Camshaft Installation

Check that the valve rocker arm sub-assembly is firmly set to the valve lash adjuster assembly.

Apply a light coat of engine oil to the camshaft journals of the cylinder head sub-assembly and the thrust portion of the camshaft.

Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and install the camshaft timing sprocket to the No. 2 chain sub-assembly.

HINT:

Make sure the timing mark of the camshaft timing sprocket face the front side.

Align the knock pin of the No. 1 camshaft to the groove of the sprocket and install the No. 1 camshaft to the camshaft timing sprocket, and set the bolt.

Align the paint mark of the No. 2 chain sub-assembly and timing mark of the camshaft timing sprocket, and install the camshaft timing sprocket to the No. 2 chain sub-assembly.

HINT:

Make sure the timing mark of the camshaft timing sprocket face the front side.

Align the knock pin of the No. 2 camshaft to the groove of the sprocket and install the No. 2 camshaft to the camshaft timing sprocket, and set the bolt.

HINT:

Glove is at the rear end of the No. 2 camshaft.

Check the timing mark of the camshaft timing sprocket and the paint mark of the No. 2 chain sub-assembly.

Set the No. 1 camshaft bearing cap and 8 No. 2 camshaft bearing caps to the cylinder head sub-assembly as shown in the illustration.

Temporarily install the 20 bolts.

Uniformly tighten the 20 bolts in several steps in the order shown in the illustration.

Torque:

for bolt A:

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

for bolt B:

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

Text in Illustration

	Bolt A
	Bolt B

Hold the hexagonal portion of the No. 1 camshaft and No. 2 camshaft with a wrench, and tighten the 2 bolts.

Torque:

81 N*m{826 kgf*cm, 60 ft.*lbf}

NOTICE:

Be careful not to damage the cylinder head sub-assembly with the wrench.

Remove the pin from the No. 2 chain tensioner assembly.

Install a new gasket and the oil pump relief valve plug to the timing chain cover.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Clean and degrease the contact surfaces of the cylinder head sub-assembly and No. 3 camshaft bearing cap.

Apply seal packing to the specified areas as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard seal diameter:

3.0 mm (0.118 in.)

NOTICE:

1. Do not allow seal packing to contact the oil passage of the No. 3 camshaft bearing cap.
   
2. After applying seal packing, install the No. 3 camshaft bearing cap within 3 minutes and tighten the bolts within 10 minutes.
   
3. Do not start the engine for at least 2 hours after installation.
   

Install the No. 3 camshaft bearing cap with the 2 bolts.

Torque:

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

Wipe off excess seal packing from between No. 3 camshaft bearing cap and cylinder head sub-assembly.

Install the timing chain guide to the cylinder head sub-assembly with the bolt.

Torque:

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

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

Install a new cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets to the cylinder head cover sub-assembly.

Clean and degrease the contact surfaces of the cylinder head cover sub-assembly and cylinder head sub-assembly.

Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard seal diameter:

3.0 to 6.0 mm (0.118 to 0.236 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Tighten the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and camshaft position sensor in the order shown in the illustration.

Text in Illustration

	Bolt
	Nut
	Nozzle Holder Clamp Seat

Torque:

10 N*m{107 kgf*cm, 7 ft.*lbf}

NOTICE:

1. When reusing the camshaft position sensor, check the O-rings.
   
2. Make sure that the O-ring is not cracked or jammed when installing it on the cylinder head cover sub-assembly.
   
3. Replace with a new part if it is dropped or if it receives a strong impact.
   
4. Check the torque of bolts 1 to 4 again.
   

Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly.

Install 4 new injection nozzle seats to the cylinder head sub-assembly.

Apply a light coat of engine oil to the O-ring on each injector assembly.

Install a new O-ring to each injector assembly.

Install the 4 injector assemblies to the cylinder head sub-assembly.

NOTICE:

Fit the injector assembly to the injection nozzle seats.

Install the nozzle holder clamps and washers as shown in the illustration.

NOTICE:

Pay attention to the mounting orientation (beveled edge) of the washer.

Temporarily install the nozzle holder clamp bolts.

NOTICE:

When temporarily installing the nozzle holder clamp bolt to the No. 1 nozzle holder clamp, make sure that the bolt and clamp are not at an angle.

HINT:

Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

Temporarily install the 2 No. 2 injection pipe sub-assemblies 4 union nuts.

Temporarily install the 2 No. 1 injection pipe sub-assemblies 4 union nuts.

Tighten the 4 nozzle holder clamp bolts.

Torque:

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

Using SST, tighten the No. 1 and No. 2 injection pipe sub-assemblies 8 union nuts.

Torque:

Specified tightening torque:

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

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
   
2. When using SST (fulcrum length of 50 mm (1.97 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 31 N*m (316 kgf*cm, 23 ft.*lbf)
   

Temporarily install the nozzle leakage pipe assembly and 4 new gaskets with the 4 union bolts and bolt.

Tighten the 4 union bolts and bolt in the order shown in the illustration.

