Camshaft Installation

Using SST, grip the hexagonal portion, and then secure SST and No. 2 camshaft in a vise as shown in the illustration.

SST

09212-31010

NOTICE:

1. Do not damage the No. 2 camshaft.
   
2. Never grip areas other than the hexagonal portion, as this may cause damage.
   

Align and attach the straight pin of the No. 2 camshaft with the straight pin hole of the camshaft timing exhaust gear assembly.

Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

NOTICE:

Be sure not to remove the other 4 bolts. If removing the bolts, exchange the camshaft timing exhaust gear assembly.

Fix the camshaft timing exhaust gear assembly with the flange bolt.

Torque:

78 N*m{795 kgf*cm, 58 ft.*lbf}

Using SST, grip the hexagonal portion, and then secure SST and camshaft in a vise as shown in the illustration.

SST

09212-31010

NOTICE:

1. Do not damage the camshaft.
   
2. Never grip areas other than the hexagonal portion, as this may cause damage.
   

Align the straight pin hole and straight pin and install the camshaft timing gear assembly to the camshaft.

Lightly press the gear against the camshaft and turn the gear. Push further at the position where the straight pin enters the straight pin hole.

NOTICE:

Be sure not to turn the camshaft timing gear assembly in the retard direction (the right angle).

Check that there is no clearance between the camshaft timing gear assembly and the flange of the camshaft.

NOTICE:

1. Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.
   
2. Be sure not to remove the other 3 bolts. If removing the bolts, exchange the camshaft timing gear assembly.
   

With the camshaft timing gear assembly fixed in place, install the flange bolt.

Torque:

78 N*m{795 kgf*cm, 58 ft.*lbf}

Check that the camshaft timing gear assembly can move in the retard direction (the right angle), and is locked at the most retarded position.

Apply clean engine oil to the camshaft cams and cylinder head journals.

Install the chain sub-assembly to the camshaft timing gear assembly with the paint mark of the link aligned with the timing mark of the camshaft timing gear assembly.

Temporarily install the 4 No. 2 camshaft bearing caps using the 8 bolts as shown in the illustration.

Install the chain sub-assembly to the No. 2 camshaft, and then install the No. 2 camshaft to the cylinder head sub-assembly.

HINT:

Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly.

Move the camshaft in the direction shown in the illustration to loosen the chain sub-assembly, and align the paint mark on the camshaft timing gear assembly and chain sub-assembly and connect the chain sub-assembly to the camshaft timing gear assembly.

Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

Temporarily install the No. 1 camshaft bearing cap and 4 No. 2 camshaft bearing caps using the 12 bolts.

Install the 20 bolts in the order shown in the illustration.

Torque:

16 N*m{158 kgf*cm, 11 ft.*lbf}

Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

Install a new gasket and the No. 1 chain tensioner assembly with the bolt and nut.

Torque:

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

NOTICE:

Remove the hexagon wrench after installing the timing chain guide.

Install a new gasket to the timing chain cover plate.

Install the timing chain cover plate to the timing chain cover sub-assembly with the 2 bolts.

Torque:

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

Check that the No. 1 cylinder is set to TDC/compression.

1. Rotate the crankshaft two full rotations, and then check that all timing marks are in the position shown in the illustration.
   If the timing marks do not match, set the chain sub-assembly again.
   

   Text in Illustration

   *a	Timing Mark
   *b	Groove
   *c	Approximately 13°

Install a new O-ring to the No. 1 camshaft bearing cap.

Install the timing chain guide with the 2 bolts.

Torque:

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

Install a new No. 2 camshaft bearing cap oil hole gasket and 3 new No. 3 camshaft bearing cap oil hole gaskets to the No. 1 camshaft bearing cap.

Install the cylinder head cover connector sub-assembly with the 2 bolts.

Torque:

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

Clean and degrease the contact surfaces of the cylinder head cover sub-assembly, timing chain cover sub-assembly and cylinder head sub-assembly.

Apply seal packing as shown in the illustration.

