Intake Manifold Installation

Install a new gasket to the cylinder head sub-assembly.

Text in Illustration

*1	Protrusion
	Rear side

HINT:

Install the gasket with the protrusion the rear side of the vehicle as shown in the illustration.

Temporarily install the intake manifold with the 7 bolts and 2 nuts.

Tighten the 7 bolts and 2 nuts in the order shown in the illustration.

Text in Illustration

	Bolt
	Nut

Torque:

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

Connect the wire harness bracket A, B and C with the bolt.

Torque:

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

Install the vacuum control valve set with bolt to the cylinder head sub-assembly.

Torque:

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

Connect the 2 vacuum hoses to the swirl control valve actuator and vacuum transmitting pipe subassembly.

Connect the wire harness clamp and vacuum control valve set connector.

Install the No. 2 nozzle leakage pipe assembly with the 2 bolts.

Torque:

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

Connect the No. 6 fuel hose to the No. 3 nozzle leakage pipe assembly and slide the clamp to secure the hoses.

Install the No. 4 fuel hose and No. 5 fuel hose to the No. 2 nozzle leakage pipe assembly, and slide the 4 clamps to secure the hose.

Temporarily install the fuel inlet pipe sub-assembly.

Install new No. 1 injection pipe clamp and No. 2 injection pipe clamp with the 2 bolts.

Torque:

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

SST

09245-11010

Torque:

Specified tightening torque:

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

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
   
2. When using a union nut wrench (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)
   

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.
   
2. When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 41 N*m (418 kgf*cm, 30 ft.*lbf)
   

Temporarily install the No. 3 fuel pipe and 2 new gaskets with the union bolt and supply pump hollow screw.

Tighten the union bolt and supply pump hollow screw.

Torque:

42 N*m{428 kgf*cm, 31 ft.*lbf}

Install the 2 fuel pipe clamps to the No. 3 fuel pipe and fuel filter.

Temporarily install the No. 4 fuel pipe sub-assembly and 2 new gaskets with the 2 union bolts and bolt.

Text in Illustration

	Union Bolt
	Bolt

Torque:

union bolt:

42 N*m{428 kgf*cm, 31 ft.*lbf}

bolt:

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

Connect the No. 4 fuel pipe sub-assembly to the No. 1 fuel pipe (LandCruiser RM0000028RU05SX.html).

Install the manifold stay with the 2 bolts.

Torque:

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

Install the wiring harness clamp bracket with the bolt.

Torque:

13 N*m{128 kgf*cm, 9 ft.*lbf}

Install the wiring harness clamp bracket with the bolt.

Torque:

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

Attach the 2 wire harness clamps.

Connect the diesel throttle body assembly connector and pre-stroke control valve connector.

Connect the No. 2 fuel pipe and with the bolt.

Torque:

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

Apply a light coat of engine oil to a new O-ring.

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

Install the engine oil level dipstick guide with the bolt.

Torque:

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

Connect the vacuum hose to the intake manifold.

Install the engine oil level dipstick.

Add engine coolant through the radiator reservoir filler opening until the engine coolant reaches the "B" line.

Standard Capacity:

Item		Specified Condition
for Manual Transmission	except Cold Area Specification Vehicle	10.1 liters (10.7 US qts, 8.9 Imp. qts)
	for Cold Area Specification Vehicle	11.9 liters (12.6 US qts, 10.5 Imp. qts)
for Automatic Transmission	except Cold Area Specification Vehicle	10.0 liters (10.6 US qts, 8.8 Imp. qts)
	for Cold Area Specification Vehicle	11.8 liters (12.5 US qts, 10.4 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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 is a combination of low phosphates and organic acids).

Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the coolant level drops below the B line, add engine coolant to the B line.

Install the radiator reservoir cap sub-assembly.

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.
   

   NOTICE:

   1. Immediately after starting the engine, if the radiator reservoir sub-assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
      
   2. Do not start the engine when there is no coolant in the radiator reservoir sub-assembly.
      
   3. Make sure that the needle does not show an abnormally high temperature.
      
   4. If there is not enough coolant, the engine may overheat.
      

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

2. Maintain the engine speed at 2000 to 2500 rpm.
   

3. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
   

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

Check the coolant level in the radiator reservoir sub-assembly.
If the coolant level is low, add engine coolant to the radiator reservoir sub-assembly full line.

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

Check if the engine starts.

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

Turn the engine switch off.

Connect the GTS to the DLC3.

Turn the engine switch on (IG) and turn the GTS on.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   
2. w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.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 /Trouble Codes.

Read Current DTCs.

Clear the DTCs.

1. w/ Urea SCR System: (LandCruiser RM000000PDK1E5X.html)
   w/o Urea SCR System: (LandCruiser RM000000PDK1ENX.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 / Trouble Codes.

Read Current DTCs.

OK:

No DTCs are output.