Oil Pump Installation

Apply a light coat of engine oil to the 4 new O-rings.

Install the 4 O-rings to the cylinder block sub-assembly and cylinder head sub-assembly.

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

Apply a coating of seal packing to the timing chain case assembly at the points shown in the illustration.

Seal packing:

for line area D:

Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent.

for line area A-A, B-B, C-C and E:

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

NOTICE:

1. Using non-residue solvent, clean and remove any oil from the installation surface.
   
2. Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Temporarily install the timing chain case assembly with the 15 bolts.

Bolt Length:

Item	Length	Thread Diameter
Bolt A	30 mm (1.18 in.)	8.0 mm (0.315 in.)
Bolt B	45 mm (1.77 in.)	8.0 mm (0.315 in.)
Bolt C	65 mm (2.56 in.)	8.0 mm (0.315 in.)
Bolt D	30 mm (1.18 in.)	10 mm (0.394 in.)

Temporarily install a new gasket and the engine water pump assembly with the 8 bolts.

Tighten the 23 bolts in the order shown in the illustration.

Torque:

for bolt A, B and C:

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

for bolt D:

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

NOTICE:

Check the torque of bolt 1 after tightening bolt 23.

Install the injection pump insulator to the cylinder block sub-assembly.

Install a new O-ring to the supply pump assembly.

Install the supply pump assembly to the timing chain case assembly with the 3 nuts.

Torque:

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

Install the No. 1 fuel pump bracket to the cylinder block sub-assembly and supply pump assembly with the 2 bolts.

Torque:

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

Install the No. 1 chain tensioner slipper to the straight pin.

Temporarily install the No. 1 chain vibration damper to the cylinder block sub-assembly with the bolt.

Install the crankshaft timing sprocket to the crankshaft.

Align the crankshaft pulley set key as shown in the illustration.

Align the supply pump shaft key as shown in the illustration.

Remove the crankshaft timing sprocket from the crankshaft.

Align the 2 mark plates (pink) of the No. 1 chain sub-assembly with the 2 timing marks of the crankshaft timing sprocket and install the No. 1 chain sub-assembly to the crankshaft timing sprocket as shown in the illustration.

Align the mark plate (yellow) of the No. 1 chain sub-assembly with the timing mark of the injection pump drive gear and install the No. 1 chain sub-assembly to the injection pump drive gear as shown in the illustration.

Install the crankshaft timing sprocket, injection pump drive gear and No. 1 chain sub-assembly to the crankshaft and supply pump shaft together.

Tighten the No. 1 chain vibration damper to the cylinder block sub-assembly with the bolt.

Torque:

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

Install a new gasket and No. 1 chain tensioner assembly to the cylinder block sub-assembly with the 2 bolts.

Torque:

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

HINT:

Align the claw (lower side) of the gasket with the groove of the No. 1 chain tensioner assembly body to install the No. 1 chain tensioner assembly as shown in the illustration.

Temporarily install the crankshaft pulley and crankshaft pulley set bolt to the crankshaft.

Using SST, hold the crankshaft pulley and install the supply pump shaft nut to the supply pump shaft.

SST

09213-58014(91551-80840)
09330-00021

Torque:

137 N*m{1397 kgf*cm, 101 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

NOTICE:

If the supply pump shaft nut is tightened with torque higher than the specified torque, the No. 1 chain sub-assembly may break.

Remove the crankshaft pulley set bolt and crankshaft pulley from the crankshaft.

Make sure that the timing marks of the crankshaft timing sprocket and injection pump drive gear are aligned with the mark plates of the No. 1 chain sub-assembly as shown in the illustration.

Remove the pin from the No. 1 chain tensioner assembly.

Temporarily install the 2 camshaft timing sprockets to the camshaft and No. 2 camshaft with the 2 camshaft timing sprocket bolts.

NOTICE:

Make sure that the timing mark of the camshaft timing sprocket faces the front side of the engine.

HINT:

Align the knock pins of the camshaft and No. 2 camshaft with the cutout of the camshaft timing sprocket to install the camshaft timing sprocket.

for Intake Side:

1. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing sprocket bolt to the camshaft.
   

