ENGINE ASSEMBLY INSTALLATION


  1. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the bolt and wire harness clamp bracket.

  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01E0ZS

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01DWTE

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

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

  3. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. A01DXFI

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

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

  4. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter installation surface.

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

    3. Install the oil filter, and tighten it by hand until the gasket contacts the installation surface.

    4. A01DWBQE01

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

      SST
      09228-44011

  5. INSTALL EXHAUST MANIFOLD


    1. A01E0XTE02

      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. A01DZSJ

      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 }

  6. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01E318E02

      Install the heat insulator with the 3 bolts.

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

  7. INSTALL OIL DIPSTICK GUIDE


    1. Apply clean engine oil to a new O-ring.

    2. Install the O-ring to the guide.

    3. Install the guide with the 2 bolts.

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

  8. INSTALL OIL DIPSTICK SUB-ASSEMBLY


    1. Install the dipstick to the guide.

  9. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. A01E0A9

      Install the engine mounting bracket with the 4 bolts.

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

  10. INSTALL GENERATOR ASSEMBLY


    1. Install the generator assembly Click here.

  11. INSTALL PUMP BRACKET


    1. A01E045E01

      Install the pump bracket with the 6 bolts.

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

  12. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Clean the threads of the water drain cock, and apply adhesive to them.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the water drain cock.

      Torque:
      57 N*m  { 581 kgf*cm, 42 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  { 400 kgf*cm, 29 ft.*lbf }

  14. INSTALL INTAKE MANIFOLD


    1. A01DWCOE01

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

    2. A01E0V4

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

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

  15. INSTALL WATER OUTLET HOUSING


    1. Install a new gasket to the cylinder head.

    2. A01DVY7

      Install the outlet hosing with the 3 bolts

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

  16. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    A01E00D

    1. Using a 17 mm deep socket wrench, install the sensor.

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

  17. INSTALL CRANKSHAFT POSITION SENSOR


    1. Apply clean engine oil to a new O-ring.

    2. Install the O-ring to the sensor.

    3. Install the sensor with the bolt.

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

  18. INSTALL INJECTION PUMP ASSEMBLY


    1. A01E2K6E02

      Install the injection pump to the timing gear case, and temporarily tighten the 2 nuts.

    2. Install the injection pump stay to the injection pump rear end, and temporarily tighten the 3 bolts.

    3. A01DYGKE01

      Rotate the pump body to align the marking of the pump flange and timing gear case.

    4. Tighten the 2 nuts to install the injection pump.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

    5. Tighten the 3 bolts to install the injection pump stay.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for injection pump stay to cylinder block }
      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for injection pump stay to injection pump }
    6. A01DZZ2E01

      Connect the 3 fuel hoses.

    7. Connect the engine speed sensor connector.

    8. Connect the spill control valve connector.

    9. Connect the correction unit connector.

    10. Connect the timing control valve connector.

    11. Connect the fuel temperature sensor connector.

    12. Connect the engine wire clamp.

  19. INSTALL INJECTION PUMP DRIVE PULLEY


    1. A01E2RTE01

      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. A01DWQX

      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. A01DWFME01

      Place 4 new injection nozzle seat gaskets and 4 injection nozzle seats into the injection nozzle holes of the cylinder head.

    2. Using SST, install the 4 nozzle holders 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. A01DZQ7

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

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

    2. Connect the fuel hose to the leakage pipe.

  23. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Install the glow plug connector by uniformly tightening the 4 nuts.

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

    2. Install the 4 screw grommets.

    3. Install the wire harness with the nut.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

  24. INSTALL INJECTION PIPE SET


    1. A01DX04

      Connect the 2 lower clamps on the intake manifold.

    2. Using a union nut wrench, install the 4 injection pipes.

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

    3. Secure the injection pipes with the 2 upper pipe clamps and 2 nuts.

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

  25. INSTALL VENTURI ASSEMBLY


    1. Place a new gasket and the venturi on the intake manifold.

    2. A01E2GDE02

      Connect the throttle control motor connector.

    3. A01DWS5E02

      Connect the throttle open switch connector.

  26. INSTALL INTAKE PIPE ASSEMBLY

    A01DYF6

    1. Install the intake pipe with the 2 bolts.

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

    2. Tighten the intake pipe clamp.

  27. INSTALL CRANKSHAFT TIMING PULLEY


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

    2. A01E066E02

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

      SST
      09223-46011

  28. INSTALL TIMING BELT

    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 of engine revolution.


