Water Pump Installation

Install a new gasket and the water pump with the 17 bolts.

Torque:

for bolt A:

47 N*m{479 kgf*cm, 35 ft.*lbf}

for bolt B:

11 N*m{112 kgf*cm, 8 ft.*lbf}

for bolt C:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Temporarily install the V-ribbed belt tensioner assembly with the 2 bolts.

HINT:

Make sure that the V-ribbed belt tensioner assembly is in contact with the timing chain cover sub-assembly.

Install the V-ribbed belt tensioner assembly by tightening the 2 bolts in the order shown in the illustration.

Torque:

for bolt 1:

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

for bolt 2:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Install the cooler compressor assembly (LandCruiser RM0000017ZZ07QX.html).

Install the generator assembly (LandCruiser RM000001ONM04ZX.html).

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.

for Separate Type:
Install the 2 idler pulley cover plates, 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates with the 2 bolts.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

for Integrated Type:
Install the 2 No. 2 idler pulleys with the 2 bolts.

Torque:

54 N*m{551 kgf*cm, 40 ft.*lbf}

Install a new O-ring to the water outlet pipe.

Install a new gasket to the water pump.

Apply soapy water to the gasket of the water outlet pipe.

Install the water inlet with the 5 bolts.

Torque:

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

Connect the 5 water by-pass hoses.

Connect the throttle body connector.

Install a new O-ring to the water outlet pipe.

Install a new gasket to the water pump.

Apply soapy water to the gasket of the water outlet pipe.

Install the water inlet with the 5 bolts.

Torque:

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

Connect the 5 water by-pass hoses.

Connect the oil cooler hose.

Connect the No. 2 oil cooler hose.

Connect the throttle body connector.

Connect the air tube with the 2 bolts.

Torque:

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

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 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.

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 front bumper cover lower with the 5 bolts and clip.

Torque:

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

Install the upper radiator support seal with the 13 clips.