   Torque:

   81 N*m{826 kgf*cm, 60 ft.*lbf}

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   Be careful not to damage the camshaft or cylinder head sub-assembly with the wrench.

for Exhaust Side:

1. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing sprocket bolt to the No. 2 camshaft.
   

   Torque:

   81 N*m{826 kgf*cm, 60 ft.*lbf}

   Text in Illustration

   *a	Hold
   	Turn

   NOTICE:

   Be careful not to damage the No. 2 camshaft or cylinder head sub-assembly with the wrench.

Install the No. 2 chain vibration damper to the timing chain case assembly with the 2 bolts.

Torque:

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

Align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (intake side) and install the No. 2 chain sub-assembly to the camshaft timing sprocket (intake side) as shown in the illustration.

Align the mark plate (yellow) of the No. 2 chain sub-assembly with the timing mark of the injection pump drive gear and install the No. 2 chain sub-assembly to the injection pump drive gear as shown in the illustration.

Using a wrench, turn the hexagonal portion of the No. 2 camshaft clockwise and align the mark plate (orange) of the No. 2 chain sub-assembly with the timing mark of the camshaft timing sprocket (exhaust side) to install the No. 2 chain sub-assembly to the camshaft timing sprocket (exhaust side).

Text in Illustration

*a	Mark Plate (Orange)
*a	Timing Mark
	Turn

Install the No. 2 chain tensioner slipper to the timing chain case assembly with the bolt.

Torque:

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

Install the No. 2 chain tensioner assembly to the timing chain case assembly with the 2 bolts.

Torque:

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

Remove the pin from the No. 2 chain tensioner assembly.

Install the timing chain guide to the cylinder head sub-assembly with the bolt.

Torque:

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

Make sure that the timing marks of the camshaft timing sprocket (exhaust side), camshaft timing sprocket (intake side), injection pump drive gear and crankshaft timing sprocket are at the positions shown in the illustration.

Align the mark plate (yellow) of the No. 3 chain sub-assembly with the timing mark of the balance shaft timing sprocket and install the No. 3 chain sub-assembly to the balance shaft timing sprocket as shown in the illustration.

NOTICE:

Make sure that the timing plate of the No. 3 chain sub-assembly faces the front side of the engine.

Align the 2 mark plates (yellow) of the No. 3 chain sub-assembly with the 2 timing marks of the balance shaft timing gear sub-assembly and install the No. 3 chain sub-assembly to the balance shaft timing gear sub-assembly as shown in the illustration.

Apply engine oil to the position shown in the illustration.

Align the timing mark of the engine balancer assembly with the 2 paint marks (pink) and timing mark of the balance shaft gear sub-assembly, and then install the balance shaft timing sprocket, balance shaft gear sub-assembly with No. 3 chain sub-assembly to the crankshaft and engine balancer assembly as shown in the illustration.

Make sure that the timing marks of the balance shaft timing sprocket and balance shaft gear sub-assembly are aligned with the mark plates of the No. 3 chain sub-assembly as shown in the illustration.

Apply engine oil to the front and rear surfaces of the No. 1 balance shaft thrust plate.

Install the No. 1 balance shaft thrust plate to the crankshaft with the bolt.

Torque:

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

Install the No. 3 chain tensioner assembly to the engine balancer assembly with the 2 bolts.

Torque:

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

Remove the pin from the No. 3 chain tensioner assembly.

Install the oil pump drive gear to the crankshaft.

Install the timing chain cover plate and new gasket with the 3 bolts.

Torque:

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

Apply a light coat of engine oil to a new timing chain case gasket.

Install the timing chain case gasket to the timing chain case assembly.

Clean and degrease the contact surfaces of the timing chain cover sub-assembly and timing chain case assembly.

Apply a coating of seal packing to the timing chain cover sub-assembly at the points shown in the illustration.

Seal packing:

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

Standard seal packing diameter:

2.5 to 3.5 mm (0.0984 to 0.138 in.)

