Engine Assembly Installation

Install the front engine mounting insulator to the front engine mounting bracket with the nut.

Torque:

64 N*m{653 kgf*cm, 47 ft.*lbf}

Connect the vacuum hose to the front engine mounting insulator.

Install the engine wire to the engine assembly.

Install the No. 1 engine hanger upper and No. 2 engine hanger with the 3 bolts as shown in the illustration.

Torque:

for No. 1 engine hanger upper:

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

for No. 2 engine hanger:

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

HINT:

Attach the engine sling device and hang the engine assembly with the chain block.

Remove the engine assembly from the engine stand.

Slowly lower the engine assembly into the engine compartment.

Install the engine assembly to the body with the 4 bolt 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 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.

Install the rear end plate to the cylinder block sub-assembly with the bolt.

Torque:

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

Clean the bolts and their holes.

Using SST, hold the crankshaft pulley.

SST

09213-58014
09330-00021

for Manual Transmission:
Install the flywheel sub-assembly to the crankshaft with 8 new bolts.

Torque:

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

NOTICE:

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

for Automatic Transmission:
Install the flywheel sub-assembly, the pump impeller drive plate and the rear drive plate spacer to the crankshaft with the 8 bolts.

NOTICE:

1. 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 sub-assembly, and then install the flywheel sub-assembly, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.
   
2. Do not start the engine for at least 1 hour after installation.
   

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.

for Automatic Transmission:
Install and uniformly tighten and tighten the 8 bolts in several steps in the sequence shown in the illustration.

Torque:

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

w/o Viscous Heater:
Install the crankshaft pulley cover to the crankshaft pulley with the 4 bolts.

Torque:

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

w/ Viscous Heater:
Install the crankshaft pulley cover and viscous heater crankshaft pulley to the crankshaft pulley with the 4 bolts.

Torque:

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

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.
   

Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly 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}

NOTICE:

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

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 the viscous heater with magnet clutch assembly to the No. 1 viscous heater bracket with the 2 bolts.

Torque:

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

Connect the connector to the viscous heater with magnet clutch assembly.

Install the water hose sub-assembly B to the No. 2 water pipe and water outlet sub-assembly, slide the 4 clamps secure the hoses.

Connect the water hose sub-assembly B to the water inlet with the bolt.

Torque:

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

Temporarily install the cooler compressor assembly and stud bolt to the compressor mounting bracket.

Using an E8 "TORX" socket wrench, tighten the stud bolt.

Torque:

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

Install the 3 bolts and nut.

Torque:

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

Connect the connector to the cooler compressor assembly.

Install the generator bracket to the generator assembly with the bolt.

Torque:

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

Install the generator assembly with the 2 bolts.

Torque:

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

Attach the clamp and connect the wire harness to the generator bracket.

Connect the wire harness to the generator assembly with the bolt.

Torque:

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

Connect the wire harness to terminal B with the nut.

Torque:

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

Install the terminal cap.

Connect the connector to the generator assembly.

Connect the vane pump assembly to the generator bracket with the 2 bolts.

Torque:

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

Connect the 2 connectors to the vane pump assembly.

Connect the 2 water hose sub-assemblies to the No. 2 water pipe, and slide the clamp to secure the hoses.

Connect the 2 water hose sub-assemblies to the air conditioning unit assembly, and slide the clamp to secure the hoses.

w/ Rear Air Conditioning System:
Connect the 2 water hose sub-assemblies to the water pipe, and slide the clamp to secure the hoses.

Install the battery hold down clamp with the 2 nuts.

Torque:

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

Connect the engine room main wire to the battery with the nut.

Torque:

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

Attach the clamp.

Connect the No. 2 engine wire to the body with the bolt.

Torque:

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

Attach the 2 claws and install the nut.

Torque:

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

Attach the 3 claws to install the No. 1 relay block cover upper.

Connect the No. 2 fuel hose to the No. 3 nozzle leakage pipe, slide the clamp to secure the hose.

