Engine Unit Installation

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

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

NOTICE:

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

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

Torque:

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

NOTICE:

Do not start the engine within 1 hour of installation.

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}

Install a new gasket to the cylinder head.

HINT:

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

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}

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}

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

Torque:

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

HINT:

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

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

Adhesive:

Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

Install the union to the cylinder block.

Torque:

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

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}

HINT:

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

Install the engine mounting bracket with the 4 bolts.

Torque:

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

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

Install the O-ring to the dipstick guide.

Install the dipstick guide with the 2 bolts.

Torque:

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

Install the dipstick.

Install the engine mounting bracket with the 4 bolts.

Torque:

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

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}

Install the generator bracket with the 3 bolts.

Torque:

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

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

Install the water by-pass hose union.

Torque:

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

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

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}

Install the wire harness bracket with the bolt.

Torque:

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

Install a new gasket to the cylinder head.

Install the outlet hosing with the 3 bolts

Torque:

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

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

Torque:

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

Connect the engine coolant temperature sensor connector.

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

Install the crankshaft position sensor with the bolt.

Torque:

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

Connect the crankshaft position sensor connector.

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

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

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

Tighten the 2 nuts.

Torque:

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

Tighten the 3 bolts.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Connect the 3 fuel hoses.

Connect the 5 connectors and attach the wire harness clamp.

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}

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

Torque:

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

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

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}

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

Torque:

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

Connect the fuel hose to the leakage pipe.

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

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

Torque:

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

Install the 4 screw grommets.

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}

Install the 2 lower clamps to the intake manifold.

Install the 4 injection pipes.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Install the 2 upper pipe clamps with the 2 nuts.

Torque:

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

Install a new gasket and the diesel throttle body.

Connect the throttle control motor connector.

Install the bracket with the 2 bolts.

Torque:

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

Connect the throttle open switch connector.

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

Torque:

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

Connect the manifold absolute pressure sensor connector.

Install the heater hose bracket with the bolt.

Torque:

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

Connect the PCV hose.

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

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

SST

09223-46011

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

Text in Illustration

*1	Timing Mark
	Turn

NOTICE:

Do not turn the crankshaft pulley counterclockwise.

Set the timing and drive pulleys at each position.

NOTICE:

1. Make sure the engine is cold.
   
2. When turning the crankshaft or camshaft, the valve heads will hit against the piston top. Do not turn them more than necessary.
   

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

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

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)

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)

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

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

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

Slowly turn the crankshaft pulley.

NOTICE:

Always turn the crankshaft clockwise.

Tighten the No. 1 timing belt idler bolt.

Torque:

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

Install 2 new gaskets to the timing belt cover.

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}

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

Using SST, install the pulley bolt.

SST

09213-54015(91651-60855)
09330-00021

Torque:

235 N*m{2396 kgf*cm, 173 ft.*lbf}

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

Torque:

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