NOTICE:

1. Using non-residue solvent, clean and remove any oil from the installation surface.
   
2. Install the part within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Temporarily install the timing chain cover sub-assembly with the 20 bolts.

Bolt Length:

Item	Length	Thread Diameter
Bolt A	40 mm (1.57 in.)	8.0 mm (0.315 in.)
Bolt B	25 mm (0.984 in.)	8.0 mm (0.315 in.)

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

Torque:

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

NOTICE:

Check the torque of bolt 1 after tightening bolt 20.

Apply MP grease to the lip of a new crankshaft oil seal.

NOTICE:

1. Keep the lip free of foreign objects.
   
2. Do not allow MP grease to contact the dust seal.
   

Using SST and a hammer, tap in the front crankshaft oil seal.

SST

09214-76011

NOTICE:

1. The acceptable depth from the top of the timing chain cover assembly is 0 to 1.5 mm (0 to 0.0591 in.)
   
2. Keep the lip free from foreign matter.
   
3. Do not tap the front crankshaft oil seal at an angle.
   
4. Make sure that the front crankshaft oil seal is properly installed.
   

Clean and degrease the contact surfaces of the oil pan sub-assembly and cylinder block sub-assembly.

Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

Seal Packing

Seal packing:

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

Standard seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
   
3. Do not add engine oil within 2 hours after installation.
   
4. Do not start the engine for at least 2 hours after installation.
   

Install the oil pan sub-assembly to the cylinder block sub-assembly with the 23 bolts and 2 nuts.

Torque:

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

NOTICE:

Check the torque of all nuts and bolts labeled A again.

Clean and degrease the contact surfaces of the No. 2 oil pan sub-assembly and cylinder block sub-assembly.

Apply seal packing in a continuous line as shown in the illustration.

Text in Illustration

Seal Packing

Seal packing:

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

Standard seal diameter:

3.5 to 4.5 mm (0.138 to 0.177 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts and nuts within 10 minutes after applying seal packing.
   
3. Do not add engine oil within 2 hours after installation.
   
4. Do not start the engine for at least 2 hours after installation.
   

Install the No. 2 oil pan sub-assembly to the oil pan sub-assembly with the 11 bolts and 2 nuts.

Torque:

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

Install the engine oil level sensor to the oil pan sub-assembly with the 4 bolts.

Torque:

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

Connect the engine oil level sensor connector.

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

Install a new cylinder head cover gasket, No. 2 cylinder head cover gasket and 2 camshaft bearing cap oil hole gaskets to the cylinder head cover sub-assembly.

Clean and degrease the contact surfaces of the cylinder head 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

Standard seal diameter:

3.0 to 6.0 mm (0.118 to 0.236 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.
   
3. Do not add engine oil for at least 2 hours after installation.
   
4. Do not start the engine within 2 hours after installation.
   

Tighten the 14 bolts, 4 nozzle holder clamp seats, 2 nuts and camshaft position sensor in the order shown in the illustration.

Text in Illustration

	Bolt
	Nut
	Nozzle Holder Clamp Seat

Torque:

10 N*m{107 kgf*cm, 7 ft.*lbf}

NOTICE:

1. When reusing the camshaft position sensor, check the O-rings.
   
2. Make sure that the O-ring is not cracked or jammed when installing it on the cylinder head cover sub-assembly.
   
3. Replace with a new part if it is dropped or if it receives a strong impact.
   
4. Check the torque of bolts 1 to 4 again.
   

Install 4 new nozzle holder gaskets to the cylinder head cover sub-assembly.

Install 4 new injection nozzle seats to the cylinder head sub-assembly.

Apply a light coat of engine oil to the O-ring on each injector assembly.

Install a new O-ring to each injector assembly.

Install the 4 injector assemblies to the cylinder head sub-assembly.

NOTICE:

Fit the injector assembly to the injection nozzle seats.

Install the nozzle holder clamps and washers as shown in the illustration.

NOTICE:

Pay attention to the mounting orientation (beveled edge) of the washer.

Temporarily install the nozzle holder clamp bolts.

NOTICE:

When temporarily installing the nozzle holder clamp bolt to the No. 1 nozzle holder clamp, make sure that the bolt and clamp are not at an angle.

