Engine Unit Installation

Install the 2 engine mounting brackets with the 8 bolts.

Torque:

68 N*m{694 kgf*cm, 50 ft.*lbf}

Install the No. 2 cylinder block insulator.

Install the No. 1 vacuum pipe with the bolt.

Torque:

8.0 N*m{82 kgf*cm, 70 in.*lbf}

Install the No. 1 oil pan cover with the 4 bolts.

Torque:

9.0 N*m{92 kgf*cm, 80 in.*lbf}

Install the No. 1 vacuum transmitting pipe with the bolt and nut.

Torque:

for bolt:

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

for nut:

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

Install the oil cooler cover with the 13 bolts.

Torque:

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

Install the No. 2 vacuum transmitting pipe with the 2 nuts.

Torque:

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

Connect the vacuum hose.

Install the No. 3 vacuum transmitting pipe with the bolt.

Torque:

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

Connect the vacuum hose.

Check and clean the oil filter installation surface.

Apply clean engine oil to the gasket of a new oil filter.

Lightly screw the oil filter into place by hand. Tighten it until the gasket contacts the seat.

Using SST, tighten the oil filter. Depending on the space available, choose from the following.

SST

09228-07501

1. If enough space is available, use a torque wrench to tighten the oil filter.
   

   Torque:

   17 N*m{173 kgf*cm, 13 ft.*lbf}

2. If enough space is not available to use a torque wrench, tighten the oil filter 3/4 of a turn by hand or with a common wrench.
   

Install the No. 1 injection pump protector with the 2 bolts.

Torque:

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

Check that the injection gear in the timing gear case moves back and forth smoothly.

Install the pump drive shaft pulley and No. 2 camshaft timing pulley flange with the 4 bolts.

Torque:

31 N*m{316 kgf*cm, 23 ft.*lbf}

Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

Standard thrust clearance:

0.15 to 0.55 mm (0.00590 to 0.0217 in.)

Install the common rail with the 2 bolts.

Torque:

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

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.
   
2. Keep the fuel inlet pipe free of foreign matter.
   

Using a 17 mm union nut wrench, tighten the fuel inlet 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 fuel inlet pipe union nut on the fuel supply pump 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 No. 2 intake manifold insulator.

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 assembly and No. 4 vacuum transmitting hose assembly.

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 assembly.

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.

Using a 12 mm socket wrench, install the 4 glow plugs.

Torque:

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

Install the No. 1 intake manifold insulator.

Install the glow plug connector with the 4 nuts. Uniformly tighten the nuts.

Torque:

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

Install the 4 screw grommets.

Install a new gasket and the water outlet with the 2 bolts.

Torque:

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

Install a new gasket and the No. 2 EGR hole cover plate with the 2 nuts.

Torque:

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

Install the No. 2 intake air connector, No. 1 intake air connector, intake air connector and 2 new gaskets with the 3 nuts as shown in the illustration.

Torque:

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

Set a new gasket on the intake manifold.

NOTICE:

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

Install the intake air connector 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.

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.

Using a 6 mm hexagon wrench, install the EGR valve adapter, No. 2 EGR valve, EGR cooler, 2 new gaskets, 3 plate washers with the 3 hexagon bolts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Using a 5 mm hexagon wrench, install the bolt labeled A.

Torque:

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

Install a new gasket and the EGR cooler with pipe to the electric EGR control valve and No. 2 EGR valve with the 2 bolts.

Torque:

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

HINT:

Make sure the claws of the gasket face the electric EGR control valve.

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

NOTICE:

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

Set a new gasket on the intake manifold.

HINT:

Make sure the claws of the gasket face the intake manifold.

Temporarily install the intake air connector to the intake manifold with the 3 bolts in the illustration.

Temporarily install the EGR cooler with pipe and new gasket to the cylinder head with the bolt and 2 nuts.

Connect the No. 2 vacuum transmitting hose to the No. 2 EGR valve.

Tighten the 3 nuts labeled A in the illustration.

Torque:

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

Tighten the 3 bolts labeled B in the illustration.

Torque:

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

NOTICE:

Tighten the bolts in the order shown in the illustration.

Tighten the bolt labeled C in the illustration.

Torque:

22 N*m{224 kgf*cm, 16 ft.*lbf}

Tighten the 2 nuts labeled D in the illustration.

