Engine Mechanical Toyota Land Cruiser 200

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1. INSPECT IGNITION TIMING Warm up and stop the engine. Allow the engine to warm up to a normal operating temperature. When using the Techstream: Connect the Techstream to the DLC3. Start the engine and idle it. Turn the Techstream ON. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / IGN Advance. HINT: Refer to the Techstream operator's manual for further details. Standard ignition timing: 8 to 12° BTDC @ idling (transmission in neutral and A/C switch off) Disconnect the Techstream from the DLC3. When not using the Techstream: Connect the tester probe of a timing light to the wire of the ignition coil connector for the No. 1 cylinder. NOTE: Use a timing light that detects primary signals. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. Switch off all accessories and the A/C before connecting the terminals. Using the timing light, check the ignition timing. Standard ignition timing: 8 to 12° BTDC @ idling (transmission in neutral and A/C switch off) Remove SST from the DLC3. Check the ignition timing. Standard ignition timing: 7 to 24° BTDC @ idling (transmission in neutral and A/C switch off) Disconnect the timing light from the engine.
2. INSPECT ENGINE IDLE SPEED Warm up and stop the engine. Allow the engine to warm up to a normal operating temperature. When using the Techstream: Connect the Techstream to the DLC3. NOTE: Switch off all accessories and the A/C before connecting the Techstream. Race the engine at 2500 rpm for approximately 90 seconds. Turn the Techstream ON. Enter the following menus: Powertrain / Engine and ECT / Data List / Primary / Engine Speed. Standard idle speed: 650 to 750 rpm (transmission in neutral and A/C switch off) HINT: Refer to the Techstream operator's manual for further details. If the idle speed is not as specified, check the air intake system. Disconnect the Techstream from the DLC3. When not using the Techstream: Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3. SST 09843-18030 NOTE: Confirm the terminal number before connecting the probe. Connecting the probe to the wrong terminal can damage the engine. Switch off all accessories and the A/C before connecting the probe. Race the engine at 2500 rpm for approximately 90 seconds. Check the idle speed. Standard idle speed: 650 to 750 rpm (transmission in neutral and A/C switch off) If the idle speed is not as specified, check the air intake system. Disconnect the tachometer probe from the DLC3.
3. INSPECT COMPRESSION Warm up and stop the engine. Allow the engine to warm up to a normal operating temperature. Remove the V-bank cover. Remove the air cleaner hose assembly (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly__removal) ). Remove the air cleaner assembly (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Disconnect the water by-pass pipe assembly (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Disconnect the 2 injector connectors and 8 ignition coil connectors. Remove the 8 bolts and 8 ignition coils (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Remove the 8 spark plugs (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Check the cylinder compression pressure. NOTE: Check the compression pressure of each cylinder in the same way. Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. Standard compression pressure: 1300 kPa (13.3 kgf/cm 2 , 189 psi) Minimum pressure: 1000 kPa (10.2 kgf/cm 2 , 145 psi) Difference between each cylinder: 100 kPa (1.0 kgf/cm 2 , 15 psi) or less NOTE: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. This measurement must be done as quickly as possible. If the cylinder compression is low in one or more cylinders, pour a small amount of engine oil into the cylinder with low compression through its spark plug hole. Then inspect the cylinder compression pressure again. HINT: If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. Install the 8 spark plugs (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Install the 8 ignition coils with the 8 bolts (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Connect the 2 injector connectors and 8 ignition coil connectors. Connect the water by-pass pipe assembly (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Install the air cleaner assembly (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Install the air cleaner hose assembly (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) ). Install the V-bank cover.
4. INSPECT CO/HC HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. Start the engine. Keep the engine speed at 2500 rpm for approximately 180 seconds. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling. Immediately check CO/HC concentration at idle and/or 2500 rpm. HINT: When performing the 2 mode (2500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below. Check the A/F sensor and heated oxygen sensor operation. See the table below for possible causes, and then inspect and correct the applicable causes if necessary. TROUBLE SYMPTOM CHART CO HC Symptom Cause Normal High Rough idle Faulty ignitions: Incorrect timing Plugs (contaminated, shorted or gaps are defective) Incorrect valve clearance Leaky intake and exhaust valves Leaky cylinder Low High Rough idle (Fluctuating HC reading) Vacuum leaks: PCV hose Intake manifold Throttle body Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) Restricted air filter Faulty SFI system: Faulty pressure regulator Defective ECT sensor Faulty ECM Faulty injectors Faulty throttle position sensor Faulty MAF meter

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1. INSPECT FAN AND GENERATOR V BELT Check the belt for wear, cracks or other signs of damage. If any of the following defects is found, replace the fan and generator V belt. The belt is cracked. The belt is worn out to the extent that the cords are exposed. The belt has chunks missing from the ribs. Check that the belt fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the fan and generator V belt. Install a new fan and generator V belt correctly.
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the tensioner.

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1. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
4. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
5. REMOVE FAN AND GENERATOR V BELT While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner and the belt tensioner fixing position, and then insert a bar of with a diameter of 5 mm (0.197 in.) into the service hole to fix the belt tensioner in place. HINT: The pulley bolt for the belt tensioner has a left-hand thread. Remove the V belt.

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1. INSTALL FAN AND GENERATOR V BELT Set the V belt onto every part. While turning the belt tensioner counterclockwise, remove the bar. NOTE: Make sure that the V belt is properly set to each pulley. After installing the belt, check that it fits properly in the ribbed grooves. HINT: Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.
2. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
3. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
4. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
5. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )

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1. DISCHARGE FUEL SYSTEM PRESSURE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
3. REMOVE UPPER RADIATOR SUPPORT SEAL (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/horns/#horn-land-cruiser) )
4. REMOVE RADIATOR GRILLE (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
5. REMOVE FRONT BUMPER COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
6. REMOVE TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
7. DISCONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
8. DISCONNECT RADIATOR SIDE DEFLECTOR LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
9. REMOVE FRONT FENDER MAIN SEAL LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
10. REMOVE FRONT FENDER MAIN SEAL RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
11. REMOVE FRONT WIPER ARM LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
12. REMOVE FRONT WIPER ARM RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
13. REMOVE HOOD TO COWL TOP SEAL (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
15. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
16. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
17. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
18. REMOVE NO. 2 ENGINE UNDER COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
19. REMOVE FRONT FENDER APRON SEAL LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
20. REMOVE FRONT FENDER APRON SEAL FRONT RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
21. DRAIN ENGINE OIL (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
22. DRAIN ENGINE COOLANT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
23. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
24. REMOVE AIR CLEANER HOSE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly__removal) )
25. REMOVE AIR CLEANER ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
26. REMOVE NO. 1 RADIATOR HOSE
27. REMOVE NO. 2 RADIATOR HOSE
28. REMOVE FAN SHROUD (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
29. REMOVE RADIATOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
30. DISCONNECT ENGINE WIRE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
31. DISCONNECT AIR PUMP HOSE AND WIRE HARNESS (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
32. DISCONNECT NO. 2 WATER BY-PASS PIPE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
33. DISCONNECT COOLER COMPRESSOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
34. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
35. REMOVE OIL FILTER ELEMENT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
36. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
37. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
38. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
39. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
40. REMOVE OIL FILTER BRACKET (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
41. REMOVE OIL FILTER BRACKET (w/o Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
42. REMOVE INTAKE MANIFOLD (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly__removal) )
43. DISCONNECT VANE PUMP ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
44. DISCONNECT OIL COOLER PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
45. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/charging-system/#charging-system-3ur-fe) )
46. REMOVE NO. 1 WATER BY-PASS HOSE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
47. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
48. REMOVE FRONT WATER BY-PASS JOINT (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
49. REMOVE NO. 2 ENGINE COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
50. REMOVE NO. 1 ENGINE COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
51. REMOVE AIR TUBE SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
52. REMOVE WATER INLET HOUSING (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
53. REMOVE WATER PUMP PULLEY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
54. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
55. REMOVE FLUID COUPLING BRACKET (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
56. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
57. REMOVE IGNITION COIL ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
58. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
59. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
60. REMOVE SPARK PLUG TUBE GASKET (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
61. REMOVE CRANKSHAFT PULLEY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
62. DISCONNECT WIRE HARNESS CLAMP BRACKET (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
63. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
64. REMOVE WATER INLET PIPE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
65. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
66. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical)
67. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
68. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
69. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
70. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
71. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
72. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
73. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
74. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
75. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
76. REMOVE CRANKSHAFT TIMING GEAR KEY (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
77. REMOVE CAMSHAFT BEARING CAP LH Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 6 bearing caps. HINT: Arrange the removed parts in the correct order. Remove the No. 3 and No. 4 camshafts.
78. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use.
79. REMOVE CAMSHAFT BEARING CAP RH Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration. NOTE: Uniformly loosen the bolts while keeping the camshaft level. Remove the 6 bearing caps. HINT: Arrange the removed parts in the correct order. Remove the No. 1 and No. 2 camshafts.
80. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. HINT: Tape the screwdriver tip before use.