HINT:

Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

Install the generator bracket sub-assembly to the cylinder head sub-assembly and timing chain case assembly with the 4 bolts.

Torque:

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

Install the No. 1 engine hanger to the cylinder head sub-assembly with the 2 bolts.

Torque:

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

Install the No. 1 water hose clamp bracket to the timing chain case assembly with the bolt.

Torque:

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

Align the keyway of the crankshaft pulley with the key located on the crankshaft, and then slide the crankshaft pulley into place to install it.

Using SST, install a new pulley bolt.

SST

09213-58014(91551-80840)
09330-00021

Torque:

365 N*m{3722 kgf*cm, 269 ft.*lbf}

w/ Viscous Heater:
Install the crankshaft pulley cover to the crankshaft pulley.

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}

Install the viscous heater crankshaft pulley to the crankshaft pulley with the 4 bolts.

Torque:

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

Install the V-ribbed belt tensioner assembly to the timing chain cover sub-assembly with 3 bolts.

Torque:

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

Install the No. 1 idler pulley sub-assembly to the generator bracket sub-assembly with the bolt .

Torque:

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

Install a new gasket to the thermostat as shown in the illustration.

NOTICE:

When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the groove of the gasket is properly installed to the thermostat as shown in the illustration.

Insert the thermostat into the engine water pump assembly with the jiggle valve facing straight upward.

HINT:

The jiggle valve may be set to within 30° on either side of the prescribed position.

Install the water inlet with the 3 bolts.

Torque:

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

Install a new gasket and the water outlet sub-assembly to the timing chain cover sub-assembly with the 4 bolts and 2 nuts.

Torque:

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

Install the No. 2 water by-pass pipe sub-assembly to the engine water pump assembly and water inlet with the 2 bolts.

Torque:

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

Connect the No. 3 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.

Install a new gasket as shown in the illustration.

NOTICE:

Do not install the gasket upside down.

Temporarily install the turbo oil inlet pipe subassembly with the 2 nuts.

Install 2 new gaskets to the exhaust manifold and turbocharger sub-assembly.

Temporarily install the exhaust manifold to turbocharger sub-assembly with 3 new nuts.

Temporarily install the exhaust manifold with turbocharger sub-assembly, 8 collars and the 8 plate washers to the cylinder head sub-assembly with 8 new nuts.

Text in Illustration

*1	Collar
	Engine Side

NOTICE:

Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

Install a new gasket on the union bolt side to turbo oil inlet pipe sub-assembly.

Temporarily install the union bolt.

Install a new gasket to the turbo oil outlet pipe.

NOTICE:

The claws of the gasket must face the turbo oil outlet pipe.

Install the turbo oil outlet pipe with the 2 bolts.

Torque:

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

Connect the turbo oil outlet hose to the turbo oil outlet pipe, turbo oil inlet pipe and slide the 2 hose clips to secure the hoses.

Temporarily install the turbocharger stay to the turbocharger sub-assembly, with 3 bolts and nut.

Tighten the exhaust manifold with turbocharger sub-assembly, to the cylinder head sub-assembly with 8 nuts.

Torque:

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

HINT:

Tighten the nuts in the order shown in the illustration.

Tighten the turbocharger sub-assembly, to the exhaust manifold with the 3 nuts.

Torque:

73 N*m{744 kgf*cm, 54 ft.*lbf}

Tighten the 2 nuts and then union bolt of the turbo oil inlet pipe sub-assembly.

Torque:

for nut:

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

for union bolt:

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

NOTICE:

If the connecting part of the union bolt gasket is cracked, remove the connecting part.

Tighten the 3 bolts and nut of the turbocharger stay in the order shown in the illustration.

Torque:

24 N*m{245 kgf*cm, 18 ft.*lbf}

Temporarily install the No. 1 viscous heater bracket sub-assembly to the cylinder block sub-assembly and timing chain cover sub-assembly with the 4 bolts.

Tighten the 4 bolts in the sequence shown in the illustration to install the No. 1 viscous heater bracket sub-assembly.

