When hanging the engine, make sure to hang the engine with the angle of the sling device at 50° or less. Otherwise, the engine or engine hangers may be damaged.

Lift the engine and remove it from the engine stand.

NOTICE:

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

Place the engine onto a workbench.

6. INSTALL ENGINE ASSEMBLY

Attach an engine sling device and hang the engine with a chain block.

Slowly lower the engine into the engine compartment.

Install the front engine mounting insulator LH and RH with the 2 nuts and 4 bolts.

Torque:
for nut :
72 N*m{ 734 kgf*cm, 53 ft.*lbf}
for bolt:
79 N*m{ 806 kgf*cm, 58 ft.*lbf}

Text in Illustration
	Bolt
	Nut

Remove the 2 bolts and 2 engine hangers.

7. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Using SST, hold the crankshaft.

SST
09213-70011(09213-70020)
09330-00021

Install the crankshaft angle sensor rotor.

Text in Illustration
	Engine Side

HINT:

Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.

As the crankshaft angle sensor rotor is not reversible, be sure to install it so that it is facing in the direction shown in the illustration.

Install the drive plate and ring gear and the rear drive plate spacer to the crankshaft.

Text in Illustration
*1	Drive Plate and Ring Gear
*2	Rear Drive Plate Spacer
	Transmission Side

HINT:

As the rear drive plate spacer and the drive plate and ring gear are not reversible, be sure to install them so that they are facing in the directions shown in the illustration.

Install the drive plate and ring gear and bolts.

HINT:

The bolts are tightened in 2 progressive steps.

Clean the bolts and bolt holes.

Apply adhesive to 2 or 3 threads at the end of each of the 10 bolts.

Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Text in Illustration
*1	Adhesive

Step 1:

Uniformly install and tighten the 10 new bolts in several steps in the sequence shown in the illustration.

Torque:
30 N*m{ 301 kgf*cm, 22 ft.*lbf}

Mark the top of each drive plate installation bolt with paint.

Step 2:

Tighten the drive plate installation bolts 90°.

Check that the painted marks are now at a 90° angle to the top.

NOTICE:

Do not start the engine for at least an hour after installing the drive plate.

8. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

Install the rear No. 1 engine mounting insulator to the transmission with the 4 bolts.

Torque:
59 N*m{ 602 kgf*cm, 44 ft.*lbf}

Install the engine mounting heat insulator with the 2 bolts.

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

9. INSTALL NO. 1 WATER BY-PASS PIPE (w/o ATF Warmer)

Install the No. 1 water by-pass pipe with the 2 bolts.

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

Connect the water hose.

10. INSTALL NO. 1 WATER BY-PASS PIPE (w/ ATF Warmer)

Install the No. 1 water by-pass pipe with the 2 bolts.

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

w/ Rear Heater:

Connect the 6 water hoses.

w/o Rear Heater:

Connect the 4 water hoses.

11. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

()

12. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

Turn the crankshaft to gain access to the installation locations of the 6 bolts and install the bolts while holding the crankshaft pulley set bolt with a wrench.

Torque:
53 N*m{ 535 kgf*cm, 39 ft.*lbf}

NOTICE:

First install the black-colored bolt, and then the remaining 5 silver colored bolts.

13. INSTALL PROPELLER SHAFT ASSEMBLY

()

14. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

()

15. INSTALL OIL COOLER TUBE

Connect the oil cooler tube with the 2 bolts.

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

16. CONNECT TRANSMISSION OIL COOLER HOSE

Connect the 2 transmission oil cooler hoses to the oil cooler tube unions.

Text in Illustration
*a	Paint Mark
*b	Yellow Paint
*c	White Paint
*d	Upper
*e	-45 to 45°

NOTICE:

Make sure the pinching portion of each clip is facing the direction shown in the illustration.

Make sure the paint mark of each hose is facing outward.

17. CONNECT ENGINE WIRE

w/ Secondary Air Injection System:

Connect the connector and clamp.

Connect the 2 connectors and 2 clips to the engine room junction block.

Connect the wire to the positive (+) battery cable with the nut.

Torque:
5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

Connect the clamp and ground wire with the bolt.

Torque:
8.4 N*m{ 85 kgf*cm, 74 in.*lbf}

w/ Secondary Air Injection System:

Connect the 2 air injection control driver connectors.

