Engine Assembly Installation

Install the 2 front engine mounting insulator with the 2 nuts.

Torque:

76 N*m{775 kgf*cm, 56 ft.*lbf}

Install the engine wire to the engine.

Install 2 engine hangers with 2 bolts as shown in the illustration.

HINT:

Part No.

Torque:

for No. 1 engine hanger:

25 N*m{255 kgf*cm, 18 ft.*lbf}

for No. 2 engine hanger:

60 N*m{612 kgf*cm, 44 ft.*lbf}

NOTICE:

Install the engine hangers with new bolts.

Attach an engine sling device and hang the engine with a chain block.

Remove the engine from the engine stand.

Install the rear end plate with the bolts.

Torque:

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

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

Install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

NOTICE:

Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer with the knock pin of the flywheel and ring gear, and then install the flywheel and ring gear, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

HINT:

As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in the direction shown in the illustration.

Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

NOTICE:

Do not start the engine for at least an hour after installing the flywheel and ring gear.

Torque:

178 N*m{1815 kgf*cm, 131 ft.*lbf}

Clean the bolts and their holes.

Apply adhesive to 2 or 3 threads at the end of each bolt.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

Install the flywheel to the crankshaft.

Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

Torque:

178 N*m{1815 kgf*cm, 131 ft.*lbf}

NOTICE:

Do not start the engine for at least 1 hour after installation.

Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel to install the clutch disc.

SST

09301-00110

Text in Illustration

Flywheel Side

NOTICE:

Be sure to install the clutch disc so that it is facing in the correct direction.

Align the matchmarks on the clutch cover and flywheel.

Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

SST

09301-00110

Torque:

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

HINT:

Move SST up and down, and right and left lightly after checking that the clutch disc assembly is in the center, and then tighten the bolts.

Using a dial indicator with a roller instrument, measure the diaphragm spring tip alignment.

SST

09333-00013

Maximum non-alignment:

0.5 mm (0.0196 in.)

1. If the is alignment is more than the maximum, use SST to adjust the diaphragm spring tip alignment.
   

Slowly lower the engine into the engine compartment.

Install the engine with the 4 bolts and 4 nuts.

Torque:

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

HINT:

For RHD vehicles only:

When tightening the nut closer to the rear of the vehicle for the engine mounting bracket on the right side, make sure that the claw (stopper) of the bolt does not protrude past the rear edge of the bracket.

Remove the 2 bolts and 2 engine hangers.

Install the 4 bolts and rear No. 1 engine mounting insulator.

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}

Install the automatic transmission (LandCruiser RM0000013F4022X.html).

Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

Torque:

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

HINT:

If it is difficult to reach the setting bolts with the wrench, raise or lower the transmission jack until there is sufficient space for the wrench.

NOTICE:

Install the black bolt first, and then the 5 silver bolts.

Install the manual transmission (LandCruiser RM00000178Q014X.html).

Install the oil pan insulator with the 2 bolts.

Torque:

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

Align the matchmarks on the propeller shaft flange and differential flange.

Install the propeller shaft assembly with the 4 washer, 4 bolts and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the propeller shaft flange and transfer flange.

Install the propeller shaft assembly with the 4 washers and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the yoke and differential flange.

Install the propeller shaft assembly with the 4 washers, 4 bolts and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the yoke and transfer flange.

Install the propeller shaft assembly with the 4 washers and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Install a new gasket and the front exhaust pipe to the exhaust manifold with 3 new nuts.

Torque:

54 N*m{554 kgf*cm, 40 ft.*lbf}

for Manual Transmission:
Install the starter assembly with the bolt and nut.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

for Automatic Transmission:
Install the starter assembly with the bolt and 2 nuts.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Connect the starter wire with the nut.

Torque:

9.8 N*m{100 kgf*cm, 87 in.*lbf}

Connect the starter connector.

Install the terminal cap.

Install the starter assembly with the bolt and nut.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Connect the starter wire with the nut.

Torque:

21 N*m{215 kgf*cm, 16 ft.*lbf}

Connect the starter connector.

Install the terminal cap.

Install the starter assembly with the bolt and 2 nuts.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Connect the starter wire with the nut.

Torque:

21 N*m{215 kgf*cm, 16 ft.*lbf}

Connect the starter connector.

Install the terminal cap.

Attach the grommet to the wire harness support.

Pass the wire harness into the vehicle and install the wire harness support.

Connect the 9 connectors and attach the clamp.

Install the bolt.

Torque:

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

Connect the wire harness protector with the bolt.

Torque:

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

Connect the engine wire with the nut.

Torque:

7.5 N*m{76 kgf*cm, 66 in.*lbf}

Install the bolt.

Torque:

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

Attach the clamp and connect the connector.

Connect the 3 injection driver connectors and install the bolt.

Torque:

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

Attach the 2 claws and install the nut.

Torque:

11 N*m{112 kgf*cm, 8 ft.*lbf}

Install the No. 1 relay block cover.

Install the glove compartment door (LandCruiser RM0000046J600OX_01_0017.html)

Connect the No. 1 fuel hose and No. 2 fuel hose.

Connect the outlet heater water hose.

Connect the inlet heater water hose.

Connect the pressure feed tube and a new gasket with the union bolt.