    1. A01DZPNE01

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

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

    3. A01E039E01

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

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    4. A01DZWDE02

      Using SST, slightly turn the camshaft timing pulley clockwise. Hang the timing belt on 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 on the No. 2 timing belt idler.

  29. INSTALL TIMING BELT COVER SUB-ASSEMBLY

    A01E1Z5E01

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

    2. A01DWFG

      Install the timing belt cover with the 11 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  30. INSTALL CRANKSHAFT PULLEY


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

    2. A01DXCTE01

      Using SST, install the new pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      235 N*m  { 2,400 kgf*cm, 173 ft.*lbf }

  31. INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. Temporarily install the compressor mounting bracket with the 4 bolts.

    2. A01DXAJE02

      Using several steps, uniformly install and tighten the 4 bolts.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    3. A01E1CQE01

      Temporarily install the spacer with the bolt.

  32. INSTALL FAN BELT ADJUSTING BAR (w/o Air Conditioning System)


    1. A01DW3Z

      Install the fan belt adjusting bar with the 2 bolts.

      Torque:
      45 N*m  { 460 kgf*cm, 33 ft.*lbf }
    2. A01DXWX

      Temporarily install the bolt.

  33. INSTALL ENGINE WIRE

  34. REMOVE ENGINE STAND

  35. INSTALL ENGINE ASSEMBLY


    1. Attach the chain block and engine sling device to the engine hangers.

    2. Slowly lower the engine into the engine compartment.

    3. Install the engine mounting bracket with the 4 bolts and 4 nuts.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

      Note

      Tighten the nuts when install the engine mounting.

    4. Remove the No. 2 engine hanger.

  36. INSTALL VANE PUMP ASSEMBLY


    1. Temporarily install the vane pump assembly with the 2 bolts.

    2. A01E12BE01

      Install the pulley to the pump shaft.

    3. Using SST, stop the pulley rotation and torque the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }

  37. INSTALL COMPRESSOR AND MAGNET CLUTCH (w/ Air Conditioning System)

    A01E0VI

    1. Install the compressor with the 4 bolts.

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

  38. CONNECT HOSES AND CONNECTORS


    1. Connect the vacuum pump hose to the generator.

    2. A01E20T

      Connect the connectors as shown in the illustration.

    3. A01DV20

      Connect the compressor connector.

    4. A01E34C

      Connect the 2 water hoses.

    5. Install the water hose clamp with the bolt.

    6. A01DZOQ

      Connect the 2 fuel hoses.

    7. A01E30IE01

      Install the ground cable with the bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    8. Connect the 2 engine room junction block connectors.

    9. Install the engine room junction block wire with the nut.

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

    10. Install the engine room relay block cover (side).

    11. Install the engine room relay block cover (upper).

    12. A01DZVP

      Connect the connector and clamp as shown in the illustration.

  39. INSTALL REAR END PLATE


    1. Install the rear end plate with the 2 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  40. INSTALL FLYWHEEL SUB-ASSEMBLY

    A01DWNFE01

    1. Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Clean the bolts and bolt holes.

    3. A01E1JTE01

      Apply adhesive to 2 or 3 threads of the bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the flywheel on the crankshaft.

    5. A01DYIGE01

      Install and uniformly tighten the 8 bolts in several steps, in the sequence shown.

      Torque:
      123 N*m  { 1,250 kgf*cm, 90 ft.*lbf }

      Note

      Do not start the engine within an hour after installing.

  41. INSTALL CLUTCH DISC ASSEMBLY

    A01DX10E02

    1. Insert SST into the clutch disc. Then insert the SST (together with the clutch disc) into the flywheel.

      SST
      09301-00110

      Note

      Take care not to insert the clutch disc facing the wrong direction.

  42. INSTALL CLUTCH COVER ASSEMBLY


    1. A01E0WKE01

      Align the matchmarks on the clutch cover and flywheel.

    2. Tighten the 6 bolts as described below.


      1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.

      2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.

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

    3. Lightly move SST up and down, and right and left.

      SST
      09301-00110

    4. Check that the disc is in the center, and then tighten the bolts.

  43. INSTALL TRANSMISSION ASSEMBLY


    1. 2WD:

      Install the transmission Click here.

    2. 4WD:

      Install the transmission Click here.

  44. INSTALL PROPELLER SHAFT ASSEMBLY


    1. Front side:

      Install the propeller shaft Click here.

    2. Rear side:

      Install the propeller shaft Click here.

