Engine Assembly Installation

Install 2 engine hangers with 4 bolts as shown in the illustration.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

HINT:

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

Lift the engine and remove it from the engine stand.

Place the engine onto a work bench.

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 with the 3 nuts.

Torque:

for nut A:

72 N*m{734 kgf*cm, 53 ft.*lbf}

for nut B:

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

Install the front engine mounting insulator RH with the 3 nuts.

Torque:

for nut A:

72 N*m{734 kgf*cm, 53 ft.*lbf}

for nut B:

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

HINT:

For RHD vehicles only:

When tightening the nut closer to the rear of the vehicle for the engine mounting bracket on the right side, make sure that the claw (stopper) of the bolt does not protrude past the rear edge of the bracket.

Remove the 2 engine hangers and 4 bolts.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Install the front spacer, drive plate and rear spacer to the crankshaft.

Text in Illustration

*1	Front Spacer
*2	Drive Plate and Ring Gear
*3	Rear Spacer
	Automatic Transmission Side

HINT:

As the front spacer, drive plate and ring gear and rear spacer are not reversible, be sure to install it in the direction shown in the illustration.

Apply adhesive to 2 or 3 threads at the end of the 8 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

Torque:

83 N*m{846 kgf*cm, 61 ft.*lbf}

NOTICE:

Do not start the engine for at least 1 hour after installing.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Temporarily install the flywheel with 8 new bolts.

Install and tighten the 8 bolts uniformly in several steps.

Torque:

30 N*m{306 kgf*cm, 22 ft.*lbf}

Mark the top of the bolts with paint.

Tighten the 8 bolts 90° in the same sequence.

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

Insert SST into the clutch disc, and then install SST and the clutch disc together to the flywheel.

SST

09301-00110

Text in Illustration

Flywheel Side

NOTICE:

Be sure to install the clutch disc so that it is facing in the correct direction.

Align the matchmark on the clutch cover with the one on the flywheel.

Following the order shown in the illustration, tighten the 6 bolts, starting with the bolt located near the knock pin at the top.

SST

09301-00110

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

HINT:

1. Following the order in the illustration, tighten the bolts evenly one at a time.
   
2. Move SST up and down, and right and left lightly after checking that the clutch disc assembly is in the center, and then tighten the bolts.
   

Using a dial indicator with a roller instrument, check the diaphragm spring tip alignment.

SST

09333-00013

Maximum misalignment:

0.5 mm (0.0196 in.)

Connect the oil cooler tube with the bolt.

Torque:

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

Connect the suction hose with the bolt.

Torque:

7.8 N*m{80 kgf*cm, 69 in.*lbf}

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

Torque:

73 N*m{739 kgf*cm, 54 ft.*lbf}

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

Torque:

73 N*m{739 kgf*cm, 53 ft.*lbf}

NOTICE:

Make sure to install the engine mounting heat insulator so that its installation surface faces the right side of the vehicle.

Install the engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.

Torque:

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

Install the manual transmission to the vehicle (LandCruiser RM00000178Q013X.html).

Install the automatic transmission to the vehicle (LandCruiser RM0000018ZB05LX.html).

Align the matchmarks on the propeller shaft flange and differential flange.

Install the propeller shaft assembly with the 4 washer, 4 bolts and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the propeller shaft flange and transfer flange.

Install the propeller shaft assembly with the 4 washers and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the yoke and differential flange.

Install the propeller shaft assembly with the 4 washers, 4 bolts and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Align the matchmarks on the yoke and transfer flange.

Install the propeller shaft assembly with the 4 washers and 4 nuts.

Torque:

88 N*m{899 kgf*cm, 65 ft.*lbf}

Connect the No. 1 and No. 2 fuel pipes (LandCruiser RM0000028RU05JX.html).

Install the No. 2 fuel pipe clamp to the fuel tube connector.

w/ Rear heater:
Connect the 4 hoses and heater water hose.

HINT:

The direction of the hose clamp is indicated in the illustration.

w/o Rear heater
Connect the 2 hoses and heater water hose.

HINT:

The direction of the hose clamp is indicated in the illustration.

Connect the ECM connector.

