Sherman the Landcruiser

Prep & Engine Removal

• Label hoses and grounds (photograph routing before you touch anything)
• Drain fluids: coolant, engine oil, and depressurise fuel if opening fuel lines
• Disconnect battery
• Remove fan, shroud, radiator as needed for clearance
• Hoist engine out while supporting the transmission

Transmission Seal & Mounts (Engine Out)

• Context: engine separated from transmission (engine on stand or on floor; transmission stays in vehicle)
• Front bearing retainer (input) seal
  • Press new seal to spec depth: 15.4-16.2 mm (H14x/H15x manuals)
• Rear main seal & flywheel
  • Remove flywheel
  • Check flywheel bolts and replace if needed (replace if shank OD < 9.5 mm per Toyota inspection)
  • Reseal rear seal retainer/flange with sealant and torque retainer bolts to 20 N-m
  • Install flywheel bolts (oil threads/under-head), torque 20 N-m + 90 degrees in sequence
• Engine mounts
  • Engine mount bracket bolts: 69 N-m
  • Engine mount insulator nuts: 72 N-m
• Best practice while separated: Inspect/replace clutch wear items as needed: disc, pressure plate, throw-out bearing, pilot bush/bearing, fork/pivot, clips, alignment

Oil Cooler & Accessories (Engine Off)

• Drain coolant (oil cooler is coolant-fed)
• Remove No.1 exhaust manifold for access
• Remove oil cooler cover and cooler, replace gaskets/O-rings, inspect relief valve
• Reinstall and torque
  • Relief valve plug: 49 N-m
  • Oil cooler nuts: 17 N-m
  • Oil cooler cover to block: 21 N-m
  • Exhaust manifold nuts: 39 N-m
• Oil pressure switch threads
  • Apply approved thread sealant/adhesive (eg ThreeBond 1344 or Loctite 242) as Toyota directs

Cooling System Refresh

• Thermostat
  • Replace thermostat and gasket
  • Align jiggle valve +/15 degrees
  • Water inlet nuts: 21 N-m
• Water pump
  • Replace water pump and gasket
  • Water pump bolts: 21 N-m
• Belts
  • Fit new accessory belts
  • Tension per spec (deflection at 98 N):
    • New belt: 11-15 mm
    • Used belt: 15-20 mm
• Recheck tension after running

Timing Cover / Oil Pump Reseal (Head Removed)

• Drain engine oil
• Remove water pump
• Remove cylinder head (reassembly uses new head gasket, head bolts, and washers)
• Remove No.2 oil pan then No.1 oil pan (Toyota order)
• Remove crank pulley (use holding tool/SST)
• Remove drive belt idler
• Remove timing cover/oil pump assembly and its two O-rings
• Cleaning
  • Scrape old sealant completely
  • Clean sealing surfaces with non-residue solvent
  • Use Toyota FIPG 08826-00080 (or equivalent)
  • Assemble within 5 minutes of bead application (otherwise remove and redo)
• Reassembly
  • Set crank to TDC (key down)
  • Align timing chain bright links with timing marks and secure chain
  • Install new O-rings
  • Apply FIPG and install timing cover/oil pump: 21 N-m
  • Refit idler pulley: 43 N-m
  • Refit crank pulley and torque crank bolt: 412 N-m
• Front crank seal
  • Install flush in cover, grease seal lip
• Oil pans
  • No.1 oil pan with fresh FIPG:
    • 43 N-m (14 mm head fasteners)
    • 20 N-m (12 mm head fasteners)
  • No.2 oil pan:
    • Bolts 7.8 N-m
    • Nuts 8.8 N-m
• Pre-lube/prime step before finishing pans: Pour ~15 cm^3 fresh oil into the timing cover gallery to help prime the pump

Top End Seals & Head Reassembly

• Half-moon plugs
  • Install half-moon plugs using FIPG
• Distributor
  • Fit new distributor O-ring (lightly oil it)
  • Set distributor at TDC during install
  • Distributor hold-down bolt: 18 N-m (ignition adjustment spec)
• Head gasket and head bolts
  • Install new head gasket
  • Use new head bolts and new washers
  • Torque exactly per Toyota spec + angle steps and sequence (torque-to-angle bolts: treat as replace, not reuse)
• Valve cover
  • Install with new valve cover gasket
  • Torque fasteners per manual

Sources

Final Assembly

• Mate engine to transmission
  • Do not rest engine weight on the clutch
  • Torque transmission-to-engine bolts: 72 N-m
• Starter
  • Install and torque mounting bolt/nut: 39 N-m
• Reconnect everything
  • Vacuum hoses, heater lines, grounds/earths, and wiring (verify against your photos/diagrams)
  • Reinstall exhaust manifold and remaining hardware (use new studs/nuts if needed)