Install the 2 clamps to the No. 2 fuel hose.

Connect the No. 1 fuel hose to the No. 2 fuel pipe, slide the clamp to secure the hose.

Install the clamp to the No. 1 fuel hose.

Connect the vane pump oil reservoir sub-assembly to the body with the 3 bolts.

Torque:

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

Connect the urea tank filler pipe assembly to the body with the 2 bolts.

Torque:

5.5 N*m{56 kgf*cm, 49 in.*lbf}

Install the air tube assembly to the diesel throttle body assembly and tighten the hose clamp.

Torque:

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

Connect the connector to the intake air temperature sensor.

Temporarily install the air tube support bracket with the 3 bolts.

Tighten the 3 bolts in the order shown in the illustration.

Torque:

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

Attach the clamp and connect the No. 1 fuel hose to the air tube support bracket.

Install the No. 2 intercooler air hose and tighten the 2 hose clamps.

Torque:

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

Connect the oil return hose and slide the 2 clips to secure the hose.

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

Torque:

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

for Cold Area Specification Vehicles:
Connect the wire harness clamps.

Attach the 4 clips to install the air cleaner cap sub-assembly with air cleaner hose.

Tighten the hose clamp.

Torque:

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

Connect the mass air flow meter connector and attach the 2 wire harness clamps.

While pushing the No. 1 engine cover sub-assembly towards the rear, attach the 2 rear pins.

Attach the 2 front clips to install the No. 1 engine cover sub-assembly.

Attach the grommet to the wire harness support.

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

Attach the clamp and connect the engine wire to the bracket.

Install the ECM (LandCruiser RM0000013YY02PX.html).

Install the hood sub-assembly with the 8 bolts.

Torque:

Bolt A:

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

Bolt B:

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

Text in Illustration

	Bolt A
	Bolt B

Connect the washer nozzle hose.

Adjust the hood position.

1. Loosen the 4 hinge bolts on the hood.
   

2. Move the hood and adjust the clearance between the hood and front fender.
   

3. Tighten the 4 hinge bolts on the hood.
   

   Torque:

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

Adjust the height of the front end of the hood using the cushion rubbers.

1. Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.
   

   HINT:

   Raise or lower the front end of the hood by turning the 2 cushion rubbers.

Adjust the hood lock.

1. Loosen the 3 bolts.
   

2. Adjust the hood lock and tighten the 3 bolts.
   

   Torque:

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

3. Check that the striker can smoothly engage with the hood lock.
   

Add new engine oil and install the oil filler cap assembly.

Oil Grade:

Oil Grade	Oil Viscosity (SAE)
ACEA C2 (Using engine oil other than ACEA C2 may damage the catalytic converter)	- 0W-30 - 5W-30

Standard Capacity:

Item	Specified Condition
Drain and refill without oil filter sub-assembly change	7.0 liters (7.4 US qts, 6.2 Imp. qts)
Drain and refill with oil filter sub-assembly change	7.5 liters (7.9 US qts, 6.6 Imp. qts)
Dry fill	8.0 liters (8.5 US qts, 7.0 Imp. qts)

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.

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.

Remove the radiator reservoir cap sub-assembly.

Fill the radiator assembly with engine coolant and attach a radiator cap tester.

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator assembly to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator assembly and engine water pump assembly for leaks.
If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.

Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.

Warm up the engine, and then stop the engine and wait 5 minutes.

Check that the engine oil level is between the engine oil level dipstick low level mark and full level mark.
If the engine oil level is low, check for leaks and add engine oil 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, 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.
   

1. If low quality oil or oil of an inappropriate viscosity is used.
   

1. When driving at a high engine speed or with a heavy load, when towing, or when driving while accelerating or decelerating frequently.
   

1. When idling for a long time, or when driving frequently through heavy traffic.
   

When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.

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 front bumper lower cover with the clip and 5 bolts.

Torque:

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