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1. INSTALL CAMSHAFT BEARING CAP RH Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. Install the No. 1 and No. 2 camshafts to the camshaft housing. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions. Temporarily install the 10 bolts in the order shown in the illustration.
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH Make sure that the valve rocker arms are installed as shown in the illustration. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.5 to 4.0 mm (0.138 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Install the camshaft housing, and install the 18 bolts in the order shown in the illustration. Torque: for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) Except bolt A 30 N*m (306 kgf*cm, 22 ft.*lbf) NOTE: Do not start the engine for at least 2 hours after the installation. Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing. Tighten the 10 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTE: Thoroughly wipe clean any seal packing.
3. INSTALL CAMSHAFT BEARING CAP LH Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps. Install the No. 3 and No. 4 camshafts to the camshaft housing. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions. Temporarily install the 10 bolts in the order shown in the illustration.
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH Make sure that the valve rocker arms are installed as shown in the illustration. Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.5 to 4.0 mm (0.138 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the camshaft housing within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Install the camshaft housing, and install the 18 bolts in the order shown in the illustration. Torque: for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) Except bolt A 30 N*m (306 kgf*cm, 22 ft.*lbf) NOTE: Do not start the engine for at least 2 hours after the installation. Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing. Tighten the 10 bolts in the order shown in the illustration. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) NOTE: Thoroughly wipe clean any seal packing.
5. INSTALL CRANKSHAFT TIMING GEAR KEY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
6. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
7. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
8. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
9. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
10. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
12. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
13. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
14. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
16. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
17. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
18. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
19. INSTALL WATER INLET PIPE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
20. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
21. INSTALL SPARK PLUG TUBE GASKET (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
24. INSTALL IGNITION COIL ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
25. INSTALL CRANKSHAFT TIMING GEAR KEY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
26. INSTALL CRANKSHAFT PULLEY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
27. CONNECT WIRE HARNESS CLAMP BRACKET (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
28. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
29. INSTALL WATER PUMP PULLEY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
30. INSTALL WATER INLET HOUSING (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
31. INSTALL AIR TUBE SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
32. INSTALL NO. 1 ENGINE COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
33. INSTALL NO. 2 ENGINE COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
34. INSTALL FRONT WATER BY-PASS JOINT (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
35. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
36. INSTALL NO. 1 WATER BY-PASS HOSE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
37. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/charging-system/#charging-system-3ur-fe__installation) )
38. CONNECT OIL COOLER PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
39. CONNECT VANE PUMP ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
40. INSTALL INTAKE MANIFOLD (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
41. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
42. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
43. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
44. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
45. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
46. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
47. INSTALL OIL FILTER ELEMENT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
48. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
49. CONNECT COOLER COMPRESSOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
50. CONNECT NO. 2 WATER BY-PASS PIPE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
51. CONNECT AIR PUMP HOSE AND WIRE HARNESS (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
52. CONNECT ENGINE WIRE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
53. INSTALL RADIATOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
54. INSTALL FAN SHROUD (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
55. INSTALL NO. 2 RADIATOR HOSE
56. INSTALL NO. 1 RADIATOR HOSE
57. INSTALL AIR CLEANER ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
58. INSTALL AIR CLEANER HOSE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
59. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
60. ADD ENGINE OIL (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
61. ADD ENGINE COOLANT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
63. INSPECT FOR OIL LEAK (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
64. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
65. INSPECT ENGINE OIL LEVEL (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
66. INSPECT IGNITION TIMING (See «ENGINE»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
67. INSPECT ENGINE IDLE SPEED (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
68. INSTALL FRONT FENDER APRON SEAL FRONT RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
69. INSTALL FRONT FENDER APRON SEAL LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
70. INSTALL NO. 2 ENGINE UNDER COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
71. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
72. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
73. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
74. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
75. INSTALL HOOD TO COWL TOP SEAL (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
76. INSTALL FRONT FENDER MAIN SEAL LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
77. INSTALL FRONT FENDER MAIN SEAL RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
78. INSTALL FRONT WIPER ARM LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
79. INSTALL FRONT WIPER ARM RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) )
80. CONNECT RADIATOR SIDE DEFLECTOR LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
81. CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
82. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
83. INSTALL FRONT BUMPER COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
84. INSTALL RADIATOR GRILLE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
85. INSTALL UPPER RADIATOR SUPPORT SEAL (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/horns/#horn-land-cruiser__installation) )

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

1. DISCHARGE FUEL SYSTEM PRESSURE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
3. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY Remove the exhaust manifold (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) ).
4. REMOVE CAMSHAFT Remove the camshaft (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ).
5. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
6. REMOVE VALVE LASH ADJUSTER ASSEMBLY (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
7. REMOVE VALVE STEM CAP (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
8. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to arrange the removed parts for each installation position separately. Remove the cylinder head and gasket.
9. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers. NOTE: Be careful not to drop washers into the cylinder head. Head warpage or cracking could result from removing bolts in an incorrect order. HINT: Be sure to arrange the removed parts for each installation position separately. Remove the cylinder head and gasket.

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

1. INSPECT CYLINDER HEAD SET BOLT (See «INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY (See «INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
3. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH Check the piston protrusions for each cylinder. Clean the cylinder block with solvent. Set the piston of the cylinder to be measured to slightly ATDC. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward. NOTE: Be careful of the installation direction. Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket. Place the cylinder head on the cylinder block. NOTE: Ensure that no oil is on the mounting surface of the cylinder head. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2: Mark each cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts 90° in the sequence shown in step 1. Step 3: Tighten the cylinder head bolts another 90° in the sequence shown in step 1. Check that the painting marks are now facing rearward. Uniformly install the 2 bolts in the sequence shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH Check the piston protrusions for each cylinder. Clean the cylinder block with solvent. Set the piston of the cylinder to be measured to slightly ATDC. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward. NOTE: Be careful of the installation direction. Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket. Place the cylinder head on the cylinder block. NOTE: Ensure that no oil is on the mounting surface of the cylinder head. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head. HINT: The cylinder head bolts are tightened in 3 progressive steps. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts. Step 1: Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration. Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) Step 2: Mark each cylinder head bolt head with paint as shown in the illustration. Tighten the cylinder head bolts 90° in the sequence shown in step 1. Step 3: Tighten the cylinder head bolts another 90° in the sequence shown in step 1. Check that the painted marks are now facing rearward. Uniformly install the 2 bolts in the sequence shown in the illustration. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
5. INSTALL VALVE STEM CAP (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
6. INSTALL VALVE LASH ADJUSTER ASSEMBLY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
7. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
8. INSTALL CAMSHAFT Install the camshaft (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ).
9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY Install the exhaust manifold (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) ).
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
11. INSPECT FOR EXHAUST GAS LEAK (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
12. INSPECT IGNITION TIMING (See «ENGINE»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
13. INSPECT ENGINE IDLE SPEED (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
4. DRAIN ENGINE COOLANT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
5. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
6. REMOVE NO. 1 RADIATOR HOSE
7. REMOVE FAN SHROUD (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
8. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
9. REMOVE OIL FILTER BRACKET (w/o Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
10. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
11. DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) Remove the 3 bolts and disconnect the 2 water bypass hoses from the oil cooler.
12. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
13. REMOVE OIL FILTER BRACKET (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
14. REMOVE CRANKSHAFT PULLEY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
15. REMOVE CRANKSHAFT TIMING GEAR KEY Remove the crankshaft timing gear key from the crankshaft.
16. REMOVE FRONT CRANKSHAFT OIL SEAL Using a screwdriver, pry out the oil seal. NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft. HINT: Tape the screwdriver tip before use.