Connect the 2 connectors and 2 clips to the engine room junction block.

Connect the wire and 2 clips to the engine room junction block with the nut.

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

Connect the ground wire with the bolt.

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

Connect the 4 connectors and 2 clamps to the connector holder block.

Connect the wire harness clamp and ECM connector.

HINT:

Refer to the following procedures to connect the ECM connector ().

18. CONNECT FUEL HOSE AND FUEL TUBE SUB-ASSEMBLY

Connect the fuel hose and fuel tube sub-assembly ().

Attach the clamp and install the fuel pipe clamp to the fuel tube connector.

19. INSTALL STARTER ASSEMBLY

Install the flywheel housing side cover.

Install the starter with the 2 bolts.

Torque:
37 N*m{ 377 kgf*cm, 27 ft.*lbf}

Install the starter wire with the nut.

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

Connect the starter connector.

20. INSTALL STARTER COVER

Install the starter cover with the 3 bolts.

Torque:
12 N*m{ 117 kgf*cm, 8 ft.*lbf}

21. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

w/ Secondary Air Injection System:

Install a new gasket to the No. 3 air tube.

HINT:

Install the gasket with the claws of the gasket facing the tube.

Install a new gasket to the cylinder head.

Text in Illustration
*1	Tab
*a	Front

HINT:

Install the gasket with the gasket tab facing toward the front of the engine.

w/ Secondary Air Injection System:

Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

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

Install the exhaust manifold to the No. 3 air tube with the 2 nuts labeled B.

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

w/o Secondary Air Injection System:

Install the exhaust manifold with 7 new nuts.

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

Connect the air fuel ratio sensor connector and attach the wire harness clamp.

22. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with 3 new bolts.

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

23. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

w/ Secondary Air Injection System:

Install a new gasket to the No. 4 air tube.

HINT:

Install the gasket with the claws of the gasket facing the tube.

Install a new gasket to the cylinder head.

Text in Illustration
*1	Tab
*a	Front

HINT:

Install the gasket with the gasket tab facing toward the rear of the engine.

w/ Secondary Air Injection System:

Install the exhaust manifold to the cylinder head with the 7 new nuts labeled A.

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

Install the exhaust manifold to the No. 4 air tube with the 2 nuts labeled B.

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

w/o Secondary Air Injection System:

Install the exhaust manifold with 7 new nuts.

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

Connect the air fuel ratio sensor connector and attach the wire harness clamp.

24. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with 3 new bolts.

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

25. INSTALL MANIFOLD STAY

Temporarily install the manifold stay with the 3 bolts.

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

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

26. INSTALL NO. 2 MANIFOLD STAY

Temporarily install the manifold stay with the 3 bolts.

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

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

27. INSTALL FRONT EXHAUST PIPE ASSEMBLY

()

28. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

Install a new gasket and the front No. 2 exhaust pipe to the exhaust manifold LH with the 2 nuts.

Torque:
54 N*m{ 554 kgf*cm, 40 ft.*lbf}

29. INSTALL CENTER EXHAUST PIPE ASSEMBLY

Install 2 new gaskets to the center exhaust pipe.

Connect the center exhaust pipe to the 3 exhaust pipe supports.

Install the center exhaust pipe with the 4 bolts.

Torque:
48 N*m{ 489 kgf*cm, 35 ft.*lbf}

30. INSTALL TAILPIPE ASSEMBLY

Install a new gasket to the center exhaust pipe.

Install the tailpipe to the 2 exhaust pipe supports.

Install a new clamp.

Torque:
32 N*m{ 326 kgf*cm, 24 ft.*lbf}

Text in Illustration
*a	Top
*b	LH Side

HINT:

Install the clamp within the angle range shown in the illustration.

31. INSTALL HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

Temporarily install the sensor to the front exhaust pipe by hand.

Using SST, tighten the heated oxygen sensor.

SST
09224-00010

Torque:
without SST:
44 N*m{ 449 kgf*cm, 32 ft.*lbf}
with SST:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Text in Illustration
*1	Fulcrum Length

HINT:

Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification ().

Make sure SST and the wrench are connected in a straight line.

Attach the clamp and connect the heated oxygen sensor connector.