Torque:

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

Connect the No. 1 turbo water hose and No. 2 turbo water hose to the water outlet sub-assembly, engine water pump assembly and slide the 2 hose clips to secure the hoses.

NOTICE:

The turbocharger sub-assembly may be damaged if the No. 1 turbo water hose and No. 2 turbo water hose are connected to the wrong locations.

Install a new gasket and the No. 1 water by-pass pipe to the timing chain cover sub-assembly with the 3 bolts.

Torque:

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

HINT:

Make sure that the claw of the gasket faces the No. 1 water by-pass pipe.

Connect the 2 water hoses to the oil cooler assembly and No. 2 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Install the No. 3 water by-pass pipe with the bolt.

Torque:

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

for Cold Area Specification Vehicles:
Install the water hose to the compressor inlet elbow and No. 3 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Set a new gasket and the exhaust manifold converter sub-assembly to the turbocharger sub-assembly.

Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the 3 bolts.

Install a new exhaust pipe clamp to the exhaust manifold converter sub-assembly with a new nut.

Torque:

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

Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly.

Torque:

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

Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and exhaust manifold converter sub-assembly with the bolt and 2 new nuts.

Torque:

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

Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.

Torque:

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

Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

Torque:

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

Using SST, install the air fuel ratio sensor to the front exhaust pipe.

SST

09224-00011

Torque:

Specified tightening torque:

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

HINT:

1. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
2. When using SST (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 38 N*m (384 kgf*cm, 28 ft.*lbf)
   

Connect the connector and 2 clamps.

Install a new gasket and the No. 2 exhaust manifold heat insulator to the No. 1 injector holder with the 3 nuts.

Torque:

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

Install the injector holder to the No. 1 injector holder with the 2 bolts.

Torque:

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

Connect the No. 4 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

Attach the clamp and install the No. 5 water by-pass hose to the No. 1 water hose clamp bracket.

Connect the No. 5 water by-pass hose to the No. 1 injector holder and water outlet sub-assembly, and slide the 2 clamps to secure the hose.

Connect the PCV pipe to the compressor inlet elbow, cylinder head cover sub-assembly and slide the 2 hose clips to secure the hoses.

Install the PCV pipe with the bolt to the compressor inlet elbow.

Torque:

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

Connect the No. 19 water by-pass hose to the compressor inlet elbow and slide the hose clip to secure the hoses.

Install the No. 20 water by-pass hose to the PCV pipe and No. 1 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Attach the clamp and install the PCV hose.

Slide the 2 hose clips to secure the hoses.

Temporarily install the No. 1 compressor mounting bracket to the cylinder block sub-assembly with the 2 bolts.

HINT:

Temporarily install the No. 1 compressor mounting bracket with the 2 bolts so that the No. 1 compressor mounting bracket can be moved by hand.

Push the No. 1 compressor mounting bracket toward the cylinder block sub-assembly as shown in the illustration and tighten bolt A.

Torque:

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

HINT:

Make sure there is no clearance between the cylinder block sub-assembly and No. 1 compressor mounting bracket as shown in the illustration.

Uniformly tighten the 3 bolts in the order shown in the illustration.

Torque:

39 N*m{398 kgf*cm, 29 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.

Install the hose bracket to the cylinder head sub-assembly with the 2 bolts.

Torque:

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

Temporarily install the 2 No. 2 injection pipe sub-assemblies 4 union nuts.

Temporarily install the 2 No. 1 injection pipe sub-assemblies 4 union nuts.

Tighten the 4 nozzle holder clamp bolts.

Torque:

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

Using SST, tighten the No. 1 and No. 2 injection pipe sub-assemblies 8 union nuts.

Torque:

Specified tightening torque:

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

HINT:

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

for LHD:
Install the 3 wiring harness clamp brackets to the cylinder head cover sub-assembly with the 3 bolts.

Torque:

for bolt A:

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

for bolt B:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

for RHD:
Install the 2 wiring harness clamp brackets to the cylinder head cover sub-assembly with the 2 bolts.