Seal packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal packing diameter:

4.0 mm (0.157 in.)

Text in Illustration

Seal Packing

NOTICE:

1. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
2. Do not add the engine oil for at least 4 hours after the installation.
   
3. Do not start the engine for at least 4 hours after the installation.
   

Install a new No. 1 camshaft bearing cap oil hole gasket to the cylinder head cover spacer.

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

Install the cylinder head cover sub-assembly, 2 plate washers and 2 seal washers with the 21 bolts and 2 nuts, and tighten the 21 bolts and 2 nuts in the sequence shown in the illustration.

Torque:

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

Text in Illustration

*1	Plate Washer and Seal Washer
	Seal Packing
	Nut

NOTICE:

Make sure that the metal face of the seal washer is facing upward.

Connect the PCV hose to the PCV valve sub-assembly and slide the clip to secure the hose.

Install the 4 ignition coil assemblies with the 4 bolts.

Torque:

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

Connect the 4 ignition coil connectors.

Install the fan pulley to the engine water pump assembly.

Place the shroud together with the coupling fan between the radiator assembly and engine.

NOTICE:

Be careful not to damage the radiator core.

Temporarily install the fluid coupling fan to the engine water pump assembly with the 4 nuts. Tighten the nuts as much as possible by hand.

Attach the claws of the shroud to the radiator assembly as shown in the illustration.

Install the fan shroud with the 2 bolts.

Torque:

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

Install the fan and generator V-belt (LandCruiser RM000000YMN02UX.html).

Tighten the 4 nuts of the fluid coupling fan.

Torque:

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

Attach the claw to close the flexible hose clamp as shown in the illustration.

Install the radiator reservoir with the 3 bolts.

Torque:

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

Connect the reservoir hose to the radiator assembly.

Install the intake air connector with the 3 bolts.

Torque:

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

Tighten the hose clamp.

Torque:

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

Connect the vacuum hose.

Connect the No. 2 ventilation hose.

Connect the vacuum hose to the air pressure sensor.

Connect the air pressure sensor connector.

Attach the wire harness and vacuum hose to the intake air connector.

Install the air cleaner hose and align its matchmark with the matchmark of the intake air connector as shown in the illustration.

Tighten the hose clamp.

NOTICE:

Check that the air cleaner hose is securely installed.

Attach the 4 clamps.

Connect the mass air flow meter connector and attach the 3 clamps.

Clean and install the oil pan drain plug and a new gasket.

Torque:

38 N*m{382 kgf*cm, 28 ft.*lbf}

Add fresh engine oil.

Standard Oil Grade:

Oil Grade	Oil Viscosity (SAE)
API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil	0W-20 5W-20 5W-30 10W-30
API grade SL, SM or SN multigrade engine oil	15W-40 20W-50*

NOTICE:

*: This grade of engine oil cannot be used for Euro IV or higher.

Standard Capacity:

Item	Specified Condition
Drain and refill without oil filter sub-assembly change	5.5 liters (5.8 US qts, 4.8 Imp. qts)
Drain and refill with oil filter sub-assembly change	5.9 liters (6.2 US qts, 5.2 Imp. qts)
Dry fill	6.4 liters (6.8 US qts, 5.6 Imp. qts)

Install the oil filler cap.

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

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

Check that the oil level is between the dipstick low level mark and full level mark.
If the level is low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not fill engine oil above the full level mark.

Warm up and stop the engine.

When using the GTS:

1. Connect the GTS to the DLC3.
   

2. Start the engine and idle it.
   

3. Turn the GTS on.
   

4. Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance.
   

   Standard ignition timing:

   5 to 15° BTDC @ idle
   

   HINT:

   Refer to the GTS operator's manual for further details.

   NOTICE:

   1. When checking the ignition timing, the transmission should be in N or P.
      
   2. Switch off all the accessories and the A/C before connecting the GTS.
      

5. Check that the ignition timing advances immediately when the engine speed is increased.
   

6. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1.
   