32. INSTALL HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

Temporarily install the sensor to the front No. 2 exhaust pipe by hand.

Using SST, tighten the heated oxygen sensor.

SST
09224-00010

Torque:
without SST:
44 N*m{ 449 kgf*cm, 32 ft.*lbf}
with SST:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Text in Illustration
*1	Fulcrum Length

HINT:

Make sure SST and the wrench are connected in a straight line.

Connect the heated oxygen sensor connector.

33. INSTALL PROPELLER SHAFT HEAT INSULATOR

Install the insulator with the 2 bolts.

Torque:
16 N*m{ 160 kgf*cm, 12 ft.*lbf}

34. CONNECT COOLER COMPRESSOR ASSEMBLY

Install the cooler compressor and stud bolt.

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

Install the 3 bolts and nut.

Torque:
24.5 N*m{ 250 kgf*cm, 18 ft.*lbf}

HINT:

Tighten the bolts and nut in the order shown in the illustration.

Connect the connector.

35. INSTALL GENERATOR ASSEMBLY

for 130A, 150A Type:
()

for 180A Type:
()

36. INSTALL VANE PUMP ASSEMBLY

HINT:

Before performing the following procedures, move the spacer until the vane pump can be installed.

Text in Illustration
	Spacer

Connect the vane pump to the timing chain cover with the 2 bolts.

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

37. CONNECT PRESSURE FEED TUBE

Install a new gasket to the pressure feed tube.

Connect the pressure feed tube with the union bolt.

Torque:
50 N*m{ 510 kgf*cm, 37 ft.*lbf}

38. CONNECT SUCTION HOSE

Connect the suction hose to the vane pump assembly with the clip.

39. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Apply engine oil to a new O-ring, and then 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}

Attach the engine wire clamp.

Install the engine oil level dipstick.

40. INSTALL INTAKE MANIFOLD

Place 2 new gaskets on the intake manifold.

Place the intake manifold on the cylinder head.

Install and uniformly tighten the 8 bolts and 2 nuts in several steps.

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

Connect the fuel tube to the No. 2 fuel delivery pipe ().

Connect the fuel tube to the fuel delivery pipe ().

Attach the 3 wire harness clamps to the 3 wire harness brackets.

Install the bolt.

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

Connect the purge VSV connector.

Connect the purge line hose to the purge VSV.

Connect the vacuum switching valve connector (for ACIS).

Connect the PCV valve hose.

Connect the No. 4 water by-pass hose.

Connect the throttle position sensor and throttle control motor connector.

w/o Secondary Air Injection System:

Install the bracket with the 2 bolts.

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

Attach the clamp and connect the manifold absolute pressure sensor connector.

41. INSTALL AIR TUBE SUB-ASSEMBLY (w/ Secondary Air Injection System)

Install the air tube.

Install the bolt.

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

Install the bracket with the 2 bolts.

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

Attach the clamp and connect the manifold absolute pressure sensor connector.

Align the paint mark with the projection and connect the No. 2 air injection system hose.

Text in Illustration
*1	Projection
*2	Paint Mark

HINT:

Make sure the direction of the hose clamp is as shown in the illustration.

42. INSTALL PCV HOSE ASSEMBLY

Install the PCV hose with the bolt.

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

Connect the PCV hose to the PCV pipe of the cylinder head cover LH and RH.

43. INSTALL EGR VALVE BRACKET

Install the EGR valve bracket with the 3 bolts.

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

Attach the 2 wire harness clamps and PCV hose clamp.

44. INSTALL NO. 5 WATER BY-PASS PIPE

Install the No. 5 water by-pass pipe with the 2 bolts and connect the 2 water by-pass hoses.

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

45. CONNECT NO. 3 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

Connect the No. 3 air injection system hose.

46. INSTALL RADIATOR ASSEMBLY

Insert the radiator bracket hooks into the radiator support holes.

Install the radiator with the 4 bolts.

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

47. INSTALL NO. 2 RADIATOR HOSE

48. INSTALL FAN SHROUD

Install the fan pulley to the engine water pump.

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

NOTICE:

Be careful not to damage the radiator core.

Temporarily install the fluid coupling fan to the fluid coupling bracket with the 4 nuts. Tighten the nuts as much as possible by hand.