1. Attach the grommet to the wire harness support.
   

   Text in Illustration

   *1	Grommet
   *2	Wire Harness Support

2. Pass the wire harness into the vehicle and install the wire harness support.
   





3. Connect the 9 connectors and attach the clamp.
   

   Text in Illustration

   *A	for LHD
   *B	for RHD

Install the glove compartment door (LandCruiser RM0000046J600OX.html).

Connect the connector and install the bolt.

Torque:

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

Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.

Torque:

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

NOTICE:

Install the black colored bolt first, and then the remaining 5 silver colored bolts.

Install the starter assembly with the 2 bolts.

Torque:

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

Connect the starter wire with the bolt and nut.

Torque:

for bolt:

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

for nut:

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

Close the terminal cap.

Connect the starter connector.

Connect the ground wire with the bolt.

Torque:

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

Install the generator bracket to the generator with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Install the generator with the 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install the generator bracket with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the wire harness clamp.

Install the wire harness with the 2 bolts.

Torque:

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

Connect the generator connector to the generator.

Connect the generator wire with the nut.

Torque:

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

Close the terminal cap.

Install the wiring harness clamp bracket with the bolt.

Torque:

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

Attach the clamp.

Install a new gasket to the cylinder head.

Text in Illustration

*1	Protrusion
	Front

NOTICE:

Be careful of the installation direction.

Temporarily install the manifold with 6 new nuts.

Tighten the 6 nuts in the sequence shown in the illustration.

Torque:

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

Connect the air fuel ratio sensor connector.

Install the heat insulator with the 3 bolts.

Torque:

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

Install 2 new gaskets to the No. 2 air tube.

Install the No. 2 air tube with the 2 bolts and 2 nuts.

Torque:

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

Install the manifold stay with the 3 bolts.

Torque:

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

Install a new gasket to the cylinder head.

Text in Illustration

*1	Protrusion
	Front

NOTICE:

Be careful of the installation direction.

Temporarily install the manifold with 6 new nuts.

Tighten the 6 nuts in the sequence shown in the illustration.

Torque:

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

Connect the air fuel ratio sensor connector.

Install the heat insulator with the 3 bolts.

Torque:

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

for Power tilt and power telescopic steering column:
Connect the No. 2 steering intermediate shaft (LandCruiser RM0000039SG032X.html).

for Manual tilt and manual telescopic steering column:
Connect the No. 2 steering intermediate shaft (LandCruiser RM0000039SG031X.html).

Install 2 new gaskets to the air tube.

Install the air tube with the 2 bolts and 2 nuts.

Torque:

10 N*m{102 kgf*cm, 7 in.*lbf}

Install the manifold stay with the 3 bolts.

Torque:

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

Install the front exhaust pipe (LandCruiser RM00000456H00TX.html).

Install the stud bolt.

Torque:

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

Temporarily install the cooler compressor assembly with the 3 bolts and nut.

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

Torque:

for bolt:

25 N*m{255 kgf*cm, 18 ft.*lbf}

for nut:

25 N*m{255 kgf*cm, 18 ft.*lbf}

Connect the connector.

Remove the attached vinyl tape from the hose.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the suction hose.

Connect the suction hose to the cooler compressor with the 2 bolts.

Torque:

for bolt C:

7.8 N*m{80 kgf*cm, 69 in.*lbf}

for bolt D:

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

Remove the attached vinyl tape from the hose.

Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.

Compressor oil:

ND-OIL 8 or equivalent

Install the O-ring to the discharge hose.

Connect the discharge hose to the cooler compressor with the bolt.

Torque:

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

Connect the vane pump with the 2 bolts.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Attach the 2 wire harness clamps.

Connect the 2 connectors.

Set the V belt onto every part.

While turning the belt tensioner counterclockwise, remove the pin.

NOTICE:

Make sure that the V belt is properly installed to each pulley.

Check that the belt fits properly in the ribbed grooves.

HINT:

Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

Install a new gasket to the intake air surge tank.

Install the intake air surge tank with the 4 bolts and 2 nuts in the order shown in the illustration.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Install the No. 1 surge tank stay with the 2 bolts.

Torque:

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

Attach the wire harness clamp.

