PREPARATION

ENGINE MECHANICAL . . . . . . . . . . . . . . . . . . . PP–1

TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . PP–8
EMISSION CONTROL . . . . . . . . . . . . . . . . . . . . PP–11
ELECTRONIC CONTROL DIESEL . . . . . . . . . PP–13
ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . PP–15
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP–18
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . PP–22
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP–27
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PP–30
 PP–1
PREPARATION – ENGINE MECHANICAL

ENGINE MECHANICAL
PP27K–01

SST (Special Service Tools)

09201–10000 Valve Guide Bushing Remover &
Replacer Set

(09201–01060) Valve Guide Bushing Remover &

Replacer 6

09202–70020 Valve Spring Compressor

(09202–00010) Attachment

09213–54015 Crankshaft Pulley Holding Tool

(91651–60855) Bolt

09223–15030 Oil Seal & Bearing Replacer Crankshaft rear oil seal

09223–46011 Crankshaft Front Oil Seal Crankshaft timing pulley

Replacer Camshaft oil seal

09229–55010 Oil Cooler Relief Valve Wrench

09248–55050 Valve Clearance Adjust Tool Set

(09248–05510) Valve Lifter Press

(09248–05520) Valve Lifter Stopper

PP–2
PREPARATION – ENGINE MECHANICAL

09316–60011 Transmission & Transfer Bearing

Replacer

(09316–00011) Replacer Pipe Crankshaft front oil seal

(09316–00021) Replacer ”A” Crankshaft front oil seal

09330–00021 Companion Flange Holding Tool Crankshaft pulley

09950–40011 Puller B Set

(09951–04010) Hanger 150 Camshaft timing pulley

(09952–04010) Slide Arm Camshaft timing pulley

(09953–04020) Center Bolt 150 Camshaft timing pulley

(09954–04010) Arm 25 Camshaft timing pulley

(09955–04071) Claw No.7 Camshaft timing pulley

(09957–04010) Attachment Camshaft timing pulley

(09958–04011) Holder Camshaft timing pulley

09950–50012 Puller C Set

 PP–3
PREPARATION – ENGINE MECHANICAL

(09951–05010) Hanger 150 Crankshaft pulley

Supply pump drive pulley
Crankshaft timing pulley

(09952–05010) Slide Arm Crankshaft pulley

Supply pump drive pulley
Crankshaft timing pulley

(09953–05010) Center Bolt 100 Crankshaft pulley

Supply pump drive pulley
Crankshaft timing pulley

(09953–05020) Center Bolt 150 Crankshaft pulley

Supply pump drive pulley
Crankshaft timing pulley

(09954–05020) Claw No.2 Supply pump drive pulley

Crankshaft timing pulley

(09954–05030) Claw No.3 Crankshaft pulley

09950–60010 Replacer Set

(09951–00280) Replacer 28 Nozzle holder gasket

(09951–00500) Replacer 50 Nozzle holder gasket

(09952–06010) Adapter Nozzle holder gasket

09950–70010 Handle Set

(09951–07100) Handle 100 Valve guide bushing

Nozzle holder gasket
Crankshaft rear oil seal

09960–10010 Variable Pin Wrench Set

PP–4
PREPARATION – ENGINE MECHANICAL

(09962–01000) Variable Pin Wrench Arm Assy

(09963–01000) Pin 10 Camshaft timing pulley

Supply pump drive pulley

09992–00025 Cylinder Compression Check Gauge

Set

(09992–00121) No. 4 Attachment

(09992–00211) Gauge Assy

 PP–5
PREPARATION – ENGINE MECHANICAL
PP27L–01

RECOMMENDED TOOLS
09040–00011 Hexagon Wrench Set .

(09043–20060) Socket Hexagon Wrench 6. Cylinder block oil orifice

(09043–20080) Socket Hexagon Wrench 8. No.1 idler pulley bolt

Oil jet pressure valve

09200–00010 Engine Adjust Kit .

PP–6
PREPARATION – ENGINE MECHANICAL
PP12U–02

EQUIPMENT
Abrasive compound
Caliper gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Groove cleaning tool
Heater
Magnetic finger
Micrometer
Piston ring compressor
Piston ring expander
Plastic–faced hammer
Plastigage
Precision straight edge
Press
Ridge reamer
Soft brush
Spring tester Valve spring
Steel square
Thermometer Valve spring
Torque wrench
Valve seat cutter
V–block
Vernier calipers
Wire brush
 PP–7
PREPARATION – ENGINE MECHANICAL
PP27M–01

SSM (Special Service Materials)

08826–00080 Seal Packing Black or equivalent Timing belt cover
(FIPG) No.5 camshaft bearing cap
Camshaft oil seal retainer
Cylinder head semi–circular plug
Cylinder head
Rear oil seal retainer
08826–00100 Seal Packing 1282B, Engine coolant drain union
THREE BOND 1282B or equivalent
(FIPG)

08833–00070 Adhesive 1324, Rear oil seal retainer stud bolt

THREE BOND 1324 or equivalent Drive plate bolt
PP–8
PREPARATION – TURBOCHARGING

TURBOCHARGING
PP283–01

SST (Special Service Tools)

09350–32014 TOYOTA Automatic Transmission
Tool Set

(09351–32070) No.2 Piston Spring Compressor Bearing housing

09992–00242 Turbocharger Pressure Gauge

09992–00600 Crank Type Spindle

 PP–9
PREPARATION – TURBOCHARGING
PP27N–01

RECOMMENDED TOOLS
09042–00010 Torx Socket T30 . Actuator

09082–00040 TOYOTA Electrical Tester.

