Engine Cooling System Toyota Land Cruiser 100 рестайлинг 2

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1. CHECK COOLING SYSTEM FOR LEAKS 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. Fill the radiator with coolant and attach a radiator cap tester. Warm up the engine. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm, 17 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.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR Check that the engine coolant level is between the LOW and FULL lines when the engine is cold. If the engine coolant is low, check for leaks and add "TOYOTA Super Long Life Coolant" or similar high quality ethylene glycol based non-silicate, non-amino, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the FULL line. NOTE: Do not substitute plain water for engine coolant.
3. CHECK ENGINE COOLANT QUALITY Remove the radiator cap. 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 there are no excessive deposits of rust or scales around the radiator cap and radiator filler hole. Also, the coolant should be free of oil. If excessively dirty, clean the coolant passage and replace the coolant. Install the radiator cap.

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1. DRAIN ENGINE COOLANT 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. Remove the radiator cap. Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs. Then drain the coolant. HINT: Collect the coolant in a container and dispose of it according to the regulations in your area.
2. ADD ENGINE COOLANT Tighten the radiator drain cock plug by hand. Tighten the 2 cylinder block drain cock plugs. Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) Add engine coolant. Standard capacity ENGINE COOLANT SPECIFICATIONS w/Front heater w/Front heater and rear heater 14.8 liters (15.6 US qts, 13.0 imp.qts) 15.3 liters (16.2 US qts, 13.4 imp.qts) NOTE: Do not use plain water. 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). Please contact your TOYOTA dealer for further details. Slowly pour coolant into the radiator reservoir until it reaches the FULL line. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant. Install the radiator cap. Bleed air from the cooling system. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. HINT: Adjust the air conditioner set temperature to MAX (HOT). Maintain the engine speed at 2,000 to 2,500 RPM. Press the inlet and outlet radiator hoses several times by hand to bleed air. CAUTION: Wear protective gloves. Be careful as the radiator hoses are hot. Keep your hands away from the radiator fan. Stop the engine, and wait until the engine coolant cools down to ambient temperature. Check the coolant level in the radiator reservoir. If the coolant level is low, add SLLC to the radiator reservoir FULL line.
3. CHECK FOR ENGINE COOLANT LEAKS Check for engine coolant leaks (see «COOLING SYSTEM»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
3. DRAIN ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
4. REMOVE V-BANK COVER SUB-ASSEMBLY (See «MIL CIRCUIT»(/toyota/land-cruiser/100-2-2005-2007/remont/testing-diagnostics/#engine-control-system) )
5. REMOVE INTAKE AIR CONNECTOR PIPE (See «MIL CIRCUIT»(/toyota/land-cruiser/100-2-2005-2007/remont/testing-diagnostics/#engine-control-system) )
6. REMOVE COOLER COMPRESSOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/automatic-hvac-system/#air-conditioning) )
7. REMOVE DRIVE BELT (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
8. REMOVE RADIATOR ASSEMBLY Remove the radiator assembly (see «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).
9. REMOVE OIL COOLER PIPE (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
10. REMOVE TIMING BELT Remove the timing belt (see «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) ).
11. REMOVE NO. 2 TIMING BELT IDLER PULLEY SUBASSEMBLY Remove the bolt and idler pulley.
12. REMOVE WATER INLET HOUSING Disconnect the water by-pass hose from the water inlet housing. Remove the 2 bolts holding the water inlet housing to the water pump. Disconnect the water inlet housing from the front water by-pass joint, and remove the water inlet and inlet housing.
13. REMOVE WATER PUMP ASSEMBLY Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket. Remove the O-ring from the water by-pass pipe.

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1. INSPECT WATER PUMP ASSEMBLY Visually check the water drain hole for coolant leakage. If leakage is found, replace the water pump assembly. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If it moves roughly or noisily, replace the water pump assembly.
2. INSPECT FAN BRACKET SUB-ASSEMBLY Check that the fan pulley turns smoothly. If necessary, replace the fan bracket.