Install the No. 2 surge tank stay with the 2 bolts.

Torque:

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

Install the throttle body bracket with the 2 bolts.

Torque:

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

Connect the No. 1 ventilation hose.

Connect the No. 1 vacuum switching valve connector.

Connect the No.1 fuel feed hose.

HINT:

Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

Connect the throttle body connector.

Connect the No. 4 water by-pass hose.

Connect the No. 5 water by-pass hose.

HINT:

Connect the hose so that the direction of the hose clamp is as indicated in the illustration.

Connect the 2 heater hose clamps.

for Bank 1 Side:
Align the paint mark with the projection and connect the air tube assembly to the emission control valve set.

HINT:

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

for Bank 2 Side:
Align the paint mark with the projection and connect the air tube assembly to the No. 2 emission control valve set.

HINT:

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

Install the 3 bolts.

Torque:

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

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}

for Automatic Transmission:
Connect the 2 oil cooler hoses.

HINT:

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

Install the fan pulley to the water pump.

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

NOTICE:

Be careful not to damage the radiator core.

Align the paint marks on the heads of the water pump stud bolts with the paint marks of the same color on the outer edge of the fluid coupling flange and install the fluid coupling to the water pump.

Temporarily install the fluid coupling fan to the water pump 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:

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

Install the fan and generator V-belt (LandCruiser RM0000017L901RX.html).

Tighten the 4 nuts of the fluid coupling fan.

Torque:

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

Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

Torque:

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

Connect the oil cooler tube with the 2 bolts, and attach the claw to close the flexible hose clamp.

Torque:

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

Install the radiator reservoir with the 3 bolts.

Torque:

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

Connect the reservoir hose to upper side of the radiator tank upper.

Connect the No. 2 radiator hose so that its paint mark aligns with the radiator protrusion as shown in the illustration.

HINT:

1. Make sure the paint mark of the No. 1 air injection system hose is facing upward.
   
2. Make sure the direction of the hose clamp is as shown in the illustration.
   

Connect the No. 2 radiator hose so that its paint mark aligns with the water inlet housing protrusion as shown in the illustration.

HINT:

1. Make sure the paint mark of the No. 1 air injection system hose is facing upward.
   
2. Make sure the direction of the hose clamp is as shown in the illustration.
   

Connect the No. 1 radiator hose to the water inlet housing shown in the illustration labeled A.

HINT:

1. Make sure the paint mark of the No. 1 radiator hose is facing upward.
   
2. Make sure the direction of the hose clamp is as shown in the illustration.
   

Connect the No. 1 radiator hose so that its paint mark aligns with the radiator protrusion as shown in the illustration labeled B.

HINT:

1. Make sure the paint mark of the No. 1 radiator hose is facing upward.
   
2. Make sure the direction of the hose clamp is as shown in the illustration.
   

Attach the 3 claws.

Install the deflector with the clip.

Attach the 3 claws.

Install the deflector with the clip.

Install the retainer with the 3 bolts.

Torque:

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

Install the air cleaner case with the 3 bolts.

Torque:

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

Attach the wire harness clamp.

Install the air cleaner filter element.

Install the air cleaner cap and hose.

1. Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.
   

   Torque:

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

2. Tighten the clamp.
   

   Torque:

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

3. Attach the 4 clamps and connect the ventilation hose, vacuum hose and mass air flow meter connector.
   

   HINT:

   The direction of the hose clamp is indicated in the illustration.

Install the front bumper cover (LandCruiser RM0000038JV027X.html).

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

Install the battery hold down clamp with the 2 nuts.

Torque:

6.0 N*m{61 kgf*cm, 53 in.*lbf}

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.

Add fresh oil.

Standard Engine Oil:

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 (w/o Oil Cooler):

Item	Specified Condition
Drain and refill without oil filter change	5.7 liters (6.0 US qts, 5.0 Imp. qts)
Drain and refill with oil filter change	6.1 liters (6.4 US qts, 5.4 Imp. qts)
Dry fill	6.9 liters (7.3 US qts, 6.1 Imp. qts)

Standard Oil Capacity (w/ Oil Cooler):

Item	Specified Condition
Drain and refill without oil filter change	5.7 liters (6.0 US qts, 5.0 Imp. qts)
Drain and refill with oil filter change	6.2 liters (6.6 US qts, 5.5 Imp. qts)
Dry fill	7.1 liters (7.5 US qts, 6.2 Imp. qts)

Install the cowl top ventilator louver (LandCruiser RM000001OV105JX.html).

