Thermostat - Installation

Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1UR-FE COOLING

THERMOSTAT - INSTALLATION

1. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT

Install a new gasket and the water inlet with thermostat with the 3 nuts.

  • Torque:
  • 10 N*m{ 102 kgf*cm, 7 ft.*lbf}
2. CONNECT NO. 2 RADIATOR HOSE
3. INSTALL FAN SHROUD

Install the fan pulley to the engine water pump.

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

  • NOTICE:
  • Be careful not to damage the radiator core.

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

Thermostat - Installation. 1UR-FE COOLING. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the claws of the shroud to the radiator as shown in the illustration.

Install the shroud with the 2 bolts.

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

Connect the oil cooler tube to the fan shroud with the 2 bolts.

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

w/ Air Cooled Transmission Oil Cooler:


Pass the hose through the flexible hose clamp and close the clamp as shown in the illustration.

Connect the reservoir hose to the upper radiator tank.

Install the fan and generator V belt ().

Tighten the 4 nuts of the fluid coupling fan.

  • Torque:
  • 21 N*m{ 214 kgf*cm, 15 ft.*lbf}
4. INSTALL NO. 1 RADIATOR HOSE
5. INSTALL AIR CLEANER CAP AND HOSE

Install the air cleaner cap and hose, and then tighten the hose clamp.

  • Torque:
  • 2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Attach the 4 clamps.

Connect the mass air flow meter connector and attach the clamp.

Connect the No. 2 PCV hose and No. 1 air hose.

6. ADD ENGINE COOLANT

Add engine coolant.

  • Standard Capacity (w/o ATF Warmer):
  • ItemSpecified Condition
    w/ Rear Heater16.5 liters (17.4 US qts, 14.5 Imp. qts)
    w/o Rear Heater13.8 liters (14.6 US qts, 12.1 Imp. qts)
  • Standard Capacity (w/ ATF Warmer):
  • ItemSpecified Condition
    w/ Rear Heater17.0 liters (18.0 US qts, 15.0 Imp. qts)
    w/o Rear Heater14.2 liters (15.0 US qts, 12.5 Imp. qts)
  • NOTICE:
  • Do not substitute plain water for engine coolant.
  • HINT:
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).
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

ItemCondition
Fan speedAny setting except off
TemperatureToward WARM
Air conditioning switchOff

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:
Wear protective gloves. Hot areas on the parts may injure your hands.
Be careful of the fan.
Be careful as the engine, radiator and radiator hoses are hot and can cause burns.
  • NOTICE:
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.
Do not start the engine when there is no coolant in the radiator reservoir.
Pay attention to the needle of the engine coolant temperature receiver gauge. Make sure that the needle does not show an abnormally high temperature.
If there is not enough coolant, the engine may burn out or overheat.
  • HINT:
Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air while warming up the engine.
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.

7. INSPECT FOR COOLANT LEAK
  • CAUTION:
  • To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.

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 engine water pump for leakage. If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block and head.

8. INSTALL V-BANK COVER SUB-ASSEMBLY
Thermostat - Installation. 1UR-FE COOLING. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 2 V-bank cover hooks to the bracket. Then align the 3 V-bank cover grommets with the 3 pins, and press down on the V-bank cover to attach the pins.

Text in Illustration
*1Grommet
*2Pin
*3Hook
*4Bracket
9. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Install the No. 1 engine under cover sub-assembly with the 10 bolts.

  • Torque:
  • 29 N*m{ 296 kgf*cm, 21 ft.*lbf}
10. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

11. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.