DISCONNECT NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)
DISCONNECT VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)
REMOVE OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET
DISCONNECT NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)
Exhaust Manifold W/ Turbocharger -- Removal |
| 1. 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).
| 2. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY |
| 3. 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.
| 4. 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}
| 5. REMOVE INTERCOOLER AIR HOSE |
Loosen the 2 hose bands and remove the intercooler air hose.
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| 6. 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.
| 7. REMOVE 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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| 8. REMOVE NO. 1 RADIATOR HOSE |
Slide the 2 hose clamps and remove the No. 1 radiator hose.
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| 9. REMOVE RADIATOR RESERVOIR ASSEMBLY |
Detach the 2 clamps to disconnect the No. 2 water by-pass hose from the fan shroud.
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Slide the hose clamp and disconnect the No. 2 water by-pass hose from the water inlet.
Slide the hose clamp and disconnect the No. 1 water by-pass hose from the radiator assembly.
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Detach the 2 clamps to disconnect the No. 1 water by-pass hose from the fan shroud.
Remove the 3 bolts and radiator reservoir assembly.
| 10. DISCONNECT NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles) |
Disconnect 2 cables from 2 positive battery terminals.
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Detach the 3 wire harness clamps to disconnect the No. 3 engine wire from the fan shroud.
| 11. REMOVE FAN SHROUD |
Loosen the 4 nuts holding the fan with fluid coupling assembly.
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Remove the fan and generator V belt (LandCruiser RM00000122Y00LX_01_0004.html).
Remove the 2 bolts holding the fan shroud.
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Slide the fan shroud in upper side to detach the guide and remove the fan shroud together with the fan with fluid coupling assembly.
- NOTICE:
- Be careful not to damage the radiator core.
Remove the fan pulley.
| 12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 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.
| 13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY |
Remove the air cleaner element sub-assembly from the air cleaner case.
| 14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY |
Remove the 3 bolts and air cleaner case sub-assembly.
Text in Illustration *A for Cold Area Specification Vehicles
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| 15. DISCONNECT VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles) |
Disconnect the viscous heater connector.
Remove the 2 bolts and viscous heater with magnet clutch assembly.
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| 16. 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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| 17. REMOVE NO. 3 WATER BY-PASS PIPE |
for Cold Area Specification Vehicles:
Slide the 2 clips and remove the water hose from the compressor inlet elbow and No. 3 water by-pass pipe.
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Slide the 2 clips and disconnect the 2 water hoses from the oil cooler assembly and No. 2 water bypass pipe.Text in Illustration *A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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Remove the bolt and No. 3 water by-pass pipe.
| 18. REMOVE PCV PIPE (for Cold Area Specification Vehicles) |
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Slide the 2 clips and disconnect the No. 20 water by-pass hose from the compressor inlet elbow and No. 3 water by-pass pipe.
Slide the clip and disconnect the No. 19 water bypass hose from the compressor inlet elbow.
Remove the bolt and disconnect the PCV pipe from the compression inlet elbow.
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Slide the 2 clips and remove the PCV pipe.
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| 19. REMOVE PCV HOSE (except Cold Area Specification Vehicles) |
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Slide the 2 clips.
Slide the 2 clips, detach the clamp and remove the PCV hose.
| 20. REMOVE NO. 1 WATER BY-PASS PIPE |
Detach the wire harness clamp and disconnect the 2 connectors from the turbocharger sub-assembly.
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Remove the 3 bolts and disconnect the No. 1 water by-pass pipe from the engine water pump assembly.
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Remove the gasket from the No. 1 water by-pass pipe.
| 21. DISCONNECT TURBO WATER HOSE |
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Slide the 2 clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the water outlet sub-assembly and water pump assembly.
| 22. REMOVE OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET |
for Automatic Transmission:
Remove the bolt and disconnect the oil cooler tube bracket.
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Remove the bolt and disconnect the wire harness.
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| 23. DISCONNECT NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles) |
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Remove the detach the clamp and disconnect the wire harness.
Remove the bolt and disconnect the No. 4 engine harness.
Text in Illustration 
No. 1 Viscous Heater Bracket Sub-assembly Bolt 
No. 4 Engine Harness Bolt
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Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly.
| 24. REMOVE TURBOCHARGER STAY |
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Remove the 3 bolts, nut and the turbocharger stay.
| 25. REMOVE TURBO OIL OUTLET PIPE |
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Slide the 2 clips and disconnect the turbo oil outlet hose from the turbo oil outlet pipe.
Remove the 2 bolts and turbo oil outlet pipe and gasket.
| 26. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY |
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Remove the union bolt and gasket.
Remove the 2 nuts and the turbo oil inlet pipe subassembly.
- NOTICE:
- Do not loosen the nut labeled A.
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Remove the gasket.
| 27. REMOVE TURBOCHARGER SUB-ASSEMBLY |
Remove the 3 nuts and turbocharger sub-assembly.
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Remove the gasket from the exhaust manifold.
| 28. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY |
Remove the bolt and disconnect the No. 1 EGR pipe sub-assembly from the vacuum transmitting pipe sub-assembly.
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Remove the 4 nuts and the No. 1 EGR pipe sub-assembly from the exhaust manifold and EGR valve adapter.
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Remove the 2 gaskets.
Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the exhaust manifold.
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| 29. REMOVE EXHAUST MANIFOLD |
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Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.
Remove the gasket.
| 30. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY |
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Slide the 2 hose clips and disconnect the No. 1 turbo water hose and No. 2 turbo water hose from the turbo water pipe sub-assembly.
Remove the bolt.
Remove the 2 nuts, turbo water pipe sub-assembly and gasket.
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| 31. REMOVE COMPRESSOR INLET ELBOW |
Remove the 2 bolts and compressor inlet elbow stay.
Text in Illustration *A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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Remove the 2 nuts and compressor inlet elbow from turbocharger sub-assembly.
Text in Illustration *A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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Using an E8 "TORX" socket wrench, remove the stud bolt shown in the illustration together with the compressor inlet elbow and gasket.
Text in Illustration *A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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| 32. REMOVE COMPRESSOR OUTLET ELBOW |
Remove the 2 nuts and compressor outlet elbow.
Text in Illustration *A for Cold Area Specification Vehicles *B except Cold Area Specification Vehicles
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Remove the gasket.
except Cold Area Specification Vehicles:
Remove the bolt and hose clamp
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| 33. DISCONNECT STUD BOLT |
Using an E5 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.
- NOTICE:
- If a stud bolt is deformed or its threads are damaged, replace it.
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Using an E8 "TORX" socket wrench, remove the 4 stud bolts shown in the illustration.
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Using an E10 "TORX" socket wrench, remove the 3 stud bolts shown in the illustration.
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