PP–10
PREPARATION – TURBOCHARGING
PP12Y–02

EQUIPMENT
Dial indicator
Protractor
Steel square
Torque wrench
 PP–11
PREPARATION – EMISSION CONTROL

EMISSION CONTROL
PP287–01

RECOMMENDED TOOLS
09082–00040 TOYOTA Electrical Tester.
PP–12
PREPARATION – EMISSION CONTROL
PP288–01

EQUIPMENT
MITYVAC (Hand–held vacuum tester
Torque wrench
Vacuum gauge
 PP–13
PREPARATION – ELECTRONIC CONTROL DIESEL

ELECTRONIC CONTROL DIESEL

PP289–01

RECOMMENDED TOOLS
09082–00040 TOYOTA Electrical Tester.
PP–14
PREPARATION – ELECTRONIC CONTROL DIESEL
PP28A–01

EQUIPMENT
19 mm deep socket wrench
22 mm deep socket wrench
OBD II scan tool
Torque wrench
Vacuum gauge
 PP–15
PREPARATION – ENGINE FUEL

ENGINE FUEL
PP28B–01

SST (Special Service Tools)

09228–64030 Fuel Filter Wrench

09023–12700 Union Nut Wrench 17mm

09023–12900 Union Nut Wrench 19mm

09992–00242 Turbocharger Pressure Gauge

PP–16
PREPARATION – ENGINE FUEL
PP28C–01

RECOMMENDED TOOLS
09082–00040 TOYOTA Electrical Tester.
 PP–17
PREPARATION – ENGINE FUEL
PP28D–01

EQUIPMENT
Torque wrench
OBD II scan tool
PP–18
PREPARATION – COOLING

COOLING
PP136–02

SST (Special Service Tools)

09230–01010 Radiator Service Tool Set

09231–14010 Punch
 PP–19
PREPARATION – COOLING
PP27O–01

RECOMMENDED TOOLS
09042–00030 Torx Socket T20 . No.1 cooling fan motor

09082–00040 TOYOTA Electrical Tester.

PP–20
PREPARATION – COOLING
PP138–02

EQUIPMENT
Heater
Radiator cap tester
Thermometer
Torque wrench
Vernier calipers
 PP–21
PREPARATION – COOLING
PP139–02

COOLANT
Item Capacity Classification
Engine coolant ”Toyota Long Life Coolant” or equivalent
w/ Power heater 7.1 liters (7.5 US qts, 6.3 Imp. qts)
w/o Power heater 6.9 liters (7.3 US qts, 6.1 Imp. qts)
PP–22
PREPARATION – LUBRICATION

LUBRICATION
PP13A–02

SST (Special Service Tools)

09032–00100 Oil Pan Seal Cutter

09228–10002 Oil Filter Wrench

09229–55010 Oil Cooler Relief Valve Wrench

 PP–23
PREPARATION – LUBRICATION
PP27P–01

RECOMMENDED TOOLS
09040–00011 Hexagon Wrench Set .

(09043–20080) Socket Hexagon Wrench 8. Oil jet pressure valve

09200–00010 Engine Adjust Kit .

PP–24
PREPARATION – LUBRICATION
PP13C–02

EQUIPMENT
Oil pressure switch
Torque wrench
 PP–25
PREPARATION – LUBRICATION
PP13D–02

LUBRICANT
Item Capacity Classification
Engine oil API grade CF–4
Dry fill 6.5 liters (6.9 US qts, 5.7 Imp. qts) (You may also use API CF or CE or CD)
Drain and refill
w/ Oil filter change 6.4 liters (6.8 US qts, 5.6 Imp. qts)
w/o Oil filter change 5.4 liters (5.7 US qts, 4.8 Imp. qts)
PP–26
PREPARATION – LUBRICATION
PP27Q–01

SSM (Special Service Materials)

08826–00080 Seal Packing Black or equivalent Oil pump
(FIPG) No.1 oil pan
No.2 oil pan

08833–00070 Adhesive 1324, Oil pump stud bolt

THREE BOND 1324 or equivalent

08833–00080 Adhesive 1344 Oil pressure switch

THREE BOND 1344
LOCTITE 242 or equivalent
 PP–27
PREPARATION – STARTING

STARTING
PP27R–01

SST (Special Service Tools)

09950–60010 Replacer Set

(09951–00340) Replacer 34 Brush holder

PP–28
PREPARATION – STARTING
PP27S–01

RECOMMENDED TOOLS
09082–00040 TOYOTA Electrical Tester.
 PP–29
PREPARATION – STARTING
PP1MU–03

EQUIPMENT
Dial indicator Commutator
Feeler gauge
Sandpaper Commutator
Vernier calipers Commutator, Brush
Torque wrench
V–block
Vise
PP–30
PREPARATION – CHARGING

CHARGING
PP27E–01

SST (Special Service Tools)

09285–76010 Injection Pump Camshaft Bearing Rotor rear bearing cover
Cone Replacer

09286–46011 Injection Pump Spline Shaft Rectifier end frame

Puller

09820–00021 Alternator Rear Bearing Puller

09820–00030 Alternator Rear Bearing Replacer

09820–63010 Alternator Pulley Set Nut Wrench

Set

09950–60010 Replacer Set Rotor front bearing

(09951–00230) Replacer 23

(09951–00500) Replacer 50

(09952–06010) Adapter
 PP–31
PREPARATION – CHARGING
PP1TH–03

RECOMMENDED TOOLS
09082–00040 TOYOTA Electrical Tester.
PP–32
PREPARATION – CHARGING
PP1TI–03

EQUIPMENT
Ammeter(A)
Battery specific gravity gauge Except maintenance–free battery
Torque wrench
Vernier calipers Rotor (Slip ring)
Plastic hammer
Belt Tension gauge