Fill & First Run

• Refill engine oil and coolant
• Prime oil system
  • Crank with ignition/fuel disabled until you see oil pressure
• Start and leak-check
  • Timing cover perimeter and crank seal area
  • No.1 and No.2 oil pan seams
  • Oil cooler cover and relief plug area
  • Rear main/seal retainer area
• After ~5 minutes run time
  • Recheck and re-tension belts to spec
• Verify ignition timing and final checks
  • Confirm all hoses and grounds are secure

Torque and Spec Quick Sheet

Shopping List

Engine Hardware & Fasteners

• Head bolts (TTY) - 90910-02111 x14
• Head bolt washers - 90201-12222 x14
• Flywheel bolts (M/T) - 90105-12244 x10
• Exhaust manifold studs (No.1 manifold) - 90116-10169 x6 (optional/recommended)
• Exhaust manifold nuts - 90179-10128 x6 (optional/recommended)
• Exhaust-to-pipe studs - 90080-12007 x2 (optional/recommended)
• Exhaust lock nuts - 90080-17187 x2 (optional/recommended)

Top-end Gasket Kit (recommended approach)

• Full OEM head gasket set / top-end kit (example: EGGK66030) x1
  • Includes (typically): head gasket, valve cover gasket, intake/exhaust manifold gaskets, throttle body gasket, distributor O-ring, spark plug tube seals, half-moons, valve stem seals, injector seals (varies), EGR gaskets (if applicable)

Top-end Items (only if not Included in Your kit)

• Spark plug tube seals - 11193-15010 x6
• Half-moon plugs - 11183-50010 x2
• Distributor O-ring - 90099-14118 x1
• Valve stem seals (intake + exhaust) - (buy set if not in kit) x1 set
• Injector O-rings + insulators/grommets - (application dependent) x6 sets
• EGR gaskets - (only if EGR fitted) x1 set

Front of Engine / Timing Cover / Oil Pump / Sump Reseal

• FIPG sealant (Toyota seal packing) - 08826-00080 x2
• Front crankshaft oil seal - 90311-52022 x1
• Timing cover/oil pump O-ring (round) - 96761-24042 x1
• Timing cover gasket/O-ring (square) - 11328-66020 x1
• Oil strainer/pickup gasket - 15147-66020 x1 (only if strainer removed)
• Oil pump gasket - 15188-66020 x1

Oil Cooler Service

• Oil cooler cover gasket (cover-to-block) - 15725-66010 x1
• Oil cooler gaskets (cooler-to-cover) - 15785-66010 x2
• Oil cooler relief valve gasket - 15134-20010 x2
• Oil cooler plug / relief valve plug parts (only if removed)
  • Plug, oil cooler - 90341-20002 x1
  • Plug, oil cooler relief valve - 15133-20010 x2

Rear of Engine

• Rear main seal - 90311-99009 x1
• Rear main seal retainer reseal - uses FIPG (no paper gasket)

Cooling System

• Water pump - 16100-69325 x1 (or equivalent quality)
• Water pump gasket - (comes with pump / application dependent) x1
• Thermostat - 90916-03117 x1
• Thermostat gasket/seal - 16346-66020 x1
• Water bypass tube O-ring - 90301-29006 x3 (buy 3 to cover joints you disturb)
• Hoses (condition-based)
  • Water bypass hose No.1 - 16261-66040 x1 (if brittle/soft)
  • Water bypass hose No.2 - 16264-66021 x1 (if brittle/soft)
  • Radiator/heater hoses - (as needed)
• Hose clamps - assorted spares

Drive Belts (replace as a set)

• Belt - 90916-02452 x1
• Belt - 90916-02353 x1
• A/C belt - 99332-60910 x1

Breather/PCV & Vacuum (optional refresh)

• PCV valve - 12204-35040 x1
• PCV grommet - 90480-18001 x1
• Crankcase vent hoses - 12261-66021 x1 (inspect/replace)
• Crankcase vent hoses - 12262-66021 x1 (inspect/replace)

Thread/seal Chemicals

• Thread seal/locker for oil pressure sender threads - ThreeBond 1344 / Loctite 242 equivalent x1

Driveline / Clutch (only if Refreshing while separated)

• Transmission input/front bearing retainer oil seal - 90311-35023 x1
• Pilot bearing/bush - (application dependent) x1
• Throw-out bearing - (application dependent) x1
• Clutch kit - (only if needed) x1

Notes

• "Only if removed" items: buy if your workflow includes removing that subassembly.
• For any kit (EGGK66030 or similar), confirm the included contents before doubling up on seals.