Torque:

50 N*m{510 kgf*cm, 37 ft.*lbf}

Connect the power steering oil pressure switch connector.

Temporarily install the vane pump oil reservoir with the 3 bolts.

Tighten the 3 bolts of the vane pump oil reservoir in the order shown in the illustration.

Torque:

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

Install the fuel filter (LandCruiser RM0000045HW007X.html).

Install the diesel throttle body (LandCruiser RM0000013ZB02VX.html).

Connect the cooler compressor with the 4 bolts.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the compressor connector.

Install the No. 1 viscous heater bracket with the 4 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Install the viscous heater with magnet clutch with the 2 bolts.

Torque:

45 N*m{459 kgf*cm, 33 ft.*lbf}

Connect the water by-pass hose and water hose.

Connect the viscous heater connector.

Install the compressor outlet elbow with the 2 bolts and tighten the hose clamp.

Torque:

for bolt:

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

for hose clamp:

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

Install the wire harness bracket with the bolt.

Torque:

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

Attach the 3 wire harness clamps.

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

Torque:

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

Attach the 4 clamps to install the air cleaner cap sub-assembly.

except Cold Area Specification Vehicles:
Attach the 2 clamps and connect the mass air flow meter connector.

for Cold Area Specification Vehicles:
Attach the 3 clamps and connect the mass air flow meter connector.

Install the No. 1 air cleaner hose with the 2 hose clamps.

NOTICE:

1. When installing the No. 1 air cleaner hose, align the protrusion of the No. 1 air cleaner hose with the protrusion of the compressor inlet elbow as shown in the illustration.
   
2. When installing the No. 1 air cleaner hose, align the groove of the No. 1 air cleaner hose with the protrusion of the air cleaner cap as shown in the illustration.
   

Tighten the 2 hose clamps.

Torque:

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

NOTICE:

When tightening the 2 hose clamps, make sure that they are positioned as shown in the illustration.

Install the battery hold down clamp with the 2 nuts.

Torque:

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

Install the radiator (LandCruiser RM000002SKN00QX.html).

Park the vehicle on a level surface.

Check that the oil level is between 0 to 5 mm (0 to 0.196 in.) from the bottom lip of the filler plug opening.

1. If the result is not as specified, add transmission oil.
   

NOTICE:

1. Problems may occur when the oil level is too high or low.
   
2. After replacing the oil, drive the vehicle and check the oil level again.
   

Inspect for oil leaks when the oil level is low.

1. If the result is not as specified, add transmission oil.
   

Install a new gasket and the filler plug.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Add new engine oil.

Standard Oil Grade:

Oil Grade	Oil Viscosity (SAE)
G-DLD1, API CF-4, CF or ACEA B1 (You may also use API CE or CD)	- 5W-30 - 10W-30 - 15W-40 - 20W-50

Standard Capacity:

Item	Specified Condition
Drain and refill without oil filter change	6.7 liters (7.1 US qts, 5.9 Imp. qts)
Drain and refill with oil filter change	7.0 liters (7.4 US qts, 6.2 Imp. qts)
Dry fill	7.5 liters (7.9 US qts, 6.6 Imp. qts)

Install the oil filler cap.

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.

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.

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.

Install the cowl top ventilator louver (LandCruiser RM000001OV105JX.html).

Install the hood with the 8 bolts.

Torque:

for bolt A:

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

for bolt B:

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

Text in Illustration

	Bolt A
	Bolt B

Connect the washer nozzle hose.

Add automatic transmission fluid (LandCruiser RM0000013CK06DX_01_0009.html).

Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

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.

Connect the intelligent tester to the DLC3.

If a tester is not available, connect the tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

SST

09843-18040

Inspect the idle speed.

HINT:

1. Make sure that the engine is warmed up.
   
2. Make sure that the A/C switch is off.
   
3. w/ DPF:
   Make sure that PM regeneration is not being performed.
   

1. Start the engine and measure the idle speed.
   

   Idle Speed:

   Item	Specified Condition
   for Automatic Transmission	650 to 750 rpm
   for Manual Transmission	610 to 710 rpm

Inspect the maximum speed.

1. Start the engine.
   

2. Fully depress the accelerator pedal.
   

3. Measure the maximum speed.
   

   Maximum Speed:

   4450 to 4750 rpm
   

If the tester probe of a tachometer is connected to the DLC3, disconnect the tester probe together with SST from terminal 9 of the DLC3.

Disconnect the intelligent tester from the DLC3.

Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.
If low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not fill engine oil above the full level mark.

HINT:

A certain amount of engine oil will be consumed while driving. In the following situations, engine oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.

1. When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
   
2. If low quality engine oil or oil of an inappropriate viscosity is used.
   
3. When driving at high engine speed or with a heavy load, when towing, or when driving while accelerating or decelerating frequently.
   
4. When leaving the engine idling for a long time, or when driving frequently through heavy traffic.
   

Install the rear engine under cover with the 4 bolts.

Torque:

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

Install the transmission under cover with the 2 bolts.

Torque:

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

Install the No. 1 engine under cover with the 4 bolts.

Torque:

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

Install the lower front bumper cover with the clip and 5 bolts.

Torque:

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