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

Install the shroud with the 2 bolts.

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

Connect the oil cooler tube to the fan shroud with the 2 bolts.

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

w/ Air Cooled Transmission Oil Cooler:

Pass the hose through the flexible hose clamp and close the clamp as shown in the illustration.

Connect the reservoir hose to the upper radiator tank.

Install the fan and generator V belt ().

Tighten the 4 nuts of the fluid coupling fan.

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

49. INSTALL NO. 1 RADIATOR HOSE

50. INSTALL AIR CLEANER AND HOSE

Install the air cleaner and hose with the 3 bolts, and then tighten the hose clamp.

Torque:
for bolt:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}
for hose clamp:
2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Attach the clamp and connect the mass air flow meter connector.

Connect the No. 2 PCV hose and No. 1 air hose.

51. INSTALL BATTERY

Install the battery.

Temporarily install the nut and install the bolt.

Adjust the battery clamp's position.

Tighten the 2 nuts and bolt.

Torque:
for bolt:
12 N*m{ 122 kgf*cm, 9 ft.*lbf}
for nut:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

52. INSTALL FRONT FENDER APRON TRIM PACKING C

Install the front fender apron trim packing C with the 4 clips.

53. INSTALL FRONT FENDER APRON TRIM PACKING A

Install the front fender apron trim packing A with the 3 clips.

54. INSTALL FRONT FENDER APRON TRIM PACKING D

Install the front fender apron trim packing D with the 4 clips.

55. INSTALL FRONT FENDER APRON TRIM PACKING B

w/ KDSS

Install the front fender apron trim packing B with the 3 clips.

w/o KDSS

Install the front fender apron trim packing B with the 4 clips.

56. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

()

57. INSTALL HOOD SUB-ASSEMBLY

Install the hood with the 6 bolts.

Torque:
for bolt A:
13 N*m{ 133 kgf*cm, 10 ft.*lbf}
for bolt B:
18 N*m{ 178 kgf*cm, 13 ft.*lbf}

Text in Illustration
	for Bolt A
	for Bolt B

58. ADJUST HOOD SUB-ASSEMBLY

Adjust the hood position.

Loosen the 4 hinge bolts of the hood.

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

Tighten the 4 hinge bolts of the hood after the adjustment.

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

Adjust the cushion rubber so that the height of the hood and fender are aligned.

HINT:

Raise or lower the hood front end by turning the cushion rubber.

Adjust the hood lock.

Using a screwdriver, remove the hood lock nut cap as shown in the illustration.

HINT:

Tape the screwdriver tip before use.

Loosen the 2 bolts and hood lock nut.

Adjust the hood lock position so that the striker can enter it smoothly.

Tighten the bolts and nut after the adjustment.

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

Install a new cap.

59. INSTALL RADIATOR SIDE DEFLECTOR LH

Install the deflector with the 4 clips.

60. INSTALL RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)

Install the deflector with the 4 clips.

61. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)

Install the oil cooler air duct with the 4 bolts.

Torque:
4.9 N*m{ 50 kgf*cm, 43 in.*lbf}

62. INSTALL FRONT BUMPER COVER

for Standard ()

w/ Winch ()

63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

64. ADD ENGINE OIL

Add fresh oil and install the oil filler cap.

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

Standard Oil Capacity:

Item	Specified Condition
Drain and refill without oil filter change	7.1 liters (7.5 US qts, 6.2 Imp. qts)
Drain and refill with oil filter change	7.5 liters (7.9 US qts, 6.6 Imp. qts)
Dry fill	9.3 liters (9.8 US qts, 8.2 Imp. qts)

65. ADD ENGINE COOLANT

Add engine coolant.

Standard Capacity (w/o ATF Warmer):
Item Specified Condition
w/ Rear Heater 16.5 liters (17.4 US qts, 14.5 Imp. qts)
w/o Rear Heater 13.8 liters (14.6 US qts, 12.1 Imp. qts)

Standard Capacity (w/ ATF Warmer):
Item Specified Condition
w/ Rear Heater 17.0 liters (18.0 US qts, 15.0 Imp. qts)
w/o Rear Heater 14.2 liters (15.0 US qts, 12.5 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 consists of a combination of low phosphates and organic acids).

Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

Slowly pour coolant into the radiator reservoir until it reaches the F line.