Torque:

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

Install a new gasket and the No. 1 EGR pipe to the electric EGR control valve with the 2 bolts.

Torque:

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

HINT:

Make sure the claws of the gasket face the electric EGR control valve.

Place a new gasket, the electric EGR control valve, another new gasket and the intake air connector onto the stud bolts of the No. 2 intake air connector and temporarily install the 3 nuts.

NOTICE:

Temporarily install the nuts so that 0 to 2 threads of each stud bolt are visible as shown in the illustration.

Set a new gasket on the intake manifold.

HINT:

Make sure the claws of the gasket face the intake manifold.

Temporarily install the intake air connector to the intake manifold with the 3 bolts.

Temporarily install the No. 1 EGR pipe and a new gasket to the cylinder head with the 2 nuts.

Tighten the 3 nuts labeled A in the illustration.

Torque:

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

Tighten the 3 bolts labeled B in the illustration.

Torque:

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

NOTICE:

Tighten the bolts in the order shown in the illustration.

Tighten the 2 nuts labeled C in the illustration.

Torque:

13 N*m{133 kgf*cm, 10 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}

Install the E-VRV bracket with the 2 bolts.

Torque:

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

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

Torque:

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

Connect the 5 vacuum hoses.

NOTICE:

Install the vacuum hoses so that they completely cover the pipes.

Connect the 2 connectors to the electric EGR control valve and E-VRV.

Attach the wire harness clamp.

Install the EGR valve bracket with the 2 nuts.

Torque:

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

Connect the No. 4 water by-pass hose to the EGR cooler.

HINT:

1. The direction of the hose clamp is indicated in the illustration.
   
2. Insert the outlet hose into the stopper.
   

Connect the No. 3 water by-pass hose to the EGR cooler.

HINT:

1. The direction of the hose clamp is indicated in the illustration.
   
2. Insert the outlet hose into the stopper.
   

Install the clamp.

Align the keyway of the pulley with the key located on the crankshaft, and then slide the pulley into place to install it.

Using SST, install the pulley bolt.

SST

09213-58014
09330-00021

Torque:

365 N*m{3722 kgf*cm, 269 ft.*lbf}

Using a 10 mm hexagon wrench, install a new washer and the No. 1 timing belt idler with the bolt.

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

Check that the idler pulley moves smoothly.
If the idler pulley does not move smoothly, check the installation condition of the idler and washer.

Check that the timing marks are aligned as shown in the illustration.

HINT:

If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of crankshaft revolution.

NOTICE:

1. Make sure that the engine is cold.
   
2. When turning the crankshaft, the valve heads will hit against the piston. Do not turn the crankshaft more than necessary.
   

Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.

Place the tensioner upright. Then set a press on the top of the tensioner.

NOTICE:

1. Do not scratch or deform the rod end.
   
2. Press in the tensioner rod.
   
3. Protect the tip of the push rod with a cloth in order to prevent damage.
   

Using the press, slowly push in the push rod using 981 to 9807 N (100 to 1000 kgf, 220 to 2205 lbf) of force.

NOTICE:

Do not apply a load of over 9807 N (1000 kgf, 2205 lbf) to the push rod.

Align the holes of the push rod and housing. Then pass a 1.5 mm hexagon wrench through the holes to fix the push rod in place.

Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

Tighten the 2 bolts.

Torque:

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

NOTICE:

Uniformly tighten the 2 bolts.

Remove the 1.5 mm hexagon wrench from the tensioner.

Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.

Install the timing belt cover and 6 washers with the 6 bolts.

Torque:

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

Attach the clamp and install the crankshaft position sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Install the camshaft position sensor with the bolt.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Install a new gasket to the engine coolant temperature sensor.

Install the engine coolant temperature sensor.

Torque:

20 N*m{200 kgf*cm, 14 ft.*lbf}

Connect the engine coolant temperature sensor connector.

Install a new O-ring and the vane pump with the 2 nuts.

Torque:

41 N*m{418 kgf*cm, 30 ft.*lbf}

Install 2 new O-rings to the vacuum pump.

Install the vacuum pump with the 2 nuts.

Torque:

21 N*m{210 kgf*cm, 15 ft.*lbf}

Install the timing gear cover insulator with the bolt.