Scheme 85

1. INSTALL FRONT CRANKSHAFT OIL SEAL Apply MP grease to the lip of a new oil seal. Using SST and a hammer, tap in the oil seal to a depth between 0 and 1.0 mm (0 and 0.0394 in.) from the timing chain cover edge. SST 09223-22010, 09506-35010 NOTE: Keep the lip free from foreign matter. Do not tap the oil seal at an angle.
2. INSTALL CRANKSHAFT TIMING GEAR KEY Install the crankshaft timing gear key.
3. INSTALL CRANKSHAFT PULLEY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
4. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
5. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
6. CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) Connect the 2 water by-pass hoses to the oil cooler. Install the 3 by-pass pipe bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
7. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
8. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
9. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
10. INSTALL FAN SHROUD (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
11. INSTALL NO. 1 RADIATOR HOSE
12. ADD ENGINE COOLANT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
13. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
14. INSPECT FOR OIL LEAK (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
15. INSPECT ENGINE OIL LEVEL (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
16. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
17. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
18. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
19. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )

Scheme 86

Scheme 87

Scheme 88

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY Remove the automatic transmission (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) ).
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
4. REMOVE REAR CRANKSHAFT OIL SEAL Using a knife, cut off the lip of the oil seal. Using a screwdriver, pry out the oil seal. HINT: Tape the screwdriver tip before use. NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft.

Scheme 89

1. INSTALL REAR CRANKSHAFT OIL SEAL Apply MP grease to the lip of a new oil seal. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-56010 NOTE: Keep the lip free from foreign matter. Do not tap on the oil seal at an angle.
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Install the automatic transmission (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) ).
4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

1. DISCHARGE FUEL SYSTEM PRESSURE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to disable the SRS system.
3. REMOVE UPPER RADIATOR SUPPORT SEAL (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/horns/#horn-land-cruiser) )
4. REMOVE RADIATOR GRILLE (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
5. REMOVE FRONT BUMPER COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
6. REMOVE TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
7. DISCONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
8. DISCONNECT RADIATOR SIDE DEFLECTOR LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
9. REMOVE HOOD SUB-ASSEMBLY Remove the 2 hood support bolts and disconnect the hood supports. CAUTION: Remove the hood support assembly while supporting the hood by hand. Remove the 4 bolts and hood.
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Remove the cowl top ventilator louver (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) ).
11. REMOVE FRONT FENDER APRON SEAL LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
12. REMOVE FRONT FENDER APRON SEAL REAR LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
13. REMOVE FRONT FENDER APRON SEAL FRONT RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
14. REMOVE FRONT FENDER APRON SEAL REAR RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
15. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
16. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
17. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Remove the 10 bolts and No. 1 engine under cover.
18. REMOVE NO. 2 ENGINE UNDER COVER Remove the 2 bolts and No. 2 engine under cover.
19. REMOVE OIL PAN PROTECTOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) )
20. DRAIN ENGINE OIL (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
21. DRAIN ENGINE COOLANT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
22. REMOVE V-BANK COVER SUB-ASSEMBLY Raise the front of the V-bank cover to detach the 3 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.
23. REMOVE AIR CLEANER HOSE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly__removal) )
24. REMOVE AIR CLEANER ASSEMBLY Remove the 3 bolts and air cleaner.
25. REMOVE NO. 1 RADIATOR HOSE
26. REMOVE NO. 2 RADIATOR HOSE
27. REMOVE FAN SHROUD (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
28. REMOVE RADIATOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
29. DISCONNECT FUEL MAIN AND RETURN HOSE Remove the fuel pipe clamp. Disconnect the fuel main and return hoses (See «FUEL SYSTEM»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) ).
30. DISCONNECT WIRE HARNESS AND HOSE Disconnect the purge line hose. Disconnect the 4 heater hoses. Disconnect the clamp and ECM connector. HINT: Refer to the following procedures to disconnect the ECM connector (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Disconnect the 4 connectors and clamp from the connector holder block. Disconnect the 2 air pump connectors and 3 clamps. Remove the nut and connector bracket. Remove the bolt and disconnect the ground wire. Disconnect the 2 air injection system hoses. Remove the nut and disconnect the wire from the positive (+) battery cable. Disconnect the cable from the positive (+) battery terminal. Remove the bolt and disconnect the ground wire from the body. Remove the bolt and disconnect the ground wire from the air injection control bracket. Disconnect the 4 air injection control driver connectors. Remove the nut and disconnect the wire and 2 clips from the engine room junction block. Disconnect the 2 connectors and 2 clips from the engine room junction block. Disconnect the 2 connectors and clamp.
31. DISCONNECT COOLER COMPRESSOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
32. DISCONNECT VANE PUMP ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
33. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/charging-system/#charging-system-3ur-fe) )
34. REMOVE TAILPIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
35. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
36. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
37. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
38. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE Disconnect the wire harness clamp. Remove the dipstick. Remove the bolt and dipstick guide. Remove the O-ring from the dipstick guide.
39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY Remove the front propeller shaft (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/driveshaft-universal-joints/#drive-shaft-propeller-shaft) ).
40. REMOVE REAR PROPELLER SHAFT ASSEMBLY Remove the rear propeller shaft (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/driveshaft-universal-joints/#drive-shaft-propeller-shaft) ).
41. REMOVE PROPELLER SHAFT HEAT INSULATOR (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
42. REMOVE NO. 2 MANIFOLD STAY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
43. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
44. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
45. REMOVE NO. 1 MANIFOLD STAY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
48. REMOVE STARTER COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/starter/#starting-system) )
49. REMOVE STARTER ASSEMBLY (See «DISASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/starter/#starting-system) )
50. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY Remove the automatic transmission (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) ).
51. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary. Remove the 2 bolts and front engine mounting insulator RH. Remove the 4 bolts and rear engine mounting insulator from the transmission.
52. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft. SST 09213-70011 (09213-70020), 09330-00021 Remove the 10 bolts, rear drive plate spacer, drive plate and crankshaft angle sensor rotor.
53. DISCONNECT OIL COOLER PIPE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
54. REMOVE NO. 2 WATER BY-PASS PIPE Remove the 2 bolts and disconnect the 2 hoses. Then remove the water by-pass pipe.
55. REMOVE ENGINE ASSEMBLY Install 2 engine hangers with 2 bolts as shown in the illustration. Engine Hanger Part No. ENGINE HANGER PART NO REFERENCE Item Part No. Engine hanger 12281-38030 Bolt 90119-14120 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Attach an engine sling device and hang the engine with a chain block. Remove the 4 engine mounting insulator bolts. Lift the engine out from the vehicle slowly and carefully. NOTE: Make sure the engine is clear of all wiring, hoses and cables.
56. REMOVE FRONT ENGINE MOUNTING INSULATOR LH Remove the nut and mounting insulator.
57. REMOVE FRONT ENGINE MOUNTING INSULATOR RH Remove the nut and mounting insulator.
58. REMOVE NO. 2 FRONT ENGINE MOUNTING BRACKET LH Remove the bolt and No. 2 front engine mounting bracket LH.
59. INSTALL ENGINE ON ENGINE STAND Install the engine onto an engine stand with bolts. Remove the 2 bolts and 2 engine hangers.

