Intake Manifold Installation

Temporarily install a new gasket and the intake manifold with the 2 nuts and 4 bolts.

Tighten the 2 nuts and 4 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

1. When installing the intake manifold, make sure that the No. 1 intake manifold insulator is not pinched.
   
2. Make sure that the swirl control valve actuator is not damaged by the surrounding parts.
   

   Text in Illustration

   *1	No. 1 Intake Manifold Insulator

Connect the vacuum hose to the intake manifold.

Attach the sensor wire connector clamp to the intake manifold.

Install the intake manifold insulator with the 2 bolts.

Torque:

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

Temporarily install the No. 2 nozzle leakage pipe with the 4 bolts.

Temporarily install a new gasket and the union bolt.

Tighten the 4 bolts and union bolt.

Torque:

for bolt:

13 N*m{130 kgf*cm, 9 ft.*lbf}

for union bolt:

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

Connect the 3 fuel hoses.

Temporarily install the No. 4 injection pipe with the union nuts.

Install the bolt.

Torque:

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

NOTICE:

1. If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
   
2. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   
3. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
   

Using a 17 mm union nut wrench, tighten the injection pipe union nut 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 vacuum control valve set with the 2 bolts.

Torque:

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

Connect the 3 vacuum hoses and 2 VSV connectors.

NOTICE:

When connecting the hoses, match the colors of the paint marks on the hoses to the colors of the paint marks on the swirl control valve as shown in the illustration.

Install the intake pipe stay with the bolt.

Torque:

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

Install the manifold stay with vacuum switching valve with the 2 bolts and connect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

NOTICE:

Make sure the vacuum hose color matches the connection area color.

w/ EGR Cooler:
Connect the No. 3 vacuum transmitting hose.

w/ EGR System:
Connect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.

NOTICE:

1. Make sure the vacuum hose color matches the connection area color.
   
2. Push on the hose until it reaches the bent part of the pipe.
   

Connect the No. 1 vacuum transmitting hose.

Connect the vacuum switching valve connector.

1. w/o EGR System:
   Connect the connector.
   

2. w/ EGR System without EGR Cooler:
   Connect the 2 connectors.
   

3. w/ EGR System with EGR Cooler:
   Connect the 3 connectors.
   

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.

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 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}

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 assembly (LandCruiser RM000002RK6044X.html).

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

HINT:

1. 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 consists of a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer for further details.
   
3. for Cold Area Specification Vehicles:
   Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

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.
   

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

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

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

After the coolant cools down, check that the coolant level is at the FULL line.
If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

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.

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.

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.