DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)
REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (for Cold Area Specification Vehicles)
REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)
DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)
REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)
REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
REMOVE PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)
Engine Assembly -- Removal |
| 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- 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).
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).
| 2. REMOVE HOOD SUB-ASSEMBLY |
Disconnect the washer nozzle hose.
Remove the 8 bolts and hood.
- 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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| 3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY |
Remove the cowl top ventilator louver (LandCruiser RM000001OV305GX.html).
| 4. REMOVE FRONT BUMPER LOWER COVER |
Remove the clip, 5 bolts and front bumper lower cover.
| 5. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 engine under cover.
| 6. REMOVE TRANSMISSION UNDER COVER |
Remove the 2 bolts and transmission under cover.
| 7. REMOVE REAR ENGINE UNDER COVER ASSEMBLY |
Remove the 4 bolts and rear engine under cover.
| 8. DRAIN ENGINE COOLANT |
- 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.
Loosen the radiator drain cock plug.
- HINT:
- Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
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Loosen the cylinder block drain cock plug.
Text in Illustration *1 Radiator Reservoir *2 Vent Plug *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug
| 9. DRAIN ENGINE OIL |
Remove the oil filler cap.
Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
Wipe the oil pan and drain plug.
Install a new gasket and the oil pan drain plug.
- Torque:
- 34 N*m{347 kgf*cm, 25 ft.*lbf}
| 10. 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}
| 11. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission) |
Remove the drain plug and gasket, and drain the ATF.
Install a new gasket and the drain plug.
- Torque:
- 20 N*m{204 kgf*cm, 15 ft.*lbf}
| 12. DRAIN POWER STEERING FLUID |
| 13. REMOVE RADIATOR ASSEMBLY |
Remove the radiator (LandCruiser RM000002SKP00QX.html).
| 14. REMOVE BATTERY HOLD DOWN CLAMP |
Remove the 2 nuts and battery hold down clamp.
| 15. REMOVE BATTERY |
| 16. REMOVE BATTERY TRAY |
| 17. REMOVE NO. 1 AIR CLEANER HOSE |
Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.
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| 18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY |
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except Cold Area Specification Vehicles:
Detach the 2 clamps and disconnect the mass air flow meter connector.Text in Illustration *A except Cold Area Specification Vehicles *B for Cold Area Specification Vehicles
for Cold Area Specification Vehicles:
Detach the 3 clamps and disconnect the mass air flow meter connector.
Detach the 4 clamps and remove the air cleaner cap sub-assembly.
| 19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY |
| 20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY |
Remove the 3 bolts and air cleaner case sub-assembly.
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| 21. REMOVE COMPRESSOR OUTLET ELBOW |
Detach the 3 wire harness clamps.
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Remove the bolt and wire harness bracket.
Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.
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| 22. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (for Cold Area Specification Vehicles) |
Disconnect the viscous heater connector.
Disconnect the water by-pass hose and water hose.
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Remove the 2 bolts and viscous heater with magnet clutch.
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| 23. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles) |
Remove the 4 bolts and No. 1 viscous heater bracket.
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| 24. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System) |
Disconnect the compressor connector.
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Remove the 4 bolts and disconnect the cooler compressor.
| 25. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
Remove the diesel throttle body (LandCruiser RM0000013ZD02OX.html).
| 26. REMOVE FUEL FILTER ASSEMBLY |
Remove the fuel filter (LandCruiser RM0000045HW007X.html).
| 27. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY |
Remove the 3 bolts and disconnect the vane pump oil reservoir.
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| 28. DISCONNECT PRESSURE FEED TUBE ASSEMBLY |
Disconnect the power steering oil pressure switch connector.
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Remove the union bolt and gasket and disconnect the pressure feed tube.
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| 29. DISCONNECT INLET HEATER WATER HOSE |
Disconnect the inlet heater water hose.
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| 30. DISCONNECT OUTLET HEATER WATER HOSE |
Disconnect the outlet heater water hose.
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| 31. DISCONNECT FUEL HOSE |
Disconnect the No. 1 fuel hose and No. 2 fuel hose.
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| 32. REMOVE GLOVE COMPARTMENT DOOR SUB-ASSEMBLY |
Remove the glove compartment door (LandCruiser RM0000046J800OX.html).
| 33. DISCONNECT ENGINE WIRE |
Remove the No. 1 relay block cover.