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1. INSTALL WATER PUMP ASSEMBLY Install a new O-ring to the water by-pass pipe end. Apply soapy water to the O-ring. Connect the water pump to the water by-pass pipe end. Install the water pump and a new gasket with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) for bolt 18 N*m (194 kgf*cm, 24 ft.*lbf) for nut and stud bolt HINT: Use bolts 35 mm (1.38 in.) in length.
2. INSTALL WATER INLET HOUSING Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and water pump. HINT: Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. Apply seal packing to the sealing groove of the water inlet housing (Scheme 14) Seal packing: Part No. 08826-00100 or equivalent Seal diameter: 2 to 3 mm (0.078 to 0.118 in.) HINT: Use a nozzle that has opening of 2 to 3 mm (0.08 to 0.12 in.). Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap after application. Install a new O-ring to the water inlet housing. Apply soapy water on the O-ring. Attach the water inlet housing end to the front water by-pass joint tube. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) HINT: Each bolt length is indicated below. Standard bolt length: BOLT LENGTH SPECIFICATIONS Bolt Length A 76 mm (3.00 in.) B 22 mm (0.87 in.)
3. INSTALL NO. 2 TIMING BELT IDLER PULLEY SUBASSEMBLY Install the idler pulley with the bolt. Torque: 34.5 N*m (352 kgf*cm, 25 ft.*lbf)
4. INSTALL TIMING BELT Install the timing belt (see «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) ).
5. INSTALL OIL COOLER PIPE (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
6. INSTALL RADIATOR ASSEMBLY Install the radiator assembly (see «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).
7. INSTALL DRIVE BELT (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
8. INSTALL COOLER COMPRESSOR ASSEMBLY (See «REASSEMBLY»(/toyota/land-cruiser/100-2-2005-2007/remont/automatic-hvac-system/#air-conditioning) )
9. INSTALL INTAKE AIR CONNECTOR PIPE (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/testing-diagnostics/#engine-control-system) )
10. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/testing-diagnostics/#engine-control-system) )
11. ADD ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
12. INSTALL ENGINE UNDER COVER (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
14. PERFORM INITIALIZATION Perform initialization (see «INITIALIZATION»(/toyota/land-cruiser/100-2-2005-2007/remont/hoistjack/#introduction__initialization) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
15. CHECK FOR ENGINE COOLANT LEAKS Check for engine coolant leaks (see «COOLING SYSTEM»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).

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REMOVAL

HINT

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if engine tends to overheat.

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1. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
2. DRAIN ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
3. REMOVE WATER INLET Remove the 3 nuts, water inlet and gasket.
4. REMOVE THERMOSTAT Remove the thermostat from the water inlet. Remove the gasket from the thermostat.

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1. INSPECT THERMOSTAT HINT: The valve opening temperature is inscribed on the thermostat. Immerse the thermostat in water and then gradually heat the water. Check the valve opening temperature of the thermostat. Standard valve opening temperature: 80 to 84°C (176 to 183°F) If the valve opening temperature is not within the specified range, replace the thermostat. Check the valve lift. Standard valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat temperature is below 40°C (104°F). If not fully closed, replace the thermostat.

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1. INSTALL THERMOSTAT Install a new gasket to the thermostat. Insert the thermostat into the water inlet housing with the jiggle valve facing straight upward. HINT: The jiggle valve may be set within 30° of either side of the prescribed position.
2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
3. ADD ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
4. CHECK FOR ENGINE COOLANT LEAKS Check for engine coolant leaks (see «COOLING SYSTEM»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).
5. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
2. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
3. DRAIN ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
4. DRAIN AUTOMATIC TRANSMISSION FLUID Drain automatic transmission fluid (see «AUTOMATIC TRANSMISSION FLUID»(/toyota/land-cruiser/100-2-2005-2007/remont/automatic-trans/#automatic-transmission-a750f) ).
5. REMOVE NO. 1 RADIATOR HOSE (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
6. REMOVE RADIATOR RESERVOIR ASSEMBLY Disconnect the clamp on the wire from the radiator. Disconnect the reservoir hose from the radiator. Remove the 2 bolts, reservoir and grommet.
7. REMOVE FAN WITH FLUID COUPLING Remove the 2 nuts, and disconnect the 2 clamps on the A/C discharge tube from the 2 wire harness brackets. Remove the 2 bolts, and disconnect the 2 wire harness brackets from the radiator. Disconnect the 2 oil cooler hoses from the clamp on the fan shroud. Loosen the 4 fan pulley mounting nuts holding the fluid coupling to the fan bracket. Remove the drive belt (see «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) ). Remove the 3 bolts holding the fan shroud to the radiator. Remove the 4 fan pulley mounting nuts. Pull out the fan with fluid coupling, fan pulley and fan shroud. NOTE: Be careful not to damage the radiator core.
8. REMOVE FAN Remove the 4 nuts and fan from the fluid coupling.

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1. INSPECT FLUID COUPLING ASSEMBLY Check that the fluid coupling is not damaged and that no silicon oil leaks. If necessary, replace the fluid coupling.

