Thermostat Installation

Install a new gasket to the thermostat.

NOTICE:

When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the gasket is properly installed to the thermostat as shown in the illustration.

Install the thermostat to the cylinder block with the jiggle valve facing straight upward.

HINT:

The jiggle valve may be set within 30° of either side of the prescribed position.

Install the inlet with the 3 bolts.

Torque:

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

for Automatic Transmission:
Install the hose clamp and bracket with bolt A. Then install the oil pipe clamp with bolt B.

Torque:

for bolt A:

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

for bolt B:

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

Connect the No. 2 water by-pass hose to the water inlet.

Connect the No. 2 radiator hose to the radiator assembly and slide the clamp to secure the hose.

HINT:

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

Install a new O-ring to the engine oil level dipstick guide.

Apply a small amount of clean engine oil to the O-ring.

Install the engine oil level dipstick guide to the cylinder block sub-assembly with the 2 bolts.

Torque:

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

Install the engine oil level dipstick.

Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover to the cylinder head sub-assembly with the bolt.

Torque:

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

Type A
Connect the No. 3 turbo water hose and No. 4 turbo water hose to the ventilation pipe, and slide the 2 clamps to secure the hose.

Install the No. 1 compressor mounting bracket with the 5 bolts.

Torque:

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

Install the generator with the 2 bolts.

Torque:

for bolt A:

62 N*m{632 kgf*cm, 46 ft.*lbf}

for bolt B:

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

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.

Install the generator bracket with the bolts.

Torque:

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

Connect the cooler compressor with the 4 bolts.

Torque:

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

Connect the compressor connector.

Install the No. 1 viscous heater bracket with the 4 bolts.

Torque:

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

Install the viscous heater with magnet clutch with the 2 bolts.

Torque:

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

Connect the water by-pass hose and water hose.

Connect the viscous heater connector.

Install the compressor outlet elbow with the 2 bolts and tighten the hose clamp.

Torque:

for bolt:

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

for hose clamp:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Install the wire harness bracket with the bolt.

Torque:

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

Attach the 3 wire harness clamps.

Align the paint mark of the intercooler air hose with the embossed mark of the intercooler.

Tighten the 2 clamps.

Torque:

6.5 N*m{66 kgf*cm, 58 in.*lbf}

Install the air cleaner case sub-assembly with the 3 bolts.

Torque:

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

Attach the 4 clamps to install the air cleaner cap sub-assembly.

except Cold Area Specification Vehicles:
Attach the 2 clamps and connect the mass air flow meter connector.

for Cold Area Specification Vehicles:
Attach the 3 clamps and connect the mass air flow meter connector.

Install the No. 1 air cleaner hose with the 2 hose clamps.

NOTICE:

1. When installing the No. 1 air cleaner hose, align the protrusion of the No. 1 air cleaner hose with the protrusion of the compressor inlet elbow as shown in the illustration.
   
2. When installing the No. 1 air cleaner hose, align the groove of the No. 1 air cleaner hose with the protrusion of the air cleaner cap as shown in the illustration.
   

Tighten the 2 hose clamps.

Torque:

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

NOTICE:

When tightening the 2 hose clamps, make sure that they are positioned as shown in the illustration.

Use the pulley set bolt of the tensioner to rotate the tensioner pulley clockwise, and then install the V belt.

NOTICE:

Make sure that the V belt is set properly on each pulley.

Check that the indicator mark of the V-ribbed belt tensioner (LandCruiser RM00000147501OX.html).

Install the front heater bracket with the 2 bolts.

Torque:

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

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

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. Please contact your TOYOTA dealer for further details.
   
3. for Cold Area Specification Vehicles:
   Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

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

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

After the coolant cools down, check that the coolant level is at the FULL line.
If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

Fill the radiator with coolant and 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 check that the pressure does not drop.
If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

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

Install the front fender apron seal RH with the 4 clips.

Install the No. 1 engine under cover with the 4 bolts.

Torque:

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

Install the lower front bumper cover with the clip and 5 bolts.

Torque:

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

Install the upper radiator support seal with the 13 clips.