DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)
DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)
REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)
REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)
REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)
REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
Engine Assembly -- Removal |
| 1. PRECAUTION |
- NOTICE:
- After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (LandCruiser RM000003YMD00TX.html).
| 2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).
| 3. REMOVE HOOD SUB-ASSEMBLY |
Disconnect the washer nozzle hose.
Remove the 8 bolts and hood sub-assembly.
- NOTICE:
- If the hood support is detached from the ball joint, it become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.
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| 4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY |
| 5. REMOVE FRONT BUMPER LOWER COVER |
Remove the clip, 5 bolts and front bumper lower cover.
| 6. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 engine under cover sub-assembly.
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| 7. REMOVE TRANSMISSION UNDER COVER |
Remove the 2 bolts and transmission under cover.
| 8. REMOVE REAR ENGINE UNDER COVER ASSEMBLY |
Remove the 4 bolts and rear engine under cover assembly.
| 9. DRAIN ENGINE COOLANT |
- CAUTION:
- Do not remove the radiator reservoir cap sub-assembly, vent plug, radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Connect a vinyl tube with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock as shown in the illustration.
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Loosen the radiator drain cock plug.
Text in Illustration *1 Radiator Reservoir Sub-assembly *2 Radiator Reservoir Cap Sub-assembly *3 Vent Plug *4 Cylinder Block Water Drain Cock Plug *5 Radiator Drain Cock Plug - -
Remove the radiator reservoir cap sub-assembly.
Using a wrench, remove the vent plug and drain the engine coolant from the radiator assembly.
- HINT:
- Collect the engine coolant in a container and dispose of it according to the local regulations.
Loosen the cylinder block water drain cock plug and drain the engine coolant from the engine.
Tighten the cylinder block water drain cock plug.
- Torque:
- 13 N*m{130 kgf*cm, 9 ft.*lbf}
Tighten the radiator drain cock plug by hand.
Remove the vinyl tube from the radiator drain cock.
| 10. DRAIN ENGINE OIL |
Remove the oil filler cap assembly.
Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
Clean and install a new gasket and the oil pan drain plug.
- Torque:
- 40 N*m{408 kgf*cm, 30 ft.*lbf}
| 11. DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission) |
Remove the filler plug and gasket.
Remove the drain plug and gasket and then drain the manual transmission oil.
Install a new gasket and the drain plug.
- Torque:
- 37 N*m{377 kgf*cm, 27 ft.*lbf}
| 12. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission) |
Remove the drain plug and gasket from the automatic transmission assembly and drain the ATF.
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Install a new gasket and the drain plug to the automatic transmission assembly.
- Torque:
- 20 N*m{204 kgf*cm, 15 ft.*lbf}
| 13. REMOVE RADIATOR ASSEMBLY |
| 14. DISCONNECT ENGINE WIRE |
Remove the ECM (LandCruiser RM0000013Z002DX.html).
Detach the clamp and disconnect the engine wire from the bracket.
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Detach the grommet from the wire harness support.
Text in Illustration *A for LHD *B for RHD
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Detach the 4 claws and remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.
Text in Illustration *A for LHD *B for RHD
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| 15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY |
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Detach the 2 front clips of the No. 1 engine cover sub-assembly.
While pulling the No. 1 engine cover sub-assembly towards the front, detach the 2 rear pins, and then remove the No. 1 engine cover sub-assembly.
| 16. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE |
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Disconnect the mass air flow meter sub-assembly connector and detach the 2 harness clamps.
Detach the 4 clips.
Loosen the hose clamp and remove the air cleaner cap sub-assembly with air cleaner hose.
| 17. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY |
| 18. REMOVE AIR CLEANER CASE |
Remove the 3 bolts and air cleaner case sub-assembly.
Text in Illustration *A for Cold Area Specification Vehicles
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| 19. REMOVE NO. 2 INTERCOOLER AIR HOSE |
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Slide the 2 clips and disconnect the oil return hose.
Loosen the 2 hose clamps and remove the No. 2 intercooler air hose.
| 20. REMOVE AIR TUBE ASSEMBLY |
Detach the clamp and disconnect the No. 1 fuel hose from the air tube support bracket.
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Remove the 3 bolts and air tube support bracket.
Disconnect the connector from the intake air temperature sensor.
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Loosen the hose clamp and remove the air tube assembly from the diesel throttle body assembly.
| 21. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System) |
Remove the 2 bolts and disconnect the urea tank filler pipe assembly from the body.
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| 22. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY |
Remove the 3 bolts and disconnect the vane pump oil reservoir sub-assembly from the body.
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| 23. DISCONNECT NO. 1 FUEL HOSE |
Disconnect the clamp from the No. 1 fuel hose.
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Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.
| 24. DISCONNECT NO. 2 FUEL HOSE |
Disconnect the 2 clamps from the No. 2 fuel hose.
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Slide the clamp and disconnect the No. 2 fuel hose from the No. 3 nozzle leakage pipe.
| 25. DISCONNECT ENGINE WIRE |
Detach the 3 claws and remove the No. 1 relay block cover upper from the engine room relay block.
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Remove the nut and detach 2 claws.
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Remove the bolt.
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Detach the clamp and disconnect the No. 2 engine wire.
Remove the nut and disconnect the engine room main wire from the battery.
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| 26. REMOVE BATTERY HOLD DOWN CLAMP |
Loosen the 2 nuts and remove the battery hold down clamp from the body.
| 27. REMOVE BATTERY |
| 28. REMOVE BATTERY TRAY |
| 29. REMOVE WATER HOSE SUB-ASSEMBLY |
w/ Rear Air Conditioning System:
Slide the 2 clamps and disconnect the 2 water hoses from the water pipe.
Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.
Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.
w/o Rear Air Conditioning System:
Slide the 2 clamps and disconnect the 2 water hoses from the air conditioning unit assembly.
Slide the 2 clamps and disconnect the 2 water hoses from the No. 2 water by-pass pipe.
| 30. DISCONNECT VANE PUMP ASSEMBLY |
Disconnect the 2 connectors from the vane pump assembly.
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Remove the 2 bolt and disconnect the vane pump assembly from the generator bracket.
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| 31. REMOVE GENERATOR ASSEMBLY |
Disconnect the connector from the generator assembly.
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Remove the terminal cap.
Remove the nut and disconnect the wire harness from terminal B.
Remove the bolt and disconnect the wire harness from the generator assembly.
Detach the clamp and disconnect the wire harness from the generator bracket.
Remove the 2 bolts and generator assembly.
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Remove the bolt and generator bracket from the generator assembly.
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| 32. DISCONNECT COOLER COMPRESSOR ASSEMBLY |
Disconnect the connector from the cooler compressor assembly.
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Remove the 3 bolts and nut.
Using an E8 "TORX" socket wrench, remove the stud bolt and disconnect the cooler compressor assembly from the compressor mounting bracket.
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| 33. REMOVE WATER HOSE SUB-ASSEMBLY B (w/ Viscous Heater) |
Remove the bolt and disconnect the water hose sub-assembly B from the water inlet.
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Slide the 4 clamps and remove the water hose sub-assembly B from the No. 2 water pipe and water outlet sub-assembly.
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| 34. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater) |
Disconnect the connector from the viscous heater with magnet clutch assembly.
Remove the 2 bolts and viscous heater with magnet clutch assembly from No. 1 viscous heater bracket.
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| 35. REMOVE FRONT EXHAUST PIPE ASSEMBLY |
| 36. REMOVE FRONT PROPELLER SHAFT ASSEMBLY |
Place matchmarks on the propeller shaft flange and differential.
Text in Illustration *a Matchmark
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Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly.
Place matchmarks on the propeller shaft flange and transfer flange.
Text in Illustration *a Matchmark
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Remove the 4 nuts, 4 washers and front propeller shaft assembly.
| 37. REMOVE PROPELLER SHAFT ASSEMBLY |
Place matchmarks on the propeller shaft flange and transfer flange.
Text in Illustration *A for 3 Door *B for 5 Door *a Matchmark
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Remove the 4 nuts and 4 washers.
Place matchmarks on the propeller shaft flange and differential flange.
Text in Illustration *A for 3 Door *B for 5 Door *a Matchmark
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Remove the 4 nuts, 4 bolts and 4 washers.
Remove the propeller shaft.
| 38. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission) |
| 39. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission) |
Turn the crankshaft to gain access to the locations of the 6 drive plate and torque converter assembly setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.
- HINT:
- There will be one black colored bolt.
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| 40. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) |
| 41. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission) |
Put matchmarks on the clutch cover and flywheel.
Text in Illustration *a Matchmark
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Loosen each set bolt one turn at a time until spring tension is released.
Remove the 6 set bolts and pull off the clutch cover.
- NOTICE:
- Do not drop the clutch disc.
| 42. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission) |
- NOTICE:
- Keep the lining part of the clutch disc, the pressure plate and the surface of the flywheel away from oil and foreign matter.
| 43. REMOVE FLYWHEEL SUB-ASSEMBLY |
w/ Viscous Heater:
Remove the 4 bolts, viscous heater crankshaft pulley and crankshaft pulley cover from the crankshaft pulley.
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w/o Viscous Heater:
Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.
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Using SST, hold the crankshaft pulley.
- SST
- 09213-58014
09330-00021
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for Manual Transmission:
Remove the 8 bolts and flywheel sub-assembly from the crankshaft.
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for Automatic Transmission:
Remove the 8 bolts, rear drive plate spacer, pump impeller drive plate and flywheel sub-assembly from the crankshaft.
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| 44. REMOVE REAR END PLATE |
Remove the bolt and rear end plate from the cylinder block sub-assembly.
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| 45. INSTALL ENGINE HANGER |
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:
No. 1 Engine Hanger Upper 12284-11010 or 12284-11020 No. 2 Engine Hanger 12282-11080 or 12282-11090 Bolt 90119-T0073 or 91552-81025 and 90119- T0219 or, 91672-80835 Text in Illustration *1 No. 1 Engine Hanger Upper *2 No. 2 Engine Hanger
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| 46. REMOVE ENGINE ASSEMBLY |
Attach an engine sling device and hang the engine assembly with a chain block.
Remove the 4 bolts and 4 nuts from the body.
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Lift the engine assembly out from the vehicle slowly and carefully.
- NOTICE:
- Make sure that the engine assembly is clear of all wiring and hoses.
- While lowering the engine assembly from the vehicle, do not allow it to contact the vehicle.
| 47. INSTALL ENGINE ASSEMBLY TO ENGINE STAND |
- NOTICE:
- 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.
- 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 assembly while it is suspended, as doing so is dangerous.
Install the engine assembly to engine stand with the bolts.
Remove the 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.
| 48. REMOVE ENGINE WIRE |
Remove the engine wire from the engine assembly.
| 49. REMOVE FRONT ENGINE MOUNTING INSULATOR (for LH Side) |
Disconnect the vacuum hose from the front engine mounting insulator.
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Remove the nut and front engine mounting insulator from the front engine mounting bracket.