Glow Plug Installation

Clean the glow plug hole.

1. Wrap tape around a drill bit with a diameter of 4.4 mm (0.173 in.), 118.5 mm (4.665 in.) from its tip.
   

2. Insert the drill bit 118.5 mm (4.665 in.) into the glow plug hole (up to the tape) and remove any carbon deposits by turning the drill bit by hand.
   

3. Insert a drill bit with a diameter of 4 mm (0.157 in.) into the glow plug hole and remove any carbon deposits from the end of the glow plug hole by turning the drill bit by hand.
   

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

   Torque:

   18 N*m{178 kgf*cm, 13 ft.*lbf}

   NOTICE:

   Do not use any tools, such as air tools, which are liable to cause an impact to the glow plugs when installing them.

Install the 4 glow plugs.

Torque:

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

NOTICE:

Do not use any tools, such as air tools, which are liable to cause an impact to the glow plugs when installing them.

Temporarily install the No. 1 glow plug connector with the 4 nuts.

Tighten the 4 nuts.

Torque:

2.2 N*m{22 kgf*cm, 19 in.*lbf}

Install the 4 screw grommets.

Connect the wire harness to the No. 1 glow plug connector with the nut.

Torque:

2.6 N*m{27 kgf*cm, 23 in.*lbf}

Install the screw grommet.

Install the No. 2 manifold stay with the bolt.

Torque:

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

Install the intake pipe stay with the bolt.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Set a new gasket on the intake manifold.

NOTICE:

Make sure the claw of the gasket face the intake manifold as shown in the illustration.

Install the intake air connector with diesel throttle body with the 3 bolts.

Torque:

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

NOTICE:

Tighten the bolts in the order shown in the illustration.

Connect the throttle position sensor connector.

Temporarily install the air connector stay with the 3 bolts.

Tighten the bolt labeled A.

Torque:

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

Tighten the 2 bolts labeled B.

Torque:

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

for LHD:
Connect the engine wire with the clamp and install the 2 bolts.

Torque:

for bolt A:

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

for bolt B:

22 N*m{220 kgf*cm, 16 ft.*lbf}

for RHD:
Connect the engine wire with the bolt.

Torque:

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

Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

Install the No. 2 and No. 3 injection pipe clamps with the 2 bolts and 2 nuts as shown in the illustration.

Torque:

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

HINT:

If the painted mark on the No. 2 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the common rail side.

Torque:

35 N*m{357 kgf*cm, 26 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).

Using a 17 mm union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

35 N*m{357 kgf*cm, 26 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 throttle body bracket with the 2 bolts.

Torque:

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

Install the gas filter with gas filter bracket with the bolt.

Torque:

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

Connect the vacuum hose.

Connect the No. 1 intake pipe with the air hose and install the 2 bolts.

Torque:

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

Tighten the 2 clamps of the No. 1 air hose.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Tighten the clamp of the intercooler air hose.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Connect the vacuum hose to the manifold absolute pressure sensor connector.

Connect the 3 connectors to the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.

Attach the 2 clamps.

Connect the No. 4 vacuum transmitting pipe with the bolt.

Torque:

8.0 N*m{82 kgf*cm, 71 in.*lbf}

Connect the inlet heater water hose with the bolt.

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install the electric EGR control valve (LandCruiser RM000002RK6044X.html).

Using the hand pump mounted on the fuel filter cap, bleed the 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.
   

Start the engine.

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 the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the intelligent tester on.

Clear the DTCs (LandCruiser RM000000PDK1DJX.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 / DTC.

Read Current DTCs.

Clear the DTCs (LandCruiser RM000000PDK1DJX.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 / DTC.

Read Current DTCs.

OK:

No DTCs are output.

Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and turn the intelligent tester on.

Select the Fuel Leak test from the Active Test mode on the intelligent tester.

If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

Check that there are no leaks from any part of the fuel system.

NOTICE:

A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

Reconnect the return hose to the common rail.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.