Monolithic Converter Installation

Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.

Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the 3 bolts.

Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.

Torque:

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

Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the bolt and 2 new nuts.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.

Torque:

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

Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

Torque:

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

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST

09224-00011

Torque:

Specified tightening torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
2. When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 38 N*m (384 kgf*cm, 28 ft.*lbf)
   

Connect the connector and 2 clamps.

Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft assembly.

HINT:

Install the steering intermediate shaft to the inside of the vehicle.

Install the bolt.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Install the engine cover bracket to the cylinder head sub-assembly with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Attach the 2 clamps and connect the engine wire to the cylinder head sub-assembly.

Install the pipe clamp to the engine cover bracket with the 3 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install a new clamp to the pipe clamp.

Temporarily install the No. 2 vacuum pipe to the exhaust manifold converter sub-assembly.

Temporarily install the No. 1 vacuum pipe to the exhaust manifold converter sub-assembly.

Install a new clamp to the No. 1 vacuum pipe and No. 2 vacuum pipe with the nut.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

Using a 17 mm union nut wrench, tighten the No. 2 vacuum pipe.

Torque:

Specified tightening torque

48 N*m {489 kgf*cm, 35 ft.*lbf}

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
2. When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)
   

Using a 17 mm union nut wrench, tighten the No. 1 vacuum pipe.

Torque:

Specified tightening torque

48 N*m {489 kgf*cm, 35 ft.*lbf}

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
2. When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)
   

Using a 14 mm union nut wrench, install the No. 3 exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

Torque:

Specified tightening torque

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

NOTICE:

1. If the No. 3 exhaust gas temperature sensor is dropped, replace the new one.
   
2. When reusing the No. 3 exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the No. 3 exhaust gas temperature sensor.
   

HINT:

1. The connector color of the No. 3 exhaust gas temperature sensor is gray.
   
2. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
3. When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)
   

Using a 14 mm union nut wrench, install the No. 2 exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

Torque:

Specified tightening torque

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

NOTICE:

1. If the No. 2 exhaust gas temperature sensor is dropped, replace the new one.
   
2. When reusing the No. 2 exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the No. 2 exhaust gas temperature sensor.
   

HINT:

1. The connector color of the No. 2 exhaust gas temperature sensor is black.
   
2. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
3. When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)
   

Using a 14 mm union nut wrench, install the exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

Torque:

Specified tightening torque

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

NOTICE:

1. If the No. 3 exhaust gas temperature sensor is dropped, replace the new one.
   
2. When reusing the exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the exhaust gas temperature sensor.
   

HINT:

1. The connector color of the exhaust gas temperature sensor is white.
   
2. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
3. When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)
   

Attach the 3 colored connectors to the pipe clamp in the positions shown in the illustration.

Close the clamp of the pipe clamp, and install the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

NOTICE:

Arrange the exhaust gas temperature sensor wires so that they do not contact each other.

Connect the No. 3 exhaust gas temperature sensor to the No. 1 vacuum pipe.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the 3 connectors to the 3 exhaust gas temperature sensor.

Install the No. 3 engine cover bracket to the engine cover bracket and No. 2 engine cover bracket with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Install the 2 air hoses to the differential pressure sensor, and slide the 2 clamps to secure the 2 hoses.

HINT:

Make sure the paint mark of the air hose side the differential pressure sensor.

Connect the 2 air hoses to the No. 1 vacuum pipe and No. 2 vacuum pipe, and slide the 2 clamps to secure the 2 hoses.

Install the differential pressure sensor to the pipe clamp with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the connector to the differential pressure sensor.

Install the air cleaner case sub-assembly with the 3 bolts.

Torque:

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

for Cold Area Specification Vehicles:
Connect the wire harness clamps.

Attach the 4 clips to install the air cleaner cap sub-assembly with air cleaner hose.

Tighten the hose clamp.

Torque:

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

Connect the mass air flow meter connector and attach the 2 wire harness clamps.

Install the No. 1 front fender apron to frame seal RH with the 5 clips.

Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
   
5. If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
   
6. If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.
   

Check if the engine starts.

NOTICE:

1. Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. Use a fully-charged battery.
   

1. When the engine can be started, proceed to the next step.
   

2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the engine switch off.

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   
2. w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.html)
   

Start the engine.*1

Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

HINT:

When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

Enter the following menus: Powertrain / Engine and ECT /Trouble Codes.

Read Current DTCs.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.html)
   

HINT:

It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine and ECT / Trouble Codes.

Read Current DTCs.

OK:

No DTCs are output.

Add engine coolant through the radiator reservoir filler opening until the engine coolant reaches the "B" line.

Standard Capacity:

Item		Specified Condition
for Manual Transmission	except Cold Area Specification Vehicle	10.1 liters (10.7 US qts, 8.9 Imp. qts)
	for Cold Area Specification Vehicle	11.9 liters (12.6 US qts, 10.5 Imp. qts)
for Automatic Transmission	except Cold Area Specification Vehicle	10.0 liters (10.6 US qts, 8.8 Imp. qts)
	for Cold Area Specification Vehicle	11.8 liters (12.5 US qts, 10.4 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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 is a combination of low phosphates and organic acids).

Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the coolant level drops below the B line, add engine coolant to the B line.

Install the radiator reservoir cap sub-assembly.

Using a wrench, install the vent plug.

Torque:

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

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.
   

   NOTICE:

   1. Immediately after starting the engine, if the radiator reservoir sub-assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
      
   2. Do not start the engine when there is no coolant in the radiator reservoir sub-assembly.
      
   3. Make sure that the needle does not show an abnormally high temperature.
      
   4. If there is not enough coolant, the engine may overheat.
      

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

2. Maintain the engine speed at 2000 to 2500 rpm.
   

3. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
   

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

Check the coolant level in the radiator reservoir sub-assembly.
If the coolant level is low, add engine coolant to the radiator reservoir sub-assembly full line.

Remove the radiator reservoir cap sub-assembly.

Fill the radiator assembly with engine coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.

Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.