Torque:

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

Install a new gasket and the engine oil level sensor with the 4 bolts.

Torque:

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

Install the No. 2 water by-pass pipe with the 2 bolts and 2 nuts.

Torque:

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

Connect the 2 hoses.

Install a new gasket to the thermostat.

NOTICE:

When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the gasket is properly installed to the thermostat, as shown in the illustration.

Install the thermostat to the cylinder block with the jiggle valve facing straight upward.

HINT:

The jiggle valve may be set within 30° of either side of the prescribed position.

Install the water inlet with the 3 bolts.

Torque:

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

Install the compressor elbow stay with the 2 bolts.

Torque:

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

Install the No. 2 cylinder head cover with the 4 bolts.

Torque:

for bolt A:

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

for bolt B:

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

Temporarily install a new gasket and the turbocharger sub-assembly to the exhaust manifold with 3 new nuts.

HINT:

It is easier to install the turbo oil inlet pipe sub-assembly if the 3 nuts are only loosely installed.

Set a new gasket on the engine and install the exhaust manifold with turbocharger sub-assembly, the 8 collars and the 8 plate washers with 8 new nuts.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

NOTICE:

Install the collars so that the side with the smaller external diameter faces the exhaust manifold.

Temporarily install the turbo oil inlet pipe sub-assembly to the turbocharger sub-assembly.

HINT:

Before installing the turbo oil inlet pipe sub-assembly, clean it.

1. Install a new gasket and the turbo oil inlet pipe sub-assembly with the 2 nuts, but only loosely install the nuts.
   

   NOTICE:

   The notch (narrow part) of the gasket must face the engine.

2. Install a new gasket and the turbo oil inlet pipe sub-assembly with the 2 bolts, but only loosely install the bolts.
   

   NOTICE:

   The claws of the gasket must face the pipe.





3. Install a new gasket and the turbo oil inlet pipe sub-assembly with the union bolt, but only loosely install the union bolt.
   
   

   
   
   
   
   

   Text in Illustration

   *1	Gasket	-	-
   *a	Wide	*b	Narrow
   *c	Claw	-	-
   	Outside	-	-

4. Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts and nut.
   

Tighten the 3 nuts of the turbocharger sub-assembly.

Torque:

52 N*m{530 kgf*cm, 38 ft.*lbf}

Tighten the 2 nuts labeled A.

Torque:

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

Tighten the union bolt labeled B.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

Tighten the 2 bolts labeled C.

Torque:

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

Tighten the 2 bolts and nut of the turbocharger stay in the order shown in the illustration.

Torque:

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

Install a new gasket and the turbine outlet elbow to the turbocharger sub-assembly with the 3 nuts.

Torque:

39 N*m{398 kgf*cm, 29 ft.*lbf}

Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clamp to secure the hose.

Temporarily install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the bolt.

Temporarily install the No. 1 turbo insulator to the turbocharger sub-assembly with the 2 bolts.

Tighten the bolt of the No. 1 exhaust manifold heat insulator and the 2 bolts of the No. 1 turbo insulator.

Torque:

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

Install a new gasket and the compressor inlet elbow with the 2 nuts.

Torque:

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

Connect the No. 2 turbo water hose and No. 3 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clamp to secure the hose.

Connect the No. 3 turbo water hose and No. 3 turbo water hose to the No. 2 water by-pass pipe, and slide the clamp to secure the hose.

Connect the 2 connectors and attach the wire harness clamp.

Install the wire harness bracket to the water inlet with the bolt.

Torque:

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

Attach the 3 wire harness clamps.

Install a new O-ring to the engine oil level dipstick guide.

Apply a small amount of clean engine oil to the O-ring.

Install the engine oil level dipstick guide to the cylinder block sub-assembly with the 2 bolts.

Torque:

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

Install the engine oil level dipstick.

Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover to the cylinder head sub-assembly with the bolt.

Torque:

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

Type A
Connect the No. 3 turbo water hose and No. 4 turbo water hose to the ventilation pipe, and slide the 2 clamps to secure the hose.

Install the No. 1 compressor mounting bracket with the 5 bolts.

Torque:

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

Install the generator bracket with the bolts.

Torque:

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

Install the generator with the 2 bolts.

Torque:

for bolt A:

62 N*m{632 kgf*cm, 46 ft.*lbf}

for bolt B:

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