Scheme 123

Scheme 124

Scheme 125

Scheme 126

1. REMOVE ENGINE STAND Install 2 engine hangers with 2 bolts as shown in the illustration. Engine Hanger Part No. ENGINE HANGER PART NO REFERENCE Item Part No. Engine hanger 12281-38030 Bolt 90119-14120 Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Attach an engine sling device and hang the engine with a chain block. Remove the bolts and engine assembly from the engine stand.
2. INSTALL NO. 2 FRONT ENGINE MOUNTING BRACKET LH Install the No. 2 front engine mounting bracket LH with the bolt. Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf)
3. INSTALL FRONT ENGINE MOUNTING INSULATOR RH Install the mounting insulator with the nut. Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf)
4. INSTALL FRONT ENGINE MOUNTING INSULATOR LH Install the mounting insulator with the nut. Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf)
5. INSTALL ENGINE ASSEMBLY Slowly lower the engine assembly into the engine compartment. NOTE: Make sure that the engine is clear of all wiring and hoses. Attach the engine mounting insulators to the vehicle. Install the 4 engine mounting insulator bolts. Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf) Remove the 2 bolts and 2 engine hangers.
6. INSTALL NO. 2 WATER BY-PASS PIPE Connect the 2 hoses and install the water by-pass pipe with the 2 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
7. CONNECT OIL COOLER PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft. SST 09213-70011 (09213-70020), 09330-00021 Install the crankshaft angle sensor rotor, drive plate and rear drive plate spacer to the crankshaft. Install and uniformly tighten 10 new bolts in the sequence shown in the illustration. Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) NOTE: Do not reuse the flywheel installation bolts. Do not strike or damage the flywheel installation bolts. Be sure to handle them carefully. Mark the upside of each flywheel installation bolt with paint. Tighten the flywheel installation bolts 90° as shown in the illustration. Check that the painted marks are now at a 90° angle to the upside.
9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR Install the rear engine mounting insulator to the transmission with the 4 bolts. Torque: 59 N*m (602 kgf*cm, 44 ft.*lbf) Install the front engine mounting insulator RH with the 2 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Install the automatic transmission (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) ).
11. INSTALL STARTER ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/starter/#starting-system) )
12. INSTALL STARTER COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/starter/#starting-system) )
13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
14. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
15. INSTALL NO. 1 MANIFOLD STAY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
18. INSTALL NO. 2 MANIFOLD STAY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
19. INSTALL PROPELLER SHAFT HEAT INSULATOR (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
20. INSTALL REAR PROPELLER SHAFT ASSEMBLY Install the rear propeller shaft (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/driveshaft-universal-joints/#drive-shaft-propeller-shaft) ).
21. INSTALL FRONT PROPELLER SHAFT ASSEMBLY Install the front propeller shaft (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/driveshaft-universal-joints/#drive-shaft-propeller-shaft) ).
22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Apply a light coat of engine oil to a new O-ring. Install the O-ring to the guide. Install the dipstick guide with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the dipstick. Connect the wire harness clamp.
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
25. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
26. INSTALL TAILPIPE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
27. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/charging-system/#charging-system-3ur-fe__installation) )
28. CONNECT VANE PUMP ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
29. CONNECT COOLER COMPRESSOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
30. CONNECT WIRE HARNESS AND HOSE Connect the clamp and 2 connectors. Connect the 2 connectors and 2 clips to the engine room junction block. Install the engine wire with the nut. Then connect the 2 clips. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the 4 air injection control driver connectors. Install the ground wire to the air injection control bracket with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Install the ground wire to the body with the bolt. Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) Connect the cable to the positive (+) battery terminal. Install the wire to the positive (+) battery cable with the nut. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the 2 air injection system hoses. Install the ground wire with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the 3 clamps and 2 air pump connectors. Install the connector bracket with the nut. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) Connect the clamp and 4 connectors to the connector holder block. Connect the 4 heater hoses. Connect the ECM connector and clamp. HINT: Refer to the following procedures to connect the ECM connector (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/testing-diagnostics/#engine-control-system) ). Connect the purge line hose.
31. CONNECT FUEL MAIN AND RETURN HOSE Connect the fuel main and return hoses (See «FUEL SYSTEM»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) ). Install the fuel pipe clamp.
32. INSTALL RADIATOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
33. INSTALL FAN SHROUD (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
34. INSTALL NO. 2 RADIATOR HOSE
35. INSTALL NO. 1 RADIATOR HOSE
36. INSTALL AIR CLEANER ASSEMBLY Install the air cleaner with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
37. INSTALL AIR CLEANER HOSE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
38. ADD ENGINE OIL (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
39. ADD ENGINE COOLANT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
41. INSPECT FOR OIL LEAK (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
42. INSPECT FOR COOLANT LEAK (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
43. INSPECT FOR EXHAUST GAS LEAK (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
44. INSPECT FOR FUEL LEAK (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
45. INSPECT SHIFT LEVER POSITION (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) )
46. INSTALL V-BANK COVER SUB-ASSEMBLY 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.
47. INSTALL OIL PAN PROTECTOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/automatic-trans/#automatic-transmission-ab60f) )
48. INSTALL NO. 2 ENGINE UNDER COVER Install the No. 2 engine under cover with the 2 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
49. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY Install the No. 1 engine under cover with the 10 bolts. Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
50. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
51. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
52. INSTALL FRONT FENDER APRON SEAL REAR RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
53. INSTALL FRONT FENDER APRON SEAL FRONT RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
54. INSTALL FRONT FENDER APRON SEAL REAR LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
55. INSTALL FRONT FENDER APRON SEAL LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exhaust/#engine-intake-exhaust-assembly) )
56. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Install the cowl top ventilator louver (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/wiperwasher-systems/#wiper-system-washer-system) ).
57. INSTALL HOOD SUB-ASSEMBLY Install the hood with the 4 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Connect the 2 hood supports with the 2 hood support bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) CAUTION: Install the hood support while supporting the hood by hand. NOTE: Check that the hood support is engaged in the ball joint and that it cannot be pulled out.
58. ADJUST HOOD SUB-ASSEMBLY (See «ADJUSTMENT»(/toyota/land-cruiser/200-2007-2012/remont/exterior-body-panels/#door-hatch__adjustment) )
59. CONNECT RADIATOR SIDE DEFLECTOR LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
60. CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
61. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
62. INSTALL FRONT BUMPER COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
63. INSTALL RADIATOR GRILLE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/exteriorinterior-trim/#exterior-panels-trim) )
64. INSTALL UPPER RADIATOR SUPPORT SEAL (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/horns/#horn-land-cruiser__installation) )
65. INSPECT IGNITION TIMING (See «ENGINE»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
66. INSPECT ENGINE IDLE SPEED (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
67. INSPECT CO/HC (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
68. INSPECT ENGINE OIL LEVEL (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
69. INSPECT ENGINE COOLANT LEVEL (See «ON-VEHICLE INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )

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Scheme 157

Scheme 158

1. REMOVE ENGINE WIRE Engine LH Side: Disconnect the 2 camshaft timing control valve connectors. Disconnect the 4 ignition coil connectors. Disconnect the 2 VVT sensor connectors. Disconnect the camshaft position sensor connector. Disconnect the vacuum switching valve connector (for ACIS). Disconnect the purge VSV connector. Disconnect the engine coolant temperature sensor connector. Disconnect the fuel injector connector. Disconnect the noise filter connector. Remove the bolt and disconnect the 7 clamps. Engine RH Side: Disconnect the 2 camshaft timing control valve connectors. Disconnect the 4 ignition coil connectors. Disconnect the 2 VVT sensor connectors. Disconnect the fuel injector connector. Disconnect the noise filter connector. Disconnect the throttle sensor connector. Disconnect the oil pressure sender gauge connector. W/ Oil Level Sensor: Disconnect the oil level sensor connector. Disconnect the 10 clamps. Engine Rear Side: Disconnect the 2 air switching valve connectors. Disconnect the 5 clamps. Remove the 3 bolts. Remove the engine wire.
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
3. REMOVE NO. 3 ENGINE COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
4. REMOVE NO. 1 FUEL HOSE Remove the fuel hose (See «FUEL SYSTEM»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) ).
5. DISCONNECT NO. 2 FUEL TUBE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
6. DISCONNECT NO. 1 FUEL TUBE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
9. REMOVE FUEL INJECTOR ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) )
10. REMOVE INTAKE MANIFOLD Disconnect the ventilation hose from the ventilation pipe of the cylinder head cover LH and RH. Disconnect the 2 water by-pass hoses. Disconnect the No. 1 ventilation hose. Remove the bolt and wire bracket from the intake manifold. Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets.
11. REMOVE NO. 2 FUEL TUBE Remove the 2 bolts and No. 2 fuel tube.
12. REMOVE NO. 1 FUEL TUBE
13. REMOVE NO. 2 ENGINE COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
14. REMOVE NO. 1 ENGINE COVER (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
15. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
16. REMOVE NO. 1 WATER BY-PASS HOSE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
17. REMOVE FRONT WATER BY-PASS JOINT (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
18. REMOVE AIR PIPE SUB-ASSEMBLY Remove the 2 bolts, air pipe and 2 No. 1 air hoses.
19. REMOVE WATER INLET HOUSING (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
20. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY Remove the 2 bolts and water by-pass pipe.
21. REMOVE AIR SWITCHING VALVE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
22. REMOVE NO. 2 AIR TUBE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
23. REMOVE NO. 3 AIR TUBE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
24. REMOVE ENGINE WIRE Disconnect the 4 knock sensor connectors. Disconnect the 3 clamps. Then remove the engine wire.
25. REMOVE SEPARATOR CASE Remove the 4 bolts and separator case.
26. REMOVE KNOCK SENSOR Remove the 4 bolts and 4 knock sensors.
27. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Remove the 2 water drain cock plugs from the water drain cocks. Remove the 2 water drain cocks from the cylinder block.
28. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH Remove the 4 bolts and mounting bracket.
29. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH Remove the 4 bolts and mounting bracket.
30. REMOVE IGNITION COIL ASSEMBLY Remove the 8 bolts and 8 ignition coils.
31. REMOVE NOISE FILTER LH: Remove the bolt and noise filter from the cylinder head cover. RH: Remove the bolt and noise filter from the cylinder head cover.