Torque:

for bolt A:

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

for bolt B:

8.4 N*m{86 kgf*cm, 74 in.*lbf}

Temporarily install the nozzle leakage pipe assembly and 4 new gaskets with the 4 union bolts and bolt.

Tighten the 4 union bolts and bolt in the order shown in the illustration.

Torque:

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

Connect the No. 5 fuel hose to the nozzle leakage pipe assembly.

Connect the No. 1 fuel pipe to the No. 4 fuel pipe.

Install a new gasket and the No. 1 fuel pipe to the cylinder head cover sub-assembly and No. 1 injector holder with the union bolt and bolt.

Torque:

for bolt:

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

for union bolt:

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

Install the wiring harness clamp bracket with bolt to the cylinder head cover sub-assembly.

Torque:

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

Connect the pressure discharge valve connector to the common rail assembly.

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 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)
   

Install the No. 1 fuel hose to the supply pump assembly and No. 2 fuel pipe, and slide the 2 clamps to secure it.

Install the No. 2 fuel hose to the supply pump assembly and No. 3 nozzle leakage pipe assembly, and slide the 2 clamps to secure it.

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).

Attach the clamp and install the fuel pump motor wire.

Connect the fuel pump motor wire connector.

Install the fuel injection pump cover sub-assembly to the supply pump assembly.

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.

Install the No. 2 fuel pipe to the manifold stay with the bolt.

Torque:

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

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

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.

Temporarily install the No. 1 EGR cooler and No. 2 EGR valve assembly with electric EGR control valve assembly to the intake manifold with the 4 bolts.

Tighten the 4 bolts in the order shown in the illustration.

HINT:

Make sure to tighten the bolts in the order.

Torque:

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

Install the No. 4 water by-pass pipe sub-assembly to the intake manifold with the 2 bolts.

Torque:

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

for Cold Area Specification Vehicles:
Attach the clamp and connect the No. 11 water by-pass hose to the No. 2 fuel pipe.

Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.

Connect the No. 6 water by-pass hose to the No. 4 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

Install the vacuum control valve set to the intake manifold with the 2 bolts.

Torque:

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

Connect the 2 vacuum hoses to the No. 2 vacuum transmitting pipe sub-assembly and No. 2 EGR valve assembly.

Connect the connector to the vacuum control valve set.

Connect the engine wire bracket with the bolt.

Torque:

13 N*m{131 kgf*cm, 9 ft.*lbf}

Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

Torque:

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

Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly with the bolt and 4 new nuts.

Torque:

for bolt:

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

for nut:

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

Attach the 2 clamps and install the connecting wire to the hose bracket.

Connect the connector to the common rail assembly.

Install the No. 3 water by-pass pipe sub-assembly to the No. 1 EGR cooler with the 2 bolts.

Torque:

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

Connect the No. 9 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure the hose.

Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.

Install 2 new gaskets and No. 2 EGR pipe to the electric EGR control valve assembly and the intake manifold with the 4 nuts.

Torque:

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

Install the EGR valve bracket to the electric EGR control valve assembly and intake manifold with the bolt and nut.

Torque:

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

Connect the vacuum hose to the diesel turbo pressure sensor.

NOTICE:

Connect the vacuum hose so that the paint mark on the vacuum hose is aligned with the protrusions of the diesel turbo pressure sensor as shown in the illustration.

Install the diesel turbo pressure sensor with the bolt.

Torque:

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

NOTICE:

Make sure the protrusion of the No. 3 water bypass pipe sub-assembly is inserted into the hole of the diesel turbo pressure sensor.

Connect the diesel turbo pressure sensor connector.

Install the gas filter to the gas filter bracket.

Connect the 2 vacuum hoses to the turbo pressure sensor and intake manifold.

Install the engine cover bracket to the cylinder head cover sub-assembly and hose bracket with the 2 bolts.

Torque:

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

Install the pipe clamp to the engine cover bracket with the 3 bolts.

Torque:

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

Install a new clamp to the pipe clamp.

Temporarily install the No. 2 vacuum pipe to the exhaust manifold converter sub-assembly.

Temporarily install the No. 1 vacuum pipe to the exhaust manifold converter sub-assembly.