Install the reservoir cap.

Install the radiator cap.*1

Start the engine and stop it immediately.*2

Allow approximately 10 seconds to pass. Then remove the radiator cap and check the coolant level. If the coolant level has decreased, add coolant.*3

Repeat steps *1, *2 and *3 until the coolant level does not decrease.

HINT:

Be sure to perform this step while the engine is cold, as air in the No. 1 radiator hose will flow into the radiator if the engine is warmed up and the thermostat opens.

Install the radiator cap.*4

Set the air conditioning as follows.*5

Item	Condition
Fan speed	Any setting except off
Temperature	Toward WARM
Air conditioning switch	Off

Start the engine, warm it up until the thermostat opens, and then continue to run the engine for several minutes to circulate the coolant.*6

CAUTION:

Wear protective gloves. Hot areas on the parts may injure your hands.

Be careful of the fan.

Be careful as the engine, radiator and radiator hoses are hot and can cause burns.

NOTICE:

Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

Do not start the engine when there is no coolant in the radiator reservoir.

Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.

If there is not enough coolant, the engine may burn out or overheat.

HINT:

Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.

The thermostat opening 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.

Stop the engine, wait until the engine coolant cools down to ambient temperature. Then remove the radiator cap and check the coolant level.*7

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

If the coolant level has decreased, add coolant and warm up the engine until the thermostat opens.*8

If the coolant level has not decreased, check that the coolant level in the radiator reservoir is at the F line.

If the coolant level is below the F line, repeat steps *4 through *8.

If the coolant level is above the F line, drain coolant until the coolant level reaches the F line.

66. ADD AUTOMATIC TRANSMISSION FLUID

()

67. ADD POWER STEERING FLUID

68. BLEED POWER STEERING FLUID

Check the fluid level.

Jack up the front of the vehicle and support it with stands.

Turn the steering wheel.

With the engine stopped, turn the wheel slowly from lock to lock several times.

Lower the vehicle.

Start the engine.

Idle the engine for a few minutes.

Turn the steering wheel.

With the engine idling, turn the wheel left or right to the full lock position and keep it there for 2 to 3 seconds, then turn the wheel to the opposite full lock position and keep it there for 2 to 3 seconds. *1

Repeat *1 several times.

NOTICE:

For vehicles with VGRS, if the steering wheel is turned from lock to lock repeatedly, the system may stop operating and the amount of rotation before the steering wheel locks may increase due to operation of the overheating prevention function. When the system temperature drops, the system operation automatically returns to normal.

Stop the engine.

Check for foaming or emulsification.

Text in Illustration
*a	Correct
*b	Incorrect

If the system has to be bled twice because of foaming or emulsification, check for fluid leaks in the system.

Check the fluid level.

69. INSPECT FOR OIL LEAK

Start the engine. Make sure that there are no oil leaks from the area that was worked on.

70. INSPECT FOR COOLANT LEAK

CAUTION:

To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.

Remove the radiator cap.

Check for excessive deposits of rust or scales around the radiator reservoir cap and radiator reservoir filler hole. Also, the engine coolant should be free of oil.

If excessively dirty, replace the engine coolant.

Install the radiator cap.

71. INSPECT FOR FUEL LEAK

Make sure that there are no fuel leaks after performing maintenance on the fuel system.

Connect the GTS to the DLC3.

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

NOTICE:

Do not start the engine.

Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

Check that there are no leaks from the fuel system.

If there are fuel leaks, repair or replace parts as necessary.

Turn the engine switch off.

Disconnect the GTS from the DLC3.

72. INSPECT ENGINE OIL LEVEL

Warm up the engine. Then stop the engine and wait for 5 minutes.

Check that the engine oil level is between the dipstick low level mark and full level mark.

Text in Illustration
*a	Measuring Surface
*b	Low Level Mark
*c	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.

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.

When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.

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

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

When leaving the 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.

73. INSPECT FOR POWER STEERING FLUID LEAK

74. INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

75. INSPECT SHIFT LEVER POSITION

When moving the shift lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that it moves smoothly and correctly into position.

Check that the shift lever does not stop when moving the shift lever from R to P, and check that the shift lever does not stick when moving the shift lever from D to S.