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Scheme 204

1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
2. REMOVE OIL FILTER ELEMENT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
3. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
4. REMOVE OIL FILTER BRACKET (w/ Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
5. REMOVE OIL FILTER BRACKET (w/o Oil Cooler) (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
6. REMOVE OIL FILLER CAP SUB-ASSEMBLY
7. REMOVE OIL FILLER CAP HOUSING Remove the 2 bolts, filler cap housing and gasket.
8. REMOVE SPARK PLUG Using a 16 mm plug wrench, remove the 8 spark plugs.
9. REMOVE VVT SENSOR LH: Remove the 2 bolts and 2 VVT sensors. RH: Remove the 2 bolts and 2 VVT sensors.
10. REMOVE CAMSHAFT POSITION SENSOR Remove the bolt and camshaft position sensor.
11. REMOVE CRANK POSITION SENSOR PROTECTOR Remove the 2 bolts and sensor protector.
12. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and crankshaft position sensor.
13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY LH: Remove the 2 bolts and 2 oil control valves. RH: Remove the 2 bolts and 2 oil control valves.
14. REMOVE WATER PUMP PULLEY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system__removal) )
15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
16. REMOVE FLUID COUPLING BRACKET (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
20. REMOVE OIL CONTROL VALVE FILTER LH: Remove the 3 bolts, cylinder head cover spacer, gasket and filter. RH: Remove the 3 bolts, cylinder head cover spacer, gasket and filter.
21. REMOVE SPARK PLUG TUBE GASKET Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more. Using a screwdriver, pry out the gaskets. NOTE: Be careful not to damage the cylinder head cover. Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one. HINT: Tape the screwdriver tip before use.
22. REMOVE CRANKSHAFT PULLEY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
23. REMOVE WATER PUMP ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system__removal) )
24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
25. REMOVE WATER INLET PIPE (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
26. REMOVE FRONT CRANKSHAFT OIL SEAL Place the timing chain cover on wooden blocks. Using a screwdriver and wooden block, pry out the oil seal. NOTE: Do not damage the surface of the oil seal press fit hole. HINT: Tape the screwdriver tip before use.
27. SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration. HINT: If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.
28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole. Remove the 2 bolts, chain tensioner and gasket.
29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH
30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH Remove the 2 bolts and chain vibration damper.
31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH While pushing down the No. 3 chain tensioner, insert a pin of with a diameter of 1.0 mm (0.0394 in.) into the hole to fix it in place. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTE: Be careful not to damage the cylinder head with the wrench. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH. Remove the No. 1 and No. 2 chains from the gears.
32. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY Remove the 2 bolts and chain tensioner.
33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole. Remove the 2 bolts and chain tensioner.
34. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH
35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH Remove the 2 bolts and vibration damper.
36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH While raising up the No. 2 chain tensioner, insert a pin of with a diameter of 1.0 mm (0.0394 in.) into the hole to fix it in place. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTE: Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear. Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. NOTE: Be careful not to damage the cylinder head with the wrench. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH. Remove the No. 1 and No. 2 chains from the gears.
37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY Remove the 2 bolts and chain tensioner.
38. REMOVE CRANKSHAFT TIMING GEAR KEY Using a screwdriver, remove the 2 timing gear keys from the crankshaft.
39. REMOVE CAMSHAFT BEARING CAP LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
41. REMOVE CAMSHAFT BEARING CAP RH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
43. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Remove the 32 valve rocker arms from the cylinder heads. HINT: Arrange the removed parts in the correct order.
44. REMOVE VALVE LASH ADJUSTER ASSEMBLY Remove the 32 valve lash adjusters from the cylinder heads. HINT: Arrange the removed parts in the correct order.
45. REMOVE VALVE STEM CAP Remove the 32 valve stem caps from the cylinder heads. HINT: Arrange the removed parts in the correct order.
46. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
47. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
48. REMOVE CYLINDER BLOCK WATER JACKET SPACER Remove the 2 water jacket spacers from the cylinder block. NOTE: Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.
49. REMOVE VENTILATION PIPE GASKET Using a screwdriver, pry out the ventilation pipe gasket. HINT: Tape the screwdriver tip before use.
50. REMOVE NO. 1 HEAT EXCHANGER COVER Remove the 12 bolts and 2 nuts. Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver. HINT: Tape the screwdriver tip before use.
51. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY W/ Oil Level Sensor: Remove the engine oil level sensor (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) ). Remove the 14 bolts and 2 nuts. Insert the blade of an oil seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan. NOTE: Be careful not to damage the contact surfaces of the oil pans.
52. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY Remove the 14 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use.
53. REMOVE NO. 1 OIL PAN BAFFLE PLATE Remove the 7 bolts and baffle plate.
54. REMOVE OIL STRAINER SUB-ASSEMBLY Remove the 2 bolts, oil strainer and O-ring.
55. REMOVE ENGINE REAR OIL SEAL RETAINER Remove the 6 bolts and oil seal retainer. Using a screwdriver, pry out the oil seal retainer. HINT: Tape the screwdriver tip before use.
56. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY Remove the bolt and oil drain pipe. Remove the O-ring.
57. REMOVE REAR CRANKSHAFT OIL SEAL Place the oil seal retainer on wooden blocks. Using a screwdriver and hammer, tap out the oil seal.
58. REMOVE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced.
59. REMOVE STUD BOLT NOTE: If the stud bolt is deformed or its threads are damaged, replace it.

