Engine Assembly Installation

Install the 2 front engine mounting insulators with the 2 nuts.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Install an engine hanger to each location shown in the illustration.

HINT:

Torque:

for No. 1 Engine Hanger:

59 N*m{602 kgf*cm, 44 ft.*lbf}

for No. 2 Engine Hanger:

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

NOTICE:

Install the engine hangers with new bolts.

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

Lift the engine and remove it from the engine stand.

Slowly lower the engine into the engine compartment.

Install the engine with the 4 bolts and 4 nuts.

Torque:

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 bolts and 2 engine hangers.

Install the rear end plate with the 2 bolts.

Torque:

27 N*m{275 kgf*cm, 20 ft.*lbf}

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Clean the bolts and bolt holes.

Apply adhesive to 2 or 3 threads of each of the bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

Install the flywheel to the crankshaft.

Temporarily install the flywheel with the 8 bolts.

Tighten the 8 bolts uniformly in several steps in the order shown in the illustration.

Torque:

123 N*m{1249 kgf*cm, 90 ft.*lbf}

NOTICE:

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

Insert SST into the clutch disc. Then insert SST (together with the clutch disc) into the flywheel to install the clutch disc.

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 matchmarks on the clutch cover and flywheel.

Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

SST

09301-00110

Torque:

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

HINT:

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.

Install the rear engine mounting insulator to the transmission with the 4 bolts.

NOTICE:

Perform this procedure when replacement of the engine mounting insulator is necessary.

Torque:

65 N*m{663 kgf*cm, 48 ft.*lbf}

Install the manual transmission (LandCruiser RM0000048B200AX.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}

Install a new gasket and the front exhaust pipe to the exhaust manifold with 3 new nuts.

Torque:

54 N*m{554 kgf*cm, 40 ft.*lbf}

Install the No. 1 exhaust pipe support bracket with the 2 bolts.

Torque:

71 N*m{724 kgf*cm, 52 ft.*lbf}

Install the clamp with the bolt.

Torque:

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

Check and clean the oil filter installation surface.

Apply clean engine oil to the gasket of a new oil filter.

Install the oil filter and tighten it by hand until the gasket contacts the installation surface.

Using SST, tighten the oil filter. Choose from the following to further tighten the oil filter.

SST

09228-44011

1. Using a torque wrench, tighten the oil filter.
   

   Torque:

   17 N*m{173 kgf*cm, 13 ft.*lbf}

2. Tighten the oil filter a 3/4 turn by hand or with a common wrench.
   

   Text in Illustration

   3/4 turn

Install the starter assembly with the 2 bolts and nut.

Torque:

68 N*m{693 kgf*cm, 50 ft.*lbf}

Connect the starter wire with the nut.

Torque:

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

Install the terminal cap.

Connect the starter connector.

Install the clutch release cylinder with the 2 bolts.

Torque:

12 N*m{120 kgf*cm, 9 ft.*lbf}

Temporarily install the vane pump with the 2 bolts and nut.

Install the pulley to the pump shaft.

Using SST, hold the pulley and install the nut.

SST

09960-10010(09962-01000,09963-01000)

Torque:

43 N*m{443 kgf*cm, 31 ft.*lbf}

Connect the 2 fuel hoses.

Connect the 2 water hoses.

Install the heater water hose clamp with the bolt.

Torque:

14 N*m{138 kgf*cm, 10 ft.*lbf}

Install the wiring harness clamp bracket with the bolt.

Torque:

22 N*m{219 kgf*cm, 16 ft.*lbf}

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.
   

Connect the 5 ECM connectors and attach the clamp.

for LHD:
Connect the 4 wire harness clamps.

Attach the 2 clamps and connect the connector.

Attach the 2 claws and install the nut.

Torque:

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

Install the No. 1 relay block cover.

Attach the clamp and install the 3 bolts.

Torque:

for bolt A:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

for bolt B:

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

for bolt C:

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

Install the glove compartment door (LandCruiser RM0000046J600OX_01_0017.html).

Temporarily install the generator with the 2 bolts.

Connect the vacuum pump oil outlet hose.

Install 2 new gaskets and the vacuum pump oil inlet hose with the union bolt.

Torque:

14 N*m{140 kgf*cm, 10 ft.*lbf}

Connect the vacuum pump hose.

Attach the vacuum pump oil inlet hose to the cord clip.

Install the generator wire with the nut.

Torque:

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

Install the terminal cap.

Connect the generator connector.

Temporarily install the cooler compressor with the 2 bolts.

Temporarily install the idle pulley bracket with the 4 bolts.

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

Torque:

for bolt A:

45 N*m{459 kgf*cm, 33 ft.*lbf}

except bolt A:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the wire harness with the bolt.

Torque:

13 N*m{131 kgf*cm, 9 ft.*lbf}

Connect the cooler compressor connector.

Install the intake pipe with the 2 bolts.

Torque:

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

Tighten the intake pipe clamp.

Torque:

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

Insert the tabs of the radiator support into the radiator service holes.

Install the radiator assembly with the 4 bolts to the radiator support.

Torque:

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

Install the fan pulley to the water pump.

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

NOTICE:

Be careful not to damage the radiator core.

Temporarily install the fluid coupling fan to the fan pulley with the 4 nuts. Tighten the nuts as much as possible by hand.