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1. INSTALL FAN Install the fan to the fluid coupling with the 4 nuts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
2. INSTALL FAN WITH FLUID COUPLING Place the fan with fluid coupling, fan pulley and fan shroud in position. Temporarily install the fan pulley mounting nuts. Install the fan shroud with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the 2 oil cooler hoses to the clamp on the fan shroud. Install the drive belt (see «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) ). Tighten the 4 fan pulley mounting nuts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) Install the 2 wire harness brackets to the radiator wire with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Install the 2 clamps on the A/C discharge tube to the 2 wire harness brackets with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
3. INSTALL RADIATOR RESERVOIR ASSEMBLY Install the grommet to the reservoir. Attach the lower side of the reservoir to the fan shroud. Install the reservoir with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the reservoir hose to the radiator. Install the clamp on the wire to the radiator.
4. INSTALL NO. 1 RADIATOR HOSE (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
5. ADD ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
6. ADD AUTOMATIC TRANSMISSION FLUID Add automatic transmission fluid (see «AUTOMATIC TRANSMISSION FLUID»(/toyota/land-cruiser/100-2-2005-2007/remont/automatic-trans/#automatic-transmission-a750f) ).
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. PERFORM INITIALIZATION Perform initialization (see «INITIALIZATION»(/toyota/land-cruiser/100-2-2005-2007/remont/hoistjack/#introduction__initialization) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
9. CHECK FOR ENGINE COOLANT LEAKS Check for engine coolant leaks (see «COOLING SYSTEM»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).
10. CHECK FOR OIL LEAKS Check for engine oil leaks (see «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/100-2-2005-2007/remont/lubrication-system/#engine-lubrication-system) ).
11. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )

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1. CHECK RADIATOR CAP NOTE: If the radiator cap contains foreign matter, rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing the 2 steps below, keep the tester at an angle of 30° or more above horizontal. Slowly pump the radiator cap tester, and then check that air is being released from the vacuum valve. Pump speed: 1 push every 3 seconds or more NOTE: Push the pump at a constant speed. If air is not being released from the vacuum valve, replace the radiator cap. Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 second NOTE: The specified pump speed is for the first pump only. It will close the vacuum valve. Once the vacuum valve is closed, the pump speed can be reduced. Standard opening pressure: 93 to 123 kPa (0.95 to 1.25 kgf/cm 2 , 13.5 to 17.8 psi) Minimum opening pressure: 78 kPa (0.8 kgf/cm 2 , 11.4 psi) HINT: Use the tester's maximum reading as the opening pressure. If the maximum reading is less than the minimum opening pressure, replace the radiator cap.

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1. CHECK FINS FOR BLOCKAGE Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the hose connections. If the fins are blocked, wash them with water or a steam cleaner. NOTE: If the distance between the steam cleaner and core is too close, the fins may be damaged. Keep the following injection distance. Standard injection distance INJECTION PRESSURE CHECK Injection Distance Injection Pressure 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kgf/cm 2 , 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kgf/cm 2 , 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electric components. Dry the fins with compressed air.

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1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
2. REMOVE NO. 1 ENGINE UNDER COVER (See «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
3. DRAIN ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
4. DISCONNECT NO. 1 RADIATOR HOSE Disconnect the radiator hose.
5. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the radiator hose.
6. DISCONNECT NO. 1 OIL COOLER INLET TUBE Disconnect the tube from the radiator.
7. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE Disconnect the tube from the radiator.
8. REMOVE RADIATOR RESERVOIR ASSEMBLY Disconnect the clamp on the wire from the radiator. Disconnect the reservoir hose from the radiator. Remove the 2 bolts, reservoir and grommet.
9. REMOVE FAN SHROUD Remove the 2 nuts, and disconnect the 2 clamps on the A/C discharge tube from the 2 wire harness brackets. Remove the 2 bolts, and disconnect the 2 wire harness brackets from the radiator. Disconnect the 2 oil cooler tubes from the clamp on the fan shroud. Loosen the fan pulley mounting nuts holding the fluid coupling to the fan bracket. Remove the drive belt (see «REMOVAL»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) ). Remove the 3 bolts holding the fan shroud to the radiator. Remove the 4 fan pulley mounting nuts. Pull out the fan with fluid coupling, fan pulley and fan shroud.
10. REMOVE RADIATOR ASSEMBLY Remove the 2 nuts. Remove the 2 bolts. Lift out the radiator.

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1. REMOVE SIDE SUPPORT Remove the 4 nuts and 2 brackets. Remove the 8 nuts and 2 side supports.
2. REMOVE DRAIN PLUG Remove the drain plug. Remove the O-ring.
3. UNCAULK LOCK PLATE Install the claw to part A of the overhaul handle as shown. SST 09230-01010 (09231-01010, 09231-01030) While squeezing the handle, adjust the stopper bolt so that dimension B is as specified below. Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.) Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230-01010 (09231-01010, 09231-01030)
4. REMOVE TANK AND O-RING Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer and remove the tank. Remove the O-ring.

