Engine Assembly Installation

Install the mounting bracket with the 4 bolts.

Torque:

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

Install the mounting bracket with the 4 bolts.

Torque:

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

Using a 17 mm deep socket wrench, install the sensor.

Torque:

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

Apply clean engine oil to a new O-ring.

Install the O-ring to the sensor.

Install the sensor with the bolt.

Torque:

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

Apply clean engine oil to a new O-ring.

Install the O-ring to the sensor.

Install the sensor with the bolt.

Torque:

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

Install a new O-ring to the vane pump.

Install the vane pump with the 2 nuts.

Torque:

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

Install 2 new O-rings to the vacuum pump.

Install the vacuum pump with the 2 nuts.

Torque:

21 N*m{214 kgf*cm, 16 ft.*lbf}

Install a new gasket and the oil cooler cover with the 13 bolts and 2 nuts.

Torque:

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

Connect the oil pressure connector and install the wire harness.

Install a new gasket and the manifold to the cylinder head with the 4 bolts and 2 nuts in the order shown in the illustration.

Torque:

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

Apply clean engine oil to a new O-ring.

Install the O-ring to the oil dipstick guide.

Install the oil dipstick guide with the bolt.

Torque:

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

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

Install a new O-ring to the pump.

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

Align the set key on the drive shaft with the groove of the injection gear.

Install the pump with the 2 nuts.

Torque:

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

Set a new O-ring before installing the set nut.

Using SST, hold the crankshaft pulley and install the set nut.

SST

09213-58013
09330-00021

Torque:

64 N*m{653 kgf*cm, 47 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 (0.0059 to 0.0217 in.)

Connect the 2 connectors.

Connect the 2 fuel hoses.

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. If the supply pump is replaced, the fuel inlet pipe must be replaced.
   
2. Keep the fuel inlet pipe free of foreign matter.
   

Using union nut wrench, tighten the injection pipe union nut on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Using union nut wrench, tighten the injection pipe union nut on the supply pump side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

Install the oil dipstick guide with the bolt.

Torque:

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

Install the clamp with the bolt.

Torque:

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

Install the common rail with the 2 bolts.

Torque:

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

Connect the fuel pressure sensor connector.

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. If the common rail is replaced, the fuel inlet pipe must be replaced.
   
2. Be careful that dust, dirt or any other foreign matter does not contact the joint area of the fuel inlet pipe.
   

Using union nut wrench, tighten the inlet pipe union nut on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

Using union nut wrench, tighten the inlet pipe union nut on the supply pump side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

Install the oil dipstick guide with the bolt.

Torque:

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

Install the clamp with the bolt.

Torque:

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

Temporarily install the leakage pipe with the 3 bolts.

Temporarily install a new gasket and the check valve.

Fully tighten the 3 bolts and check valve.

Torque:

21 N*m{214 kgf*cm, 16 ft.*lbf} for check valve

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

Connect the 2 fuel hoses.

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 bolt 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. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.

Using union nut wrench, tighten the injection pipe union nuts on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Using union nut wrench, tighten the injection pipe union nuts on the injector side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

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

Install 2 new injection pipe clamps with the 2 bolts.

Torque:

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

NOTICE:

1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
   
2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.
   

Using union nut wrench, tighten the injection pipe union nut on the common rail side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

Using union nut wrench, tighten the injection pipe union nut on the injector side.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf} for use with union nut wrench

35 N*m{357 kgf*cm, 26 ft.*lbf} for use without union nut wrench

HINT:

Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

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 work 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:

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

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

Install a new gasket and the EGR valve.

Install 2 new gaskets and the pipe with the 2 nuts and 2 bolts.

Torque:

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

HINT:

The gasket's claws should be on the pipe side.

Install a new gasket and the air connector with the 2 nuts and bolt.

Torque:

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

Install the bracket with the 3 bolts.

Torque:

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

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

Torque:

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

Connect the 2 connectors.

Install the bracket with the 2 bolts.

Torque:

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

Connect the vacuum hose at the 3 points as shown in the illustration.

Connect the 2 connectors.

Install the stay with the 2 bolts.

Torque:

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

HINT:

The stay's indented area (labeled A) must face the manifold.

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

Torque:

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

Install a new gasket to the cylinder head, as shown in the illustration.

Install the water outlet with the 2 bolts.

Torque:

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

Install the bracket with the 4 bolts.