Start the engine and make sure that the vehicle moves forward after moving the shift lever from N to D, and moves rearward after moving the shift lever to R.

If there are problems during the above inspections, perform the adjustment using the following procedures.

Move the shift lever to N

Loosen the nut of the floor shift gear shifting rod. Then, with the lever of the floor shift assembly lightly pushed towards the rear of the vehicle, tighten the nut.

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

Text in Illustration
*1	Lever

76. PERFORM RESET MEMORY

()

77. INSPECT IGNITION TIMING

NOTICE:

Turn all electrical systems off.

Perform the inspection when the cooling fan motor is turned off.

Warm up the engine.

When using the GTS:

Connect the GTS to the DLC3.

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

Standard ignition timing:
7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

HINT:

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

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

Disconnect the GTS from the DLC3.

When not using the GTS:

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

SST
09843-18040

Text in Illustration
*a	Front view of DLC3

NOTICE:

Be sure not to improperly connect the terminals. This may damage the engine.

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.

Inspect the ignition timing during idling.

Standard ignition timing:
8 to 12° BTDC @ idle (transmission in neutral and A/C switch off)

Remove SST from the DLC3.

Inspect the ignition timing during idling.

Standard ignition timing:
7 to 24° BTDC @ idle (transmission in neutral and A/C switch off)

Disconnect the timing light from the engine.

78. INSPECT ENGINE IDLE SPEED

NOTICE:

Turn all the electrical systems off.

Perform the inspection when the cooling fan motor is turned off.

Warm up the engine.

When using the GTS:

Connect the GTS to the DLC3.

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

Standard idle speed:
650 to 750 rpm (transmission in neutral and A/C switch off)

HINT:

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

Disconnect the GTS from the DLC3.

When not using the GTS:

Connect SST to terminal 9 (TAC) of the DLC3.

SST
09843-18030

Text in Illustration
*a	Front view of DLC3

NOTICE:

Be sure not to improperly connect SST. This may damage the engine.

Race the engine at 2500 rpm for approximately 90 seconds.

Inspect the engine idle speed.

Standard idle speed:
650 to 750 rpm (transmission in neutral and A/C switch off)

79. INSPECT CO/HC

HINT:

This check is to determine whether or not the idle CO/HC concentration complies with regulations.

Start the engine.

Run the engine at 2500 rpm for approximately 180 seconds.

Insert the CO/HC meter testing probe at least 40 cm (1.31 ft) into the tailpipe during idling.

Immediately check the CO/HC concentration during idling and/or at 2500 rpm.

HINT:

When carrying out the 2 tests (idling and 2500 rpm), the measurement procedures are prescribed by applicable local regulations.

If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below.

Check the air fuel ratio sensor operation () and heated oxygen sensor operation ().

Refer to the table below for possible causes, and then inspect and correct the corresponding causes if necessary.

CO	HC	Symptom	Causes
Normal	High	Rough idling	Faulty ignition: Incorrect timing Plugs are contaminated or shorted, or plug gaps are incorrect Leaky intake and exhaust valves Leaky cylinders
Low	High	Rough idling (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Lean mixture causing misfire
High	High	Rough idle (Black smoke from exhaust)	Restricted air filter Plugged PCV valve Faulty SFI system: Faulty pressure regulator Defective engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Faulty throttle position sensor

80. INSTALL OIL PAN PROTECTOR ASSEMBLY

Install the oil pan protector assembly with the 4 bolts.

Torque:
63 N*m{ 642 kgf*cm, 46 ft.*lbf}

81. INSTALL NO. 2 ENGINE UNDER COVER

Install the No. 2 engine under cover with the 2 bolts.

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

82. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Install the No. 1 engine under cover sub-assembly with the 10 bolts.

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

83. INSTALL V-BANK COVER SUB-ASSEMBLY

Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

Text in Illustration
*1	Grommet
*2	Pin
*3	Hook
*4	Bracket

1UR-FE ENGINE MECHANICAL

Land Cruiser URJ200 URJ202 GRJ200 VDJ200

ENGINE ASSEMBLY

Item	Specified Condition
w/ Rear Heater	16.5 liters (17.4 US qts, 14.5 Imp. qts)
w/o Rear Heater	13.8 liters (14.6 US qts, 12.1 Imp. qts)