Torque:

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

Connect the No. 5 fuel hose to the nozzle leakage pipe assembly.

Install the harness bracket with the bolt.

Torque:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly.

Torque:

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

Connect the pressure discharge valve connector to the common rail assembly.

Temporarily install the No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly to the intake manifold with the 4 bolts.

Tighten the 4 bolts in the order shown in the illustration.

HINT:

Make sure to tighten the bolts in the order.

Torque:

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

Install the vacuum control valve set to the intake manifold with the 2 bolts.

Torque:

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

Connect the 2 vacuum hoses to the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.

Connect the connector to the vacuum control valve set.

Connect the engine wire bracket with the bolt.

Torque:

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

Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

Torque:

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

Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold and EGR valve adapter with 4 new nuts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Connect the No. 1 EGR pipe sub-assembly to the vacuum transmitting pipe sub-assembly with the bolt.

Torque:

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

Connect the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.

Torque:

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

Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.

Connect the No. 7 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.

Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.

Torque:

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

Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure the hose.

Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.

Install 2 new gaskets and No. 2 EGR pipe to the electric EGR control valve assembly and the intake manifold with the 4 nuts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Install the EGR valve bracket to the electric EGR control valve assembly and intake manifold with the bolt and nut.

Torque:

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

Install the diesel turbo pressure sensor to the No. 3 water by-pass pipe sub-assembly with the bolt.

Torque:

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

Connect the connector to the diesel turbo pressure sensor.

Install the gas filter to the gas filter bracket.

Connect the 2 vacuum hoses to the turbo pressure sensor and intake manifold.

Connect the connector to install the emission control valve wire to the diesel throttle body assembly.

Install a new gasket and the diesel throttle body assembly with the 2 bolts and 2 nuts.

Torque:

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

Connect the connector and clamp.

for Cold Area Specification Vehicles:
Connect the No. 11 water by-pass hose and No. 14 water by-pass hose to the diesel throttle body assembly, and slide the 2 clips to secure the hose.

Install the air tube assembly to the diesel throttle body assembly and tighten the hose clamp.

Torque:

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

Connect the connector to the intake air temperature sensor.

Temporarily install the air tube support bracket with the 3 bolts.

Tighten the 3 bolts in the order shown in the illustration.

Torque:

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

Attach the clamp and connect the No. 1 fuel hose to the air tube support bracket.

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 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 a new gasket and the No. 2 exhaust manifold heat insulator to the No. 1 injector holder with the 3 nuts.

Torque:

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

Install the No. 1 injector holder to the exhaust manifold with 3 new nuts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Connect the connector to the exhaust fuel addition injector assembly.

Connect the No. 5 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

Connect the No. 4 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

Connect the PCV pipe to the compressor inlet elbow, cylinder head cover sub-assembly and slide the 2 hose clips to secure the hoses.

Install the PCV pipe with the bolt to the compressor inlet elbow.

Torque:

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

Connect the No. 19 water by-pass hose to the compressor inlet elbow and slide the hose clip to secure the hoses.

Install the No. 20 water by-pass hose to the PCV pipe and No. 1 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Connect the No. 1 fuel pipe to the No. 4 fuel pipe.

Install a new gasket and the No. 1 fuel pipe to the cylinder head cover sub-assembly and No. 1 injector holder with the union bolt and bolt.

Torque:

for bolt:

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

for union bolt:

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

Install the No. 2 engine cover bracket to the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly with the 2 bolts.

Torque:

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

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 No. 2 water by-pass pipe to the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket with the 3 bolts.

Torque:

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

Connect the No. 16 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.

Connect the No. 15 water by-pass hose to the water by-pass pipe, and slide the clamp to secure the hose.

Connect the No. 13 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.

Connect the 2 water hose sub-assemblies to the No. 2 water pipe, and slide the clamp to secure the hoses.

Connect the 2 water hose sub-assemblies to the air conditioning unit assembly, and slide the clamp to secure the hoses.

w/ Rear Air Conditioning System:
Connect the 2 water hose sub-assemblies to the water pipe, and slide the clamp to secure the hoses.

Before installing a new camshaft oil seal retainer, clean the installation surface of the No. 3 camshaft bearing cap and cylinder head sub-assembly and remove any foreign matter.

Using SST and a hammer, tap in a new camshaft oil seal retainer to the No. 3 camshaft bearing cap and cylinder head sub-assembly as shown in the illustration.

SST

09223-46011

Standard depth:

0 to 0.8 mm (0 to 0.0315 in.)

Coat 2 new O-rings with engine oil, and install them to the vacuum pump assembly.

Install the vacuum pump assembly so that the coupling teeth of the vacuum pump assembly labeled A and the groove of the No. 2 camshaft labeled B can engage.

Install the vacuum pump assembly to the cylinder head sub-assembly with the 3 bolts.

Torque:

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

Connect the No. 1 vacuum transmitting hose sub-assembly to the vacuum pump assembly.