Install a new clamp to the No. 1 vacuum pipe and No. 2 vacuum pipe with the nut.

Torque:

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

Using a 17 mm union nut wrench, tighten the No. 2 vacuum pipe.

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 (LandCruiser RM000003YMD00TX.html).
   
2. When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)
   

Using a 17 mm union nut wrench, tighten the No. 1 vacuum pipe.

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 (LandCruiser RM000003YMD00TX.html).
   
2. When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 43 N*m (437 kgf*cm, 32 ft.*lbf)
   

Using a 14 mm union nut wrench, install the No. 3 exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

Torque:

Specified tightening torque

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

NOTICE:

1. If the No. 3 exhaust gas temperature sensor is dropped, replace the new one.
   
2. When reusing the No. 3 exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the No. 3 exhaust gas temperature sensor.
   

HINT:

1. The connector color of the No. 3 exhaust gas temperature sensor is gray.
   
2. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
3. When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)
   

Using a 14 mm union nut wrench, install the No. 2 exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

Torque:

Specified tightening torque

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

NOTICE:

1. If the No. 2 exhaust gas temperature sensor is dropped, replace the new one.
   
2. When reusing the No. 2 exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the No. 2 exhaust gas temperature sensor.
   

HINT:

1. The connector color of the No. 2 exhaust gas temperature sensor is black.
   
2. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
3. When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)
   

Using a 14 mm union nut wrench, install the exhaust gas temperature sensor to the exhaust manifold converter sub-assembly.

Torque:

Specified tightening torque

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

NOTICE:

1. If the No. 3 exhaust gas temperature sensor is dropped, replace the new one.
   
2. When reusing the exhaust gas temperature sensors, clean the screws and apply anti-seize compound before installing the exhaust gas temperature sensor.
   

HINT:

1. The connector color of the exhaust gas temperature sensor is white.
   
2. Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (LandCruiser RM000003YMD00TX.html).
   
3. When using a union nut wrench (fulcrum length of 25 mm (0.984 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 26 N*m (268 kgf*cm, 19 ft.*lbf)
   

Attach the 3 colored connectors to the pipe clamp in the positions shown in the illustration.

Close the clamp of the pipe clamp, and install the bolt.

Torque:

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

NOTICE:

Arrange the exhaust gas temperature sensor wires so that they do not contact each other.

Connect the No. 3 exhaust gas temperature sensor to the No. 1 vacuum pipe.

Torque:

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

Connect the 3 connectors to the 3 exhaust gas temperature sensor.

Install the 2 air hoses to the differential pressure sensor, and slide the 2 clamps to secure the 2 hoses.

HINT:

Make sure the paint mark of the air hose side the differential pressure sensor.

Connect the 2 air hoses to the No. 1 vacuum pipe and No. 2 vacuum pipe, and slide the 2 clamps to secure the 2 hoses.

Install the differential pressure sensor to the pipe clamp with the bolt.

Torque:

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

Connect the connector to the differential pressure sensor.

Install the No. 2 water by-pass pipe to the cylinder head cover sub-assembly, No. 3 water by-pass pipe sub-assembly and No. 2 engine cover bracket with the 3 bolts.

Torque:

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

Connect the No. 16 water by-pass hose to the No. 1 EGR cooler, and slide the clamp to secure the hose.

Connect the No. 15 water by-pass hose to the water by-pass pipe, and slide the clamp to secure the hose.

Connect the No. 13 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.

Connect the connector to install the emission control valve wire to the diesel throttle body assembly.

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

Torque:

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

Connect the connector and clamp.

for Cold Area Specification Vehicles:
Connect the No. 11 water by-pass hose and No. 14 water by-pass hose to the diesel throttle body assembly, and slide the 2 clips to secure the hose.

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 engine cover bracket to the No. 3 water by-pass pipe sub-assembly and No. 2 EGR valve assembly with the 2 bolts.

Torque:

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

Install the No. 3 engine cover bracket to the No. 2 engine cover bracket and engine cover bracket with the 2 bolts.

Torque:

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