Torque:

47 N*m{479 kgf*cm, 35 ft.*lbf}

Install the bracket with the 2 bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Install the bracket with the 2 bolts.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Install the tensioner with the 4 bolts.

Torque:

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

HINT:

Firmly press and hold the tensioner against the cylinder block to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

Install the generator with the 2 bolts.

Torque:

62 N*m{630 kgf*cm, 46 ft.*lbf}for bolt A

25 N*m{254 kgf*cm, 19 ft.*lbf}for bolt B

Install the generator wire with the nut.

Torque:

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

Install the terminal cap.

Connect the generator connector.

Install a new gasket, the exhaust manifold with turbocharger, 4 new collars and 8 spacers to the cylinder head with 8 new nuts.

Torque:

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

NOTICE:

1. Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
   
2. Install the collars to the positions labeled A.
   

Install a new gasket and the outlet elbow with the 3 nuts.

Torque:

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

Connect the 2 hoses to the 2 tubes.

Move the 2 clamps to the locations where the hoses and tubes are connected.

Temporarily install the turbo insulator with the bolt.

Install the camshaft timing pulley.

Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

Torque:

98 N*m{1,000 kgf*cm, 72 ft.*lbf}

Align the pulley set key with the key groove of the pulley.

Using SST, install the pulley bolt.

SST

09213-58013

Torque:

365 N*m{3,722 kgf*cm, 270 ft.*lbf}

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 engine revolution.

NOTICE:

1. The engine should be cold.
   
2. When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.
   

Using a 10 mm hexagon wrench, install the timing belt idler pulley and new washer with the bolt.

Torque:

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

Check that the idler pulley moves smoothly.
If it does not move smoothly, check the idler sub-assembly and washer.

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 to the top of the tensioner.

NOTICE:

1. Do not scratch or deform the rod end.
   
2. Press in the tensioner rod upward.
   
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 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force.

NOTICE:

Do not impose a load of over 9,807 N (100 to 1,000 kgf, 220 to 2,205 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 keep the setting position of the push rod.

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 and install the tensioner.

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 with the 6 bolts.

Torque:

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

Install the wire harness clamp.

Install the water hose clamp with the bolt.

Torque:

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

Connect the engine wire to the engine.

Attach the chain block and engine sling device to the engine hangers.

Slowly lower the engine into the engine compartment.

Install the engine mounting bracket with the 4 bolts and 4 nuts.

Torque:

38 N*m{388 kgf*cm, 28 ft.*lbf}

Remove the 2 engine hangers.

Install the end plate with the bolt.

Torque:

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

Clean the bolt and its hole.

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using SST, hold the crankshaft.

SST

09213-58013
09330-00021

Torque:

365 N*m{3,722 kgf*cm, 270 ft.*lbf}

Install the flywheel on the crankshaft.

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

Torque:

178 N*m{1,815 kgf*cm, 132 ft.*lbf}

NOTICE:

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

Clean the bolt and its hole.

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

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Using SST, hold the crankshaft.

SST

09213-58013
09330-00021

Torque:

365 N*m{3722 kgf*cm, 270 in.*lbf}

Install the flywheel, drive plate and drive plate spacer on the crankshaft.

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

Torque:

178 N*m{1815 kgf*cm, 132 in.*lbf}

NOTICE:

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

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

SST

09301-00110

NOTICE:

Make sure not to insert the clutch disc facing the wrong direction.

Align the matchmarks on the clutch cover and flywheel.

Loosely install the 6 bolts.

Tighten the 6 bolts as described below.

1. Determine the first bolt to be tightened by choosing the bolt closest to the knock pin.
   

2. Uniformly tighten the 6 bolts in diametrically opposite pairs relative to the position of the first bolt. Use the illustration as a reference.
   

   Torque:

   19 N*m{195 kgf*cm, 14 ft.*lbf}

Lightly move SST up and down, and right and left.

SST

09301-00110

Check that the disc is in the center, and then tighten the bolts.

Install the compressor with the 4 bolts.

Torque:

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

Using a 17 mm union nut wrench, install the pressure feed tube.

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Connect the 2 fuel hoses.

Connect the vacuum pump hose.

Connect the oil reservoir to pump hose.

for LHD:
Connect the connectors.

1. Connect the turbo motor driver connector.
   

2. Connect the 5 ECM connectors.
   

for RHD:
Connect the connectors.

1. Connect the turbo motor driver connector.
   

2. Connect the 4 ECM connectors.
   

for LHD:
Connect the 2 injector driver connectors.

for RHD:
Connect the 2 injector driver connectors.