Attach the claws of the shroud 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 and vane pump V belt (LandCruiser RM00000122V00MX.html).

Tighten the 4 nuts of the fluid coupling fan.

Torque:

19 N*m{189 kgf*cm, 14 ft.*lbf}

Install the radiator hose.

HINT:

Position the hose clamps as shown in the illustration.

Install the hose clamp with the 2 nuts.

Torque:

8.5 N*m{87 kgf*cm, 75 in.*lbf}

Install the radiator hose.

HINT:

Position the hose clamps as shown in the illustration.

Attach the 3 claws to the radiator support.

Install the radiator side deflector RH with the clip.

Attach the 3 claws to the radiator support.

Install the radiator side deflector LH with the clip.

Install the front bumper upper retainer with the 3 bolts.

Torque:

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

w/ TOYOTA Parking Assist-sensor System, w/ Fog Light:
Connect the 3 connectors.

w/ TOYOTA Parking Assist-sensor System, w/o Fog Light:
Connect the connector.

w/o TOYOTA Parking Assist-sensor System, w/ Fog Light:
Connect the 2 connectors.

w/ Headlight Cleaner System:
Connect the No. 1 headlight cleaner hose.

Attach the 16 claws to install the front bumper cover.

NOTICE:

Do not hold the middle of the front bumper cover, as it may become reformed.

Install the 4 clips.

Install the 2 bolts labeled A and 2 bolts labeled B.

Torque:

bolt B:

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

Install the 2 screws.

Install the 2 screws.

HINT:

Use the same procedure for the screws on the other side.

Install the air cleaner case with the 3 bolts.

Torque:

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

Insert the hinge part of the air cleaner cap and hose into the air cleaner case, and then attach the 4 hook clamps.

Connect the air cleaner cap sub-assembly with the clamp.

Torque:

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

Attach the wire harness clamp.

Connect the 2 clamps and connector.

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

Install the front fender apron seal with the 5 clips.

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

Install the front fender apron seal with the 4 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}

Install the upper radiator support seal with the 13 clips.

Install the cowl top ventilator louver (LandCruiser RM000001OV105JX_01_0003.html).

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.
   

Install the battery hold down clamp with the 2 nuts.

Torque:

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

Connect the engine wire with the nut labeled A.

Torque:

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

Add fresh engine oil.

Standard Engine Oil:

Oil Grade	Oil Viscosity (SAE)
API CF-4 or CF	10W-30

Standard Capacity:

Item	Specified Condition
Drain and refill without oil filter change	6.0 liters (6.3 US qts, 5.3 Imp. qts)
Drain and refill with oil filter change	6.9 liters (7.3 US qts, 6.1 Imp. qts)
Dry fill	7.6 liters (8.0 US qts, 6.7 Imp. qts)

Install the oil filler cap.

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

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

Slowly fill the system with engine coolant.

Standard capacity:

8.6 liters (9.0 US qts, 7.6 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

1. Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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. New Toyota vehicles are filled with Toyota Super Long Life Coolant. When replacing the coolant, Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50% and freezing temperature is -35°C (-31°F)) is recommended
   

Slowly pour coolant into the radiator reservoir until it reaches the Full line.

Install the reservoir cap.

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.

Install the radiator cap.

Start the engine and warm it up until the thermostat opens.

HINT:

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.

Maintain the engine speed at 2000 to 2500 rpm.

NOTICE:

1. Make sure that the radiator reservoir still has some coolant in it.
   
2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
   
3. If there is not enough coolant, the engine may burn out or overheat.
   
4. 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.
   
5. Run the engine at 2000 rpm until the coolant level has stabilized.
   

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

CAUTION:

1. Wear protective gloves. Heat areas on the parts may injure your hands.
   
2. Be careful as the radiator hoses are hot.
   
3. Keep your hands away from the fan.
   

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

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.

Check that the coolant level is between the Full and Low lines.
If the coolant level is below the Low line, repeat all of the steps above.
If the coolant level is above the Full line, drain coolant so that the coolant level is between the Full and Low lines.

Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

HINT:

When checking for fuel leaks, make sure that there is pressure in the fuel line.

Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

Fill the radiator with coolant and attach a radiator cap tester to the radiator.

Warm up the engine.

Using a radiator cap tester, increase the pressure inside the radiator to 123 kPa (1.3 kgf/cm², 18 psi), and check that the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.

Warm up the engine.

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

   Idle speed:

   720 to 820 rpm
   

   NOTICE:

   1. Turn all the electrical systems and the A/C off.
      
   2. When checking the idling speed, the shift lever should be in neutral.
      

   HINT:

   Refer to the intelligent tester operator's manual for further details.

When not using an intelligent tester:

1. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.
   

   SST

   09843-18040
   

2. Check the idle speed.
   

   Standard idle speed:

   720 to 820 rpm
   

   Text in Illustration

   *a	Front View of DLC3

   NOTICE:

   1. Turn all the electrical systems and the A/C off.
      
   2. When checking the idling speed, the shift lever should be in neutral.
      
   3. Confirm the terminal number before connecting them. Connecting the wrong terminal can be damage the engine.
      

Start the engine.

Fully depress the accelerator pedal.

Check the maximum speed.

Maximum engine speed:

4850 to 4950 rpm