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Scheme 238

1. INSPECT CYLINDER HEAD SET BOLT Using a vernier caliper, measure the diameter of the elongated thread at the measuring point. Measuring point: 94 mm (3.70 in.) for intake side bolt 89 mm (3.50 in.) for exhaust side bolt Standard diameter: 10.85 to 11.00 mm (0.427 to 0.433 in.) Minimum diameter: 10.6 mm (0.417 in.) If the diameter is less than the minimum, replace the cylinder head bolt. HINT: If a visual check reveals no excessively thin areas, check the center of the bolt (Scheme 205) and find the area that has the smallest diameter.
2. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Turn the roller by hand to check that it turns smoothly. If the roller does not turn smoothly, replace the valve rocker arm.
3. INSPECT VALVE LASH ADJUSTER ASSEMBLY NOTE: Keep the adjuster free from dirt and foreign objects. Use only clean engine oil. Place the lash adjuster into a container full of new engine oil. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger. SST 09276-75010 Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times. Check the movement of the plunger and bleed air. OK: Plunger moves up and down. NOTE: When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers. OK: Plunger can be pressed 3 times. If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.
4. INSPECT CAMSHAFT SUB-ASSEMBLY Inspect the camshaft for runout. Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.00157 in.) If the circle runout is more than the maximum, replace the camshaft sub-assembly. HINT: Check the oil clearance after replacing the camshaft. Using a micrometer, measure the cam lobe height. Standard Cam Lobe Height STANDARD CAM LOBE HEIGHT Item Specified Condition Intake 44.291 to 44.441 mm (1.744 to 1.750 in.) Exhaust 44.196 to 44.346 mm (1.740 to 1.746 in.) Minimum Cam Lobe Height MINIMUM CAM LOBE HEIGHT Item Specified Condition Intake 44.241 mm (1.742 in.) Exhaust 44.146 mm (1.738 in.) If the cam lobe height is less than the minimum, replace the camshaft sub-assembly. Using a micrometer, measure the journal diameter. Standard Journal Diameter STANDARD JOURNAL DIAMETER Item Specified Condition No. 1 journal 29.956 to 29.970 mm (1.179 to 1.180 in.) Other journals 25.959 to 25.975 mm (1.022 to 1.023 in.) If the journal diameter is not as specified, check the oil clearance.
5. INSPECT CAMSHAFT OIL CLEARANCE Clean the bearing caps, camshaft housing and camshaft journals. Place the camshafts on the camshaft housing. Lay a strip of Plastigage across each of the camshaft journals. Install the camshaft bearing caps (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). NOTE: Do not turn the camshaft. Install the camshaft housing (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). NOTE: Do not turn the camshaft. Remove the camshaft bearing caps (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Measure the Plastigage at its widest point. Standard Oil Clearance CAMSHAFT STANDARD OIL CLEARANCE Item Specified Condition No. 1 journal 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Other journals 0.025 to 0.062 mm (0.000984 to 0.00244 in.) Maximum Oil Clearance CAMSHAFT MAXIMUM OIL CLEARANCE Item Specified Condition No. 1 journal 0.10 mm (0.00394 in.) Other journals 0.09 mm (0.00354 in.) If the oil clearance is more than the maximum, replace the camshaft. If necessary, replace the camshaft housing.
6. INSPECT CAMSHAFT TIMING GEAR Install the camshaft bearing caps (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). HINT: Only install the intake camshaft. Install the camshaft housing (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Apply a light coat of engine oil to the camshaft and camshaft timing gear. Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing gear. NOTE: Do not forcefully push on the camshaft timing gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear. Do not loosen or remove the 3 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing gear assembly with a new one. Apply a light coat of engine oil to the threads and under the head of the bolt. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear with the bolt. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the camshaft bearing caps (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Check the lock of the camshaft timing gear. Make sure that the camshaft timing gear is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. Break through the tape of the advance side path and retard side path as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2, 29 psi) of air pressure to the two broken paths. NOTE: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path. HINT: This operation releases the lock pin for the most retarded position. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order. NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE: Do not use air pressure to perform the smooth rotation check. Check the lock in the most retarded position. Confirm that the camshaft timing gear is locked at the most retarded position. Install the camshaft bearing caps (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). HINT: Only install the intake camshaft. Install the camshaft housing (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. Remove the camshaft bearing caps (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Remove the flange bolt and camshaft timing gear.
7. INSPECT CAMSHAFT TIMING EXHAUST GEAR Install the camshaft bearing caps (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). HINT: Only install the exhaust camshaft. Install the camshaft housing (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Apply a light coat of engine oil to the camshaft and camshaft timing exhaust gear. Using the hexagonal portion of the camshaft, align and attach the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear. NOTE: Do not forcefully push on the camshaft timing exhaust gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear. Do not loosen or remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing exhaust gear assembly with a new one. Apply a light coat of engine oil to the threads and under the head of the bolt. Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear with the bolt. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Remove the camshaft bearing caps (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear is locked. Release the lock pin. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. Break through the tape of the advance side path and retard side path as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2, 29 psi) of air pressure to the two broken paths (the advance side path and the retard side path). NOTE: Cover the paths with a piece of cloth when applying pressure to keep oil from splashing. Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path. HINT: The lock pin is released and the camshaft timing exhaust gear turns in the retard direction. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear is locked at the most advanced position. Install the camshaft bearing caps (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). HINT: Only install the exhaust camshaft. Install the camshaft housing (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt. Remove the camshaft bearing caps (See «REMOVAL»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Remove the flange bolt and camshaft timing exhaust gear.
8. INSPECT NO. 1 CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation: 136.9 mm (5.39 in.) HINT: Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the No. 1 chain.
9. INSPECT NO. 2 CHAIN SUB-ASSEMBLY Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33.0 lbf) as shown in the illustration. Using a vernier caliper, measure the length of 15 pins. Maximum chain elongation: 137.6 mm (5.42 in.) HINT: Perform the measurement at 3 random places. If the elongation is more than the maximum, replace the No. 2 chain.
10. INSPECT CRANKSHAFT TIMING SPROCKET RH Wrap the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 61.4 mm (2.42 in.) If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket RH. HINT: The vernier caliper must contact the chain rollers for the measurement.
11. INSPECT CRANKSHAFT TIMING SPROCKET LH Wrap the chain around the sprocket. Using a vernier caliper, measure the sprocket diameter with the chain. Minimum sprocket diameter (with chain): 61.4 mm (2.42 in.) If the diameter is less than the minimum, replace the chain and crankshaft timing sprocket LH. HINT: The vernier caliper must contact the chain rollers for the measurement.
12. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY Move the stopper plate clockwise to release the lock. Push the plunger and check that it moves smoothly. If necessary, replace the No. 1 chain tensioner.
13. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner. Maximum depth: 0.9 mm (0.0354 in.) If the depth is more than the maximum, replace the No. 2 chain tensioner.
14. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY Check that the plunger moves smoothly. Measure the worn depth of the chain tensioner. Maximum depth: 0.9 mm (0.0354 in.) If the depth is more than the maximum, replace the No. 3 chain tensioner.
15. INSPECT NO. 1 CHAIN TENSIONER SLIPPER for LH: Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain tensioner slipper. for RH: Measure the worn depth of the chain tensioner slipper. Maximum depth: 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain tensioner slipper.
16. INSPECT NO. 1 CHAIN VIBRATION DAMPER for LH: Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain vibration damper. for RH: Measure the worn depth of the chain vibration damper. Maximum depth: 1.0 mm (0.0394 in.) If the depth is more than the maximum, replace the No. 1 chain vibration damper.
17. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold LH contacts the cylinder head. Maximum warpage: 0.7 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold LH.
18. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH Using a precision straightedge and feeler gauge, measure the warpage of the surface where the exhaust manifold RH contacts the cylinder head. Maximum warpage: 0.7 mm (0.0276 in.) If the warpage is more than the maximum, replace the exhaust manifold RH.