7. Monitor IGN Advance.
   

8. Perform the Active Test.
   

   Standard ignition timing:

   3 to 7° BTDC @ idle
   

   NOTICE:

   When checking the ignition timing, the transmission should be in N or P.

   HINT:

   Refer to the GTS operator's manual for further details.

When not using the GTS:

1. Loosen the hose clamp from the throttle body side.
   

2. Remove the 3 bolts and disconnect the intake air connector.
   

   HINT:

   Move the intake air connector so that the tester probe of a timing light can be connected to the wire of the ignition coil for the No. 1 cylinder.

3. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.
   

   NOTICE:

   Use a timing light that detects primary signals.

4. Connect the intake air connector.
   

   HINT:

   Return the parts to their original positions so that the engine can be started.

5. Start the engine and idle it.
   





6. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
   

   SST

   09843-18040
   

   Text in Illustration

   *a	Front view of DLC3

   NOTICE:

   1. Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
      
   2. When checking the ignition timing, the shift lever should be in N or P.
      

7. Using the timing light, check the ignition timing.
   

   Standard ignition timing:

   3 to 7° BTDC @ idle
   

   NOTICE:

   1. Turn all the electrical systems and the A/C off.
      
   2. When checking the ignition timing, the shift lever should be in N or P.
      

8. Remove SST from the DLC3.
   

9. Check the ignition timing.
   

   Standard ignition timing:

   5 to 15° BTDC @ idle
   

10. Check that the ignition timing advances immediately when the engine speed is increased.
    

11. Turn the ignition switch off.
    

12. Disconnect the timing light from the engine.
    

13. Connect the intake air connector with the 3 bolts.
    

    Torque:

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

14. Tighten the hose clamp.
    

    Torque:

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

Warm up and stop the engine.

When using the GTS:

1. Connect the GTS to the DLC3.
   

2. Start the engine and idle it.
   

3. Turn the GTS on.
   

4. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.
   

   Standard idle speed:

   600 to 700 rpm
   

   NOTICE:

   1. Turn all the electrical systems and the A/C off.
      
   2. When checking the idling speed, the shift lever should be in N or P.
      

   HINT:

   Refer to the GTS operator's manual for further details.

5. Turn the ignition switch off.
   

6. Disconnect the GTS from the DLC3.
   

When not using the GTS:

1. Using SST, connect a tachometer probe to terminal 9 (TAC) of the DLC3.
   

   SST

   09843-18040
   

   NOTICE:

   1. Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.
      
   2. Turn all the electrical systems and the A/C off.
      
   3. When checking the idling speed, the shift lever should be in N or P.
      

2. Check the idle speed.
   

   Standard idle speed:

   600 to 700 rpm
   

3. Disconnect the tachometer probe from the DLC3.
   

If the engine speed is not as specified, update the idle speed control (ISC) learned value using either procedure 1 or procedure 2 below, and then check the engine speed again.

1. Procedure 1:
   After completely warming up the engine, drive the vehicle at 30 km/h (19 mph) for 30 seconds or more and idle the engine for 30 seconds or more. Repeat this pattern 5 times or more.
   
   

   
   
   
   
   

   Text in Illustration

   *a	Engine completely warmed up	*b	Vehicle being driven at 30 km/h (19 mph)
   *c	Idling	*d	1 time





2. Procedure 2:
   After completely warming up the engine, stop the engine and then idle it. Repeat this pattern 5 times or more.
   
   

   
   
   
   
   

   Text in Illustration

   *a	Engine completely warmed up	*b	Engine stopped
   *c	Engine started	*d	Idling
   *e	1 time	-	-

   HINT:

   1. Be sure to idle the engine for 150 seconds or more for each time the pattern is repeated.
      
   2. If the engine speed is not as specified after performing the procedure above, inspect the idle speed control system as it is malfunctioning.
      

Install the upper radiator support seal with the 13 clips.

Hook the No. 1 engine under cover sub-assembly to the vehicle body as shown in the illustration.

Install the 4 bolts.

Torque:

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

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

Torque:

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