Install the ground cable with the bolt.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Connect the 2 engine room junction block connectors.

Install the engine room junction block wire with the nut.

Torque:

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

Install the engine room relay block cover (side).

Install the engine room relay block cover (upper).

R151:
Install the transmission (Toyota Fortuner RM0000011B0004X.html).

R151F:
Install the transmission (Toyota Fortuner RM0000011AJ003X.html).

A340E:
Install the transmission (Toyota Fortuner RM0000010NT00IX.html).

Front side:
Install the propeller shaft (Toyota Fortuner RM000000ZYG008X_01_0001.html).

Rear side:
Install the propeller shaft (Toyota Fortuner RM000000ZZ1008X.html).

Using a vernier caliper, measure the free length of the compression spring.

Minimum length:

40 mm (1.57 in.)

Install the front pipe to the pipe support.

Install a new gasket to the outlet pipe.

NOTICE:

1. Be careful with the installation direction of the gasket.
   

1. Do not reuse the gasket.
   

1. To ensure a proper seal, do not use the front pipe to force the gasket onto the outlet pipe.
   

HINT:

Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.

Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

Torque:

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

Install the starter (Toyota Fortuner RM0000013XI00CX_01_0001.html).

Install the intake air connector to the air hoses.

Install the CAC with the 4 bolts.

Torque:

32 N*m{326 kgf*cm, 24 ft.*lbf}for bolt labeled A

12 N*m{125 kgf*cm, 9 ft.*lbf}for bolts labeled B, C and D

Tighten the 2 clamps.

Connect the vacuum hose to the manifold absolute pressure sensor.

Connect the IAT sensor connector.

Connect the manifold absolute diesel pressure sensor connector.

Install the engine cover with the 3 bolts and 2 nuts.

Torque:

7.0 N*m{71 kgf*cm, 62 in.*lbf}

Install the radiator (Toyota Fortuner RM00000144D007X.html).

Connect the air cleaner hose.

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Connect the connector to the MAF meter.

Tighten the hose clamp.

R151:
Add transmission oil (Toyota Fortuner RM0000011AV003X_01_0001.html).

R151F:
Add transmission oil (Toyota Fortuner RM0000011AF003X_01_0001.html).

A340E:
Add transmission fluid (Toyota Fortuner RM0000010NT00IX_01_0022.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 reservoir tank's B line.

Standard Capacity:

Item	Specified Condition
Manual transmission	9.8 liters (10.4 US qts, 8.6 Imp. qts)
Automatic transmission	11.1 liters (11.7 US qts, 9.8 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 is a combination of low phosphates and organic acids).
   
2. Please contact your TOYOTA dealer 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 2,500 to 3,000 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 F line.
If the coolant level is below the F line, add TOYOTA SLLC to the F line.

Wipe the oil pan and drain plug.

Install a new gasket and the drain plug.

Torque:

34 N*m{347 kgf*cm, 25 ft.*lbf}

Add new oil.

Standard oil capacity:

Item	Specified Condition
Drain and refill with oil filter change	6.9 liters (7.3 US qts, 6.1 Imp. qts)
Drain and refill without oil filter change	6.6 liters (7.0 US qts, 5.8 Imp. qts)
Dry fill	7.4 liters (7.8 US qts, 6.5 Imp. qts)

Install the oil filler cap.

Install the hood with the 4 bolts.

Torque:

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

Connect the washer nozzle hose.

Adjust the hood.

Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

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 push the intelligent tester main switch 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 an intelligent tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

SST

09843-18030

Check the idle speed.

HINT:

1. The engine is warmed up.
   
2. The A/C switch is OFF.
   

1. Start the engine and measure the idle speed.
   

   Standard idle speed:

   700 to 800 rpm
   

   If the idle speed is not as specified, perform the troubleshooting procedures in the Diagnostics section.
   

Check the maximum speed.

1. Start the engine.
   

2. Fully depress the accelerator pedal.
   

3. Measure the maximum speed.
   

   Standard maximum speed:

   4,450 to 4,750 rpm
   

   If the maximum speed is not as specified, perform the troubleshooting in the Diagnostics section.
   

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

Disconnect the intelligent tester from the DLC3.

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

NOTICE:

Do not add engine oil above the full level mark.

Inspect the fluid level (Toyota Fortuner RM0000014P800IX_01_0001.html).

Install the under cover with the 2 bolts.

Torque:

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

Install the under cover with the 4 bolts.

Torque:

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