Oil Cooler (For 1Gr-Fe) Installation

Install the 2 oil cooler brackets to the oil cooler assembly with the 2 bolts.

Torque:

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

Attach the 2 claws and install the oil cooler assembly to the vehicle body with the 3 bolts in the order shown in the illustration.

Torque:

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

Pass the No. 3 oil cooler tube sub-assembly through the hole of vehicle body from the rear of the vehicle and install it to the oil cooler bracket with the bolt.

Torque:

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

Install the No. 6 oil cooler inlet hose and No. 6 oil cooler outlet hose to the oil cooler, and slide the 2 clips to secure them.

NOTICE:

Make sure to install any hose clips without a specific installation direction in a direction that does not interfere with other parts.

Connect the No. 6 oil cooler inlet hose and No. 6 oil cooler outlet hose to the No. 3 oil cooler tube sub-assembly, and slide the 2 clips to secure them.

NOTICE:

Make sure to install any hose clips without a specific installation direction in a direction that does not interfere with other parts.

Temporarily install the oil cooler tube to the fan shroud with bolt labeled A. Install bolt labeled B and tighten it to the specified torque. Then tighten bolt labeled A to the specified torque.

Torque:

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

Install the No. 5 oil cooler inlet hose and No. 5 oil cooler outlet hose to the No. 2 oil cooler tube sub-assembly, and slide the 2 clips to secure them.

Connect the No. 5 oil cooler inlet hose and No. 5 oil cooler outlet hose to the No. 3 oil cooler tube sub-assembly, and slide the 2 clips to secure them.

Install the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose to the No. 2 oil cooler tube, and slide the 2 clips to secure them.

Connect the No. 4 oil cooler inlet hose and No. 4 oil cooler outlet hose to the radiator, and slide the 2 clips to secure them.

NOTICE:

Make sure to install any hose clips without a specific installation direction in a direction that does not interfere with other parts.

Install the 2 oil cooler tube clamps to the automatic transmission assembly and engine assembly with the 2 bolts.

Torque:

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

Install the No. 1 oil cooler inlet tube, No. 1 oil cooler outlet tube and 2 flexible hose clamps to the 2 oil cooler tube clamps with the 2 bolts.

Torque:

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

Install the 2 oil cooler tube clamps to the automatic transmission and engine assembly with the 2 bolts.

Torque:

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

Connect the ends of the No. 1 oil cooler inlet tube and No. 1 oil cooler outlet tube to the automatic transmission assembly by hand.

Close the 2 oil cooler tube clamps and install the 2 bolts.

Torque:

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

Using a 17 mm union nut wrench, tighten the No. 1 oil cooler inlet tube and No. 1 oil cooler outlet tube.

Torque:

Specified tightening torque:

34 N*m{350 kgf*cm, 25 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 (1.181 in.)) + torque wrench (fulcrum length of 180 mm (7.087 in.)): 29 N*m (300 kgf*cm, 22 ft.*lbf)
   

Install the No. 3 oil cooler inlet hose and No. 3 oil cooler outlet hose to the No. 1 oil cooler inlet tube and No. 1 oil cooler outlet tube, and slide the 2 clips to secure them.

Connect the No. 3 oil cooler inlet hose and No. 3 oil cooler outlet hose to the No. 2 oil cooler tube sub-assembly, and slide the 2 clips to secure them.

Then pass the No. 3 oil cooler inlet hose and No. 3 oil cooler outlet hose through the clamp and close the clamp.

Coat 2 new O-rings with ATF, and install them to the transmission oil cooler assembly.

Align the transmission oil cooler with the transmission oil thermostat and assemble them with the 3 bolts.

Torque:

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

Temporarily install the transmission oil cooler together with the transmission oil thermostat with bolt labeled A. Install bolts labeled B and labeled C and tighten them to the specified torque. Then tighten bolt labeled A to the specified torque.

Torque:

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

Install the No. 1 oil cooler inlet hose and No. 1 oil cooler outlet hose to the transmission oil thermostat, and slide the 2 clips to secure them.

Connect the No. 1 oil cooler inlet hose and No. 1 oil cooler outlet hose to the automatic transmission assembly, and slide the 2 clips to secure them.

NOTICE:

Make sure to install any hose clips without a specific installation direction in a direction that does not interfere with other parts.

Connect the 2 water by-pass hoses to the transmission oil cooler assembly, and slide the 2 clips to secure them.

Install the No. 2 oil cooler inlet hose and No. 2 oil cooler outlet hose to the transmission oil thermostat, and slide the 2 clips to secure them.

Connect the No. 2 oil cooler inlet hose and No. 2 oil cooler outlet hose to the No. 1 oil cooler inlet tube and No. 1 oil cooler outlet tube, and slide the 2 clips to secure them.

Tighten the cylinder block drain cock plug.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

Tighten the radiator drain cock plug by hand.

Add engine coolant.

Standard Capacity:

Item			Specified Condition
for Automatic Transmission	w/o Warmer	w/o Rear Heater	10.5 liters (11.1 US qts, 9.2 Imp. qts)
		w/ Rear Heater	12.3 liters (13.0 US qts, 10.8 Imp. qts)
	w/ Warmer	w/o Rear Heater	11.0 liters (11.6 US qts, 9.7 Imp. qts)
		w/ Rear Heater	12.8 liters (13.5 US qts, 11.3 Imp. qts)
for Manual Transmission	w/o Rear Heater		10.7 liters (11.3 US qts, 9.4 Imp. qts)
	w/ Rear Heater		12.5 liters (13.2 US qts, 11.0 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

1. 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).
   
2. 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

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:

1. Wear protective gloves. Hot areas on the parts may injure your hands.
   
2. Be careful of the fan.
   
3. Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
   

NOTICE:

1. 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.
   
2. Do not start the engine when there is no coolant in the radiator reservoir.
   
3. Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
   
4. If there is not enough coolant, the engine may burn out or overheat.
   

HINT:

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

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and then check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

Hook the engine under cover 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 rear engine under cover with the 4 bolts.

Torque:

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