Remove the nut and detach the 2 claws.
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Disconnect the 3 injection driver connectors and remove the bolt.
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Disconnect the connector and detach the clamp.
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Remove the bolt.
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Remove the nut and disconnect the engine wire.
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Remove the bolt and disconnect the wire harness protector.
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Remove the bolt and disconnect the engine wire.
Text in Illustration *A w/ KDSS *B w/o KDSS
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Detach the clamp and disconnect the 9 connectors.
Text in Illustration *A for LHD *B for RHD
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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 to 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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| 34. REMOVE STARTER ASSEMBLY (for 2.2 kW Type) |
Remove the terminal cap.
Remove the nut and disconnect the starter wire.
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Disconnect the starter connector.
for Automatic Transmission:
Remove the bolt, 2 nuts and starter assembly.
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for Manual Transmission:
Remove the bolt, nut and starter assembly.
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| 35. REMOVE STARTER ASSEMBLY (for 2.7 kW Type) |
Remove the terminal cap.
Remove the nut and disconnect the starter wire.
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Disconnect the starter connector.
Remove the bolt, nut and starter assembly.
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| 36. REMOVE STARTER ASSEMBLY (for 3.0 kW Type) |
Remove the terminal cap.
Disconnect the starter connector.
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Remove the nut and disconnect the starter wire.
Remove the bolt, 2 nuts and starter assembly.
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| 37. REMOVE FRONT EXHAUST PIPE ASSEMBLY |
Remove the 3 nuts and front exhaust pipe.
Text in Illustration *A w/ EGR Cooler *B w/o EGR Cooler
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Remove the gasket.
| 38. 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.
| 39. 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.
| 40. REMOVE OIL PAN INSULATOR |
Remove the 2 bolts and oil pan insulator.
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| 41. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission) |
Remove the manual transmission (LandCruiser RM00000178S014X.html).
| 42. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission) |
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Turn the crankshaft to gain access to the 6 bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.
- HINT:
- If it is difficult to reach the setting bolts with the wrench, raise or lower the transmission jack until there is sufficient space for the wrench.
| 43. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) |
Remove the automatic transmission (LandCruiser RM0000013F601QX.html).
| 44. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR |
- HINT:
- Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.
Remove the 4 bolts and rear No. 1 engine mounting insulator.
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| 45. REMOVE ENGINE ASSEMBLY |
Install 2 engine hangers with 2 bolts as shown in the illustration.
- HINT:
- Part No.
No. 1 engine hanger 12284-30020 No. 2 engine hanger 12282-67030 Bolt 91552-81014 and 91642-81030 - Torque:
- for No. 1 engine hanger:
- 25 N*m{255 kgf*cm, 18 ft.*lbf}
- for No. 2 engine hanger:
- 60 N*m{612 kgf*cm, 44 ft.*lbf}
Text in Illustration *1 No. 1 engine hanger *2 No. 2 engine hanger - NOTICE:
- Install the engine hangers with new bolts.
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Attach an engine sling device and hang the engine with a chain block.
Remove the 4 bolts and 4 nuts.
Text in Illustration *A for LH Side *B for RH Side
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Remove the engine by operating the engine sling device and chain block.
| 46. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission) |
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Place matchmarks on the clutch cover and flywheel.
Text in Illustration *a Matchmark
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.
| 47. 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.
| 48. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) |
Using SST, hold the crankshaft pulley.
- SST
- 09213-58014
09330-00021
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Remove the 8 bolts and flywheel.
| 49. REMOVE PUMP IMPELLER DRIVE PLATE (for Automatic Transmission) |
Using SST, hold the crankshaft pulley.
- SST
- 09213-58014
09330-00021
|
Remove the 8 bolts, the rear drive plate spacer, the pump impeller drive plate, and the flywheel and ring gear.
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| 50. REMOVE REAR END PLATE |
Remove the bolt and rear end plate.
| 51. INSTALL ENGINE TO ENGINE STAND |
| 52. REMOVE ENGINE WIRE |
Remove the engine wire from the engine.
| 53. REMOVE FRONT ENGINE MOUNTING INSULATOR |
Disconnect the 2 hoses.
Text in Illustration *A for LH Side *B for RH Side
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Remove the 2 nuts and 2 front engine mounting insulators.