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

1. Connect the intelligent tester to the DLC3.
   

2. Turn the engine switch on (IG) and turn the intelligent tester on.
   

   NOTICE:

   Do not start the engine.

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

4. Check that there are no leaks from the fuel system.
   If there are fuel leaks, repair or replace parts as necessary.
   

5. Turn the engine switch off.
   

6. Disconnect the intelligent tester from the DLC3.
   

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

Warm up the engine, and then stop the engine and wait for 5 minutes.

Check that the engine oil level is between the low level and full level marks on the dipstick.
If low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not fill engine oil above the full level mark.

Install the upper radiator support seal with the 13 clips.

Install the front No. 1 fender apron to frame seal with the 5 clips.

Install the front No. 1 fender apron to frame seal with the 5 clips.

Install the front fender apron seal with the 5 clips.

Install the front fender apron seal with the 5 clips.

Install the rear engine under cover with the 4 bolts.

Torque:

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

Install the transmission under cover with the 2 bolts.

Torque:

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

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 front bumper cover lower with the 5 bolts and clip.

Torque:

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

Perform the Reset Memory procedures (LandCruiser RM000000W7F0R3X.html).

Warm up the engine.

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

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

3. Inspect the ignition timing during idling.
   

   Standard ignition timing:

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

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

When not using the intelligent tester:

1. 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.

2. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder.
   

   NOTICE:

   1. Use a timing light that detects primary signals.
      
   1. After the inspection, be sure to wrap the wire harness with tape.
      




3. Inspect the ignition timing during idling.
   

   Standard ignition timing:

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

4. Remove SST from the DLC3.
   

5. Inspect the ignition timing during idling.
   

   Standard ignition timing:

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

6. Disconnect the timing light from the engine.
   

Warm up the engine.

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

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

3. Inspect the engine idle speed.
   

   Standard idle speed:

   690 to 790 rpm (transmission in neutral and A/C switch off)
   

When not using the intelligent tester:

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

   SST

   09843-18040
   

   Text in Illustration

   *a	Front view of DLC3

2. Race the engine at 2500 rpm for approximately 90 seconds.
   

3. Inspect the engine idle speed.
   

   Standard idle speed:

   690 to 790 rpm (transmission in neutral and A/C switch off)
   

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 orders are prescribed by the applicable local regulations.

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

1. Check the A/F sensor operation (LandCruiser RM000002RV202KX.html) and heated oxygen sensor operation (LandCruiser RM000002RV6020X.html).
   

2. See 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 Incorrect valve clearance Leaky intake and exhaust valves Leaky cylinders
   Low	High	Rough idling (Fluctuating HC reading)	Vacuum leaks: Ventilation 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

Install the hood with the 8 bolts.

Torque:

for bolt A:

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

for bolt B:

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

Text in Illustration

	Bolt A
	Bolt B

Connect the washer nozzle hose.

Adjust the hood position.

1. Loosen the 4 hinge bolts on the hood.
   

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

3. Tighten the 4 hinge bolts on the hood.
   

   Torque:

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

Adjust the height of the front end of the hood using the cushion rubbers.

1. Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.
   

   HINT:

   Raise or lower the front end of the hood by turning the 2 cushion rubbers.

Adjust the hood lock.

1. Loosen the 3 bolts.
   

2. Adjust the hood lock and tighten the 3 bolts.
   

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

3. Check that the striker can smoothly engage with the hood lock.
   

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

NOTICE:

1. Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
   
2. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
   

Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.

NOTICE:

Be sure to warm up the compressor when turning the A/C switch is on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under these conditions:

1. Stop the engine.
   
2. Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
   
3. Repeat the test 2 or 3 times.
   
4. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4.0 to 6.0 kgf/cm², 57 to 85 psi).
   

Using a halogen leak detector, check the refrigerant line for leakage.

If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

Disconnect the connector and wait for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.