIMING BELT COVER


    1. A00OAA3E02
      Text in Illustration
      *1 Gasket

      Install 2 new gaskets to the timing belt cover.

    2. A00O4CGE01

      Install the timing belt cover with the 11 bolts and washers.

      Torque:
      for bolt A
      8.5 N*m  { 85 kgf*cm, 75 ft.*lbf }
      except bolt A
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  31. INSTALL CRANKSHAFT PULLEY


    1. Align the key groove of the pulley with the pulley set key, and slide the pulley onto the crankshaft to install it.

    2. A00OAEYE02
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, install the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      235 N*m  { 2396 kgf*cm, 173 ft.*lbf }

  32. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A00K0NW

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

      Torque:
      81 N*m  { 829 kgf*cm, 60 ft.*lbf }

  33. INSTALL ENGINE WIRE