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1. INSPECT LOCK PLATE FOR DAMAGE Inspect the lock plate for damage. If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Correct any deformations with pliers. Water will leak if the bottom of the lock plate groove is damaged or dented. Repair or replace it if necessary. NOTE: The radiator can only be recaulked twice. After the second time, the radiator core must be replaced.

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1. INSTALL NEW O-RING AND TANK Check that there are no foreign objects in the lock plate groove, and install a new O-ring. Make sure the O-ring is not twisted. HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it. Install the tank without damaging the O-ring. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank. Install the punch assembly to part A of the overhaul handle as shown. SST 09230-01010 (09231-01010, 09231-01020) While gripping the handle, adjust the stopper bolt so that dimension B is as specified below. Dimension B: 8.4 mm (0.331 in.)
2. CAULK LOCK PLATE Lightly press SST against the lock plate in the order shown. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper bolt. SST 09230-01010 (09231-01010, 09231-01020) NOTE: Do not press the protruding areas around the ports A and bracket B. Do not use SST to press the areas indicated by the circle marks. Use pliers and be careful not to damage the core plates. Check the lock plate height H after completing the caulking. Plate height H: 8.8 m (0.346 in.) If the height is not within the specified height, readjust the stopper bolt of the handle and caulk the lock plate again.
3. INSTALL DRAIN PLUG Install a new O-ring to the drain plug. Install the drain plug.
4. INSPECT FOR WATER LEAKS Plug the inlet and outlet pipes of the radiator with SST. SST 09230-01010 Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm 2 , 26 psi) Submerge the radiator in water. Inspect for leaks. HINT: On radiators with resin tanks, there is clearance between the tank and lock plate where a small amount of air will remain. This air is released when the radiator is submerged in water, giving the appearance of an air leak. Before performing the water leak test, first shake the radiator in the water until all air bubbles are released.
5. INSTALL SIDE SUPPORT Install the 2 side supports with the 8 nuts. Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) Install the 2 brackets with the 4 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)

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1. INSTALL RADIATOR ASSEMBLY Install the 2 side supports with the 8 bolts. Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf) Install the 2 brackets with the 4 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the radiator to the body. Install the 2 nuts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the radiator with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
2. INSTALL FAN SHROUD Place the fan with fluid coupling, fan pulley and fan shroud in position. Temporarily install the 4 fan pulley mounting nuts. Install the fan shroud with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the 2 oil cooler tubes to the clamp on the fan shroud. Install the drive belt (see «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) ). Tighten the 4 fan pulley mounting nuts. Install the 2 wire harness brackets to the radiator wire with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Install the 2 clamps on the A/C discharge tube to the 2 wire harness brackets with the 2 nuts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
3. INSTALL RADIATOR RESERVOIR ASSEMBLY Install the grommet to the reservoir. Attach the lower side of the reservoir to the fan shroud. Install the reservoir with the 2 bolts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the reserve tank hose to the radiator. Install the clamp on the wire to the radiator.
4. CONNECT NO. 1 OIL COOLER OUTLET TUBE Connect the outlet tube.
5. CONNECT NO. 1 OIL COOLER INLET TUBE Connect the inlet tube.
6. CONNECT NO. 2 RADIATOR HOSE Connect the radiator hose.
7. CONNECT NO. 1 RADIATOR HOSE Connect the radiator hose.
8. ADD ENGINE COOLANT (See «COOLANT»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) )
9. CHECK FOR ENGINE COOLANT LEAKS Check for engine coolant leaks (see «COOLING SYSTEM»(/toyota/land-cruiser/100-2-2005-2007/remont/cooling-system-mechanical/#engine-cooling-system) ).
10. INSTALL NO. 1 ENGINE UNDER COVER (See «INSTALLATION»(/toyota/land-cruiser/100-2-2005-2007/remont/accessory-drive-belts/#engine-mechanical) )
11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. PERFORM INITIALIZATION Perform initialization (see «INITIALIZATION»(/toyota/land-cruiser/100-2-2005-2007/remont/hoistjack/#introduction__initialization) ). NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

See also:
• REMOVAL
• MIL CIRCUIT
• REMOVAL
• INITIALIZATION
• AUTOMATIC TRANSMISSION FLUID
• ON-VEHICLE INSPECTION
• COOLING SYSTEM