  45. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Temporally install the pipe support and clamp with the bolt.

    2. Install a new gasket to the exhaust manifold.

    3. Install the front exhaust pipe to the exhaust manifold with the 3 nuts. Alternately tighten the bolts in several passes.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    4. Install the stay to the transmission with the 2 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

    5. Install the clamp with the bolt.

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

  46. INSTALL STARTER ASSEMBLY


    1. A01E10K

      Install the starter with the 2 bolts and nut.

      Torque:
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }

    2. Install the stay with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    3. Install the stay with the nut.

      Torque:
      12.3 N*m  { 125 kgf*cm, 9 ft.*lbf }

    4. Connect the terminal 30 wire with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 7 ft.*lbf }
    5. A01E0BH

      Install the terminal cap.

    6. Connect the starter connector.

  47. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator Click here.

  48. CONNECT RADIATOR HOSE OUTLET

  49. CONNECT RADIATOR HOSE INLET

  50. INSTALL AIR CLEANER ASSEMBLY


    1. Install the cleaner with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    2. Connect the connector to the IAT meter.

    3. Connect the hose clamp.

  51. INSTALL BATTERY AND BATTERY TRAY

  52. INSTALL BATTERY BRACKET


    1. Install the battery bracket with the bolt.

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

  53. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood with the 4 bolts.

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

    2. Connect the washer nozzle hose.

    3. Adjust the hood.

  54. ADD ENGINE OIL


    1. Add fresh engine oil.

      Standard capacity
      Item Specified Condition
      Drain and refill with oil filter change 7.2 liters (7.6 US qts, 6.3 Imp. qts)
      Drain and refill without oil filter change 6.7 liters (7.1 US qts, 5.9 Imp. qts)
      Dry fill 8.4 liters (8.9 US qts, 7.4 Imp. qts)

    2. Reinstall the oil filler cap.

  55. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
    3. A01E10Y

      Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's FULL line.

      Standard capacity
      9.4 liters (9.9 US qts, 8.3 Imp. qts)

      Tech Tips


      • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).


      • Please contact your TOYOTA dealer for further details.

      Note

      Never use water as a substitute for engine coolant.

    4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level drops below the FULL line, add TOYOTA SLLC to the FULL line.

    5. Install the radiator reservoir cap.

    6. A01DY58E01

      Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    7. Bleed air from the cooling system.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

      2. Maintain the engine speed at 2,500 to 3,000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        CAUTION:

        When pressing the radiator hoses:


        • Wear protective gloves.


        • Be careful as the radiator hoses are hot.


        • Keep your hands away from the radiator fan.

      4. Stop the engine and wait until the coolant cools down to ambient temperature.

        CAUTION:

        Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    8. A01E10Y

      After the coolant cools down, check that the coolant level is at the FULL line.

      If the coolant level is below the low line, add TOYOTA SLLC to the FULL line.

  56. ADD FUEL

  57. TIGHTEN FUEL TANK CAP ASSEMBLY

  58. BLEED AIR FROM FUEL SYSTEM

    A01DYNDE01

    1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

  59. INSTALL FRONT WHEEL

  60. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  61. PERFORM INITIALIZATION


    1. Perform initialization Click here.

      Note

      Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

  62. CHECK FOR FUEL LEAKS

  63. CHECK FOR ENGINE OIL LEAKS

  64. CHECK FOR ENGINE COOLANT LEAKS


    1. Check for engine coolant leaks Click here.

  65. CHECK TRANSMISSION OIL


    1. 2WD:

      Check transmission oil Click here.

    2. 4WD:

      Check transmission oil Click here.

  66. CHECK FOR EXHAUST GAS LEAKS

  67. INSPECT ENGINE IDLE SPEED


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Measure the idle speed.

        Standard idle speed
        720 to 820 rpm (A/C OFF)
        750 to 850 rpm (A/C ON)

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

    3. A01E2VIE58

      When not using the intelligent tester:


      1. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18040

      2. Measure the idle speed.

        Standard idle speed
        720 to 820 rpm (A/C OFF)
        750 to 850 rpm (A/C ON)

        Note

        Switch off all accessories.

  68. INSPECT MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Measure the maximum speed.

      Maximum speed
      4,850 to 4,950 rpm

  69. INSTALL NO. 2 ENGINE UNDER COVER (for 4WD)

    A01DXC0

    1. Install the under cover with the 4 bolts.

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

  70. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD)

    A01DWKI

    1. Install the under cover with the 8 bolts.

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