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1. INSTALL STUD BOLT Install the timing chain cover stud bolt. Using an E10 "TORX" socket wrench, install the 2 stud bolts as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the oil pan stud bolt. Using an E6 and E7 "TORX" socket wrench, install the 3 stud bolts as shown in the illustration. Torque: for stud bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) for stud bolt B 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL RING PIN Using a plastic-faced hammer, tap in new ring pins to the timing chain cover. Standard Protrusion STANDARD PROTRUSION Item Ring Pin Diameter Specified Condition Ring pin A 13 mm (0.512 in.) 7.5 to 8.5 mm (0.295 to 0.335 in.) Ring pin B 11 mm (0.433 in.) 3.6 to 4.6 mm (0.142 to 0.181 In.)
3. INSTALL REAR CRANKSHAFT OIL SEAL Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100) Standard depth: 0 to 1.0 mm (0 to 0.0394 in.) NOTE: Keep the lip free from foreign matter. Do not tap on the oil seal at an angle.
4. INSTALL OIL DRAIN PIPE SUB-ASSEMBLY Apply a light coat of engine oil to a new O-ring. Install the O-ring to the drain pipe. Install the oil drain pipe with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
5. INSTALL ENGINE REAR OIL SEAL RETAINER Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard Seal diameter: 2.0 to 3.0 mm (0.0787 to 0.118 in.) Application position from inside edge of retainer: 3.5 mm (0.138 in.) NOTE: Remove any oil from the contact surface. Install the oil seal retainer within 3 minutes and tighten the bolts within 15 minutes after applying seal packing. Install the oil seal retainer with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Do not start the engine for at least 2 hours after installing. When installing the oil seal retainer, make sure the lip of the oil seal is not damaged. When installing the oil seal retainer, make sure the lip of the oil seal is not folded incorrectly.
6. INSTALL OIL STRAINER SUB-ASSEMBLY Apply a light coat of engine oil to a new O-ring. Install the O-ring to the oil strainer. Install the oil strainer with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Make sure the O-ring is not twisted or damaged.
7. INSTALL NO. 1 OIL PAN BAFFLE PLATE Install the baffle plate with the 7 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
8. INSTALL NO. 1 OIL PAN SUB-ASSEMBLY Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Install the oil pan with the 14 bolts and 2 nuts. Torque: for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt B 35 N*m (357 kgf*cm, 26 ft.*lbf) for nut 35 N*m (357 kgf*cm, 26 ft.*lbf) NOTE: Do not start the engine for at least 2 hours after installing. Standard Bolt OIL PAN STANDARD BOLTS Item Length Thread Diameter Bolt A 92 mm (3.62 in.) 6 mm (0.236 in.) Bolt B 30 mm (1.18 in.) 10 mm (0.394 in.)
9. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Standard seal diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the oil pan within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Install the oil pan with the 14 bolts and 2 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) NOTE: Do not start the engine for at least 2 hours after installing. W/ Oil Level Sensor: Install the engine oil level sensor (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) ).
10. INSTALL NO. 1 HEAT EXCHANGER COVER Apply seal packing in a continuous line as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent Standard seal diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTE: Remove any oil from the contact surface. Install the heat exchanger cover within 3 minutes and tighten the bolts and nuts within 15 minutes after applying seal packing. Install the heat exchanger cover with the 12 bolts and 2 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE: Do not start the engine for at least 2 hours after installing. Standard Bolt HEAT EXCHANGER COVER STANDARD BOLT Item Length Thread Diameter Bolt A 20 mm (0.787 in.) 8 mm (0.315 in.) Bolt B 70 mm (2.76 in.) 8 mm (0.315 in.) Bolt C 16 mm (0.630 in.) 6 mm (0.236 in.)
11. INSTALL VENTILATION PIPE GASKET Using SST, evenly tap in a new ventilation pipe gasket until its surface is flush with the lip of the ventilation pipe. SST 09950-60010 (09951-00360), 09950-70010 (09951-07100) NOTE: Do not tap the gasket at an angle. Do not tap the gasket excessively.
12. INSTALL CYLINDER BLOCK WATER JACKET SPACER Install the 2 water jacket spacers as shown in the illustration. HINT: Face the cutouts indicated by the arrows in illustration away from the engine. Face the "UP" mark as shown in the illustration.
13. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
14. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
15. INSTALL VALVE STEM CAP Apply a light coat of engine oil to the valve stem caps. Install the 32 valve stem caps to the cylinder heads.
16. INSTALL VALVE LASH ADJUSTER ASSEMBLY Inspect the valve lash adjuster before installing it (See «INSPECTION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Install the 32 valve lash adjusters to the cylinder heads. NOTE: Install the lash adjuster to the same place it was removed from.
17. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY Apply engine oil to the lash adjuster tips and valve stem cap ends. Install the 32 valve rocker arms as shown in the illustration.
18. INSTALL CAMSHAFT BEARING CAP RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
19. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
20. INSTALL CAMSHAFT BEARING CAP LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
21. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) )
22. INSTALL CRANKSHAFT TIMING GEAR KEY Install the timing gear key. HINT: The other timing gear key will be installed at a later step.
23. SET NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt. Rotate the crankshaft so that the timing gear key is as shown in the illustration. Then using a wrench, rotate each camshaft so that the timing marks are as shown in the illustration. NOTE: When the crankshaft or a camshaft is rotated excessively, the valves and pistons may interfere with each other. Remove the crankshaft pulley bolt.
24. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) While raising up the No. 2 chain tensioner, insert a pin of with a diameter of 1.0 mm (0.0394 in.) into the hole to fix it in place.
25. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH Align the No. 1 chain orange mark plates with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration. HINT: The crankshaft timing sprocket RH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears. Install the crankshaft timing sprocket RH to the crankshaft. Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear. Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear. Remove the pin from the No. 2 chain tensioner. Using a wrench to hold the hexagonal portion of the No. 1 camshaft, temporarily install the bolt. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, temporarily install the bolt.
26. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH Install the vibration damper with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
27. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.
28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Remove the hexagon wrench from the chain tensioner.
29. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY Install the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) While pushing down the No. 2 chain tensioner, insert a pin of with a diameter of 1.0 mm (0.0394 in.) into the hole to fix it in place.
30. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH Align the No. 1 chain orange mark plates with the camshaft timing gear timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 1 chain orange mark plate with the crankshaft timing sprocket timing mark, and attach the chain to the gear as shown in the illustration. Align the No. 2 chain yellow mark plates with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration. HINT: The crankshaft timing sprocket LH and camshaft timing exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears. Install the crankshaft timing sprocket LH to the crankshaft. Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear. Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear. NOTE: Because the timing mark positions of the gears may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed. Remove the pin from the No. 3 chain tensioner. Using a wrench to hold the hexagonal portion of the No. 3 camshaft, temporarily install the bolt. Using a wrench to hold the hexagonal portion of the No. 4 camshaft, temporarily install the bolt.
31. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and install the chain tensioner slipper.
32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner. Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate. Install a new gasket and the chain tensioner with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
33. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH Install the vibration damper with the 2 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Remove the hexagon wrench from the No. 1 chain tensioner.
34. TIGHTEN CAMSHAFT TIMING GEAR for Bank 1: Using a wrench, hold the hexagonal portion of the No. 3 camshaft. Tighten the bolt of the camshaft timing gear. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the bolt of the camshaft timing exhaust gear. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) for Bank 2: Using a wrench, hold the hexagonal portion of the No. 1 camshaft. Tighten the bolt of the camshaft timing gear. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the bolt of the camshaft timing exhaust gear. Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
35. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION Temporarily install the crankshaft pulley bolt. Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration. Remove the crankshaft pulley bolt.
36. INSTALL WATER INLET PIPE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
37. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
38. INSTALL WATER PUMP ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
39. INSTALL FRONT CRANKSHAFT OIL SEAL Apply MP grease to the lip of a new oil seal. Using SST and a hammer, tap in the oil seal to a depth between 0 and 1.0 mm (0 and 0.0394 in.) from the timing chain cover edge. SST 09223-22010, 09506-35010 NOTE: Keep the lip free from foreign matter. Do not tap the oil seal at an angle.
40. INSTALL CRANKSHAFT TIMING GEAR KEY Install the crankshaft timing gear key to the crankshaft.
41. INSTALL CRANKSHAFT PULLEY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
42. INSTALL SPARK PLUG TUBE GASKET Using a cutter knife, cut off the seal part of the removed gasket. Using the removed gasket and a hammer, tap in a new gasket until it stops. HINT: If the removed gasket does not fit on the new one, correct the removed one with pliers. Apply a light coat of MP grease to the lip of the gasket. Return the 4 ventilation baffle plate claws to the original positions.
43. INSTALL OIL CONTROL VALVE FILTER LH: Install the filter in the cylinder head. Install a new gasket and the cylinder head cover spacer with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) RH: Install the filter in the cylinder head. Install a new gasket and the cylinder head cover spacer with the 3 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
46. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
47. INSTALL WATER PUMP PULLEY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/cooling-fan/#engine-cooling-system) )
48. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY for Bank 1: Apply a light coat of engine oil to 2 new O-rings. Install the 2 O-rings to the 2 oil control valves. Install the 2 oil control valves with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for Bank 2: Apply a light coat of engine oil to 2 new O-rings. Install the 2 O-rings to the 2 oil control valves. Install the 2 oil control valves with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
49. INSTALL CRANKSHAFT POSITION SENSOR Install the crankshaft position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
50. INSTALL CRANK POSITION SENSOR PROTECTOR Install the sensor protector with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
51. INSTALL CAMSHAFT POSITION SENSOR Install the camshaft position sensor with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
52. INSTALL VVT SENSOR for Bank 1: Install the 2 VVT sensors with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for Bank 2: Install the 2 VVT sensors with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
53. INSTALL SPARK PLUG Using a 16 mm plug wrench, install the 8 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
54. INSTALL OIL FILLER CAP HOUSING Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing. Install the cap housing with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
55. INSTALL OIL FILLER CAP SUB-ASSEMBLY
56. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
57. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
58. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
59. INSTALL OIL FILTER ELEMENT (See «REPLACEMENT»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__replacement) )
60. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system__installation) )

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1. INSTALL NOISE FILTER RH: Install the noise filter to the cylinder head cover with the bolt. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) LH: Install the noise filter to the cylinder head cover with the bolt. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
2. INSTALL IGNITION COIL ASSEMBLY Install the 8 ignition coils with the 8 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Install the mounting bracket with the 4 bolts. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
4. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH Install the mounting bracket with the 4 bolts. Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
5. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY Apply adhesive to 2 or 3 threads of the drain cocks. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Install the water drain cocks as shown in the illustration. Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) NOTE: Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque. Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them. Install the water drain cock plugs to the water drain cocks. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
6. INSTALL KNOCK SENSOR Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) NOTE: The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position.
7. INSTALL SEPARATOR CASE After inserting the pipe on the rear of the separator case into the oil return pipe and the pipe on the front into the ventilation pipe, temporarily install bolt A. Temporarily install bolt B and tighten bolt A. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the bolts labeled C. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Tighten bolt B. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Standard Bolt STANDARD BOLT DIMENSION Item Length Thread Diameter Bolt A 25 mm (0.984 in.) 6 mm (0.236 in.) Bolt B and C 16 mm (0.630 in.) 6 mm (0.236 in.)
8. INSTALL ENGINE WIRE Connect the 3 clamps and 4 knock sensor connectors.
9. INSTALL NO. 3 AIR TUBE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
10. INSTALL NO. 2 AIR TUBE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
11. INSTALL AIR SWITCHING VALVE ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY Install the water by-pass pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
13. INSTALL WATER INLET HOUSING (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
14. INSTALL AIR PIPE SUB-ASSEMBLY Install the 2 No. 1 air hoses and air pipe with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
15. INSTALL FRONT WATER BY-PASS JOINT (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
16. INSTALL NO. 1 WATER BY-PASS HOSE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
17. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/lubrication-system/#engine-lubrication-system) )
18. INSTALL NO. 1 ENGINE COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
19. INSTALL NO. 2 ENGINE COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/auxiliary-emission-control-systems/#emission-control-system) )
20. INSTALL NO. 1 FUEL TUBE
21. INSTALL NO. 2 FUEL TUBE Install the No. 2 fuel tube with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
22. INSTALL INTAKE MANIFOLD Place 2 new gaskets on the intake manifold. Place the intake manifold on the cylinder head. Install and uniformly tighten the 8 bolts and 2 nuts in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the wire bracket to the intake manifold with the bolt. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) Connect the No. 1 ventilation hose. Connect the 2 water by-pass hoses. Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
23. INSTALL FUEL INJECTOR ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
24. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY RH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY LH (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
26. CONNECT NO. 1 FUEL TUBE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
27. CONNECT NO. 2 FUEL TUBE (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
28. INSTALL NO. 1 FUEL HOSE Install the fuel hose (See «FUEL SYSTEM»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system) ).
29. INSTALL NO. 3 ENGINE COVER (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
30. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (See «INSTALLATION»(/toyota/land-cruiser/200-2007-2012/remont/fuel-system/#engine-fuel-system__installation) )
31. INSTALL ENGINE WIRE Install the engine wire. Engine Rear Side: Install the 3 bolts as shown in the illustration. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) Connect the 5 clamps. Connect the 2 air switching valve connectors. Engine RH Side: Connect the 10 clamps. W/ Oil Level Sensor: Connect the oil level sensor connector. Connect the oil pressure sender gauge connector. Connect the throttle sensor connector. Connect the noise filter connector. Connect the fuel injector connector. Connect the 2 VVT sensor connectors. HINT: The wire harnesses on the exhaust side are wrapped with white tape. Connect the 4 ignition coil connectors. Connect the 2 camshaft timing control valve connectors. HINT: The wire harnesses on the exhaust side are wrapped with white tape. Engine LH Side: Connect the 7 clamps and install the engine wire with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Connect the noise filter connector. Connect the fuel injector connector. Connect the engine coolant temperature sensor connector. Connect the purge VSV connector. Connect the vacuum switching valve connector (for ACIS). Connect the camshaft position sensor connector. Connect the 2 VVT sensor connectors. HINT: The wire harnesses on the exhaust side are wrapped with white tape. Connect the 4 ignition coil connectors. Connect the 2 camshaft timing control valve connectors. HINT: The wire harnesses on the exhaust side are wrapped with white tape.

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1. REMOVE INTAKE VALVE Using SST and wooden blocks, compress the compression spring and remove the valve spring retainer locks. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order.
2. REMOVE EXHAUST VALVE Using SST and wooden blocks, compress the compression spring and remove the valve spring retainer locks. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) Remove the retainer, compression spring and valve. HINT: Arrange the removed parts in the correct order.
3. REMOVE VALVE STEM OIL SEAL Using needle-nose pliers, remove the oil seals.
4. REMOVE VALVE SPRING SEAT Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.
5. REMOVE NO. 1 STRAIGHT SCREW PLUG NOTE: If water leaks from the No. 1 straight screw plug or the plug is corroded, replace it. Using a 10 mm hexagon wrench, remove the 6 screw plugs and 6 gaskets.
6. REMOVE NO. 2 STRAIGHT SCREW PLUG NOTE: If water leaks from the No. 2 straight screw plug or the plug is corroded, replace it. Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets.
7. REMOVE STUD BOLT NOTE: If the stud bolt is deformed or its threads are damaged, replace it.

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1. INSPECT CYLINDER HEAD SUB-ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage of the surfaces where the cylinder head contacts the cylinder block and manifold. Standard Warpage STANDARD WARPAGE SPECIFICATION Item Specified Condition Cylinder head lower side 0.05 mm (0.00197 in.) Intake side 0.08 mm (0.00315 in.) Exhaust side 0.05 mm (0.00197 in.) Maximum warpage: 0.10 mm (0.00394 in.) If the warpage is more than the maximum, replace the cylinder head. Using a dye penetrant, check the intake ports, exhaust ports and cylinder surface for cracks. If cracked, replace the cylinder head.
2. INSPECT INTAKE VALVE Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 5.470 to 5.485 mm (0.215 to 0.216 in.) If the diameter is not as specified, replace the valve and guide bush. Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness: 1.25 mm (0.0492 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the intake valve. Using a vernier caliper, measure the valve overall length. Standard overall length: 105.85 mm (4.17 in.) Minimum overall length: 105.35 mm (4.15 in.) If the overall length is less than the minimum, replace the intake valve.
3. INSPECT EXHAUST VALVE Using a micrometer, measure the diameter of the valve stem. Standard valve stem diameter: 5.465 to 5.480 mm (0.215 to 0.216 in.) If the diameter is not as specified, replace the valve and guide bush. Using a vernier caliper, measure the valve head margin thickness. Standard margin thickness: 1.4 mm (0.0551 in.) Minimum margin thickness: 0.50 mm (0.0197 in.) If the margin thickness is less than the minimum, replace the exhaust valve. Using a vernier caliper, measure the valve overall length. Standard overall length: 110.40 mm (4.35 in.) Minimum overall length: 109.90 mm (4.33 in.) If the overall length is less than the minimum, replace the exhaust valve.
4. INSPECT INTAKE VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. HINT: Do not rotate the valve while pressing the valve. Check the valve face and valve seat. Check that the contact surfaces of the valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.). If not, correct the valve seat. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat.
5. INSPECT EXHAUST VALVE SEAT Apply a light coat of Prussian blue to the valve face. Lightly press the valve face against the valve seat. HINT: Do not rotate the valve while pressing the valve. Check the valve face and valve seat. Check that the contact surfaces of the valve seat and valve face are in the middle area of their respective surfaces, with the width between 1.1 and 1.5 mm (0.0433 and 0.0591 in.). If not, correct the valve seat. Check that the contact surfaces of the valve seat and valve face are even around the entire valve seat. If not, correct the valve seat.
6. INSPECT COMPRESSION SPRING Using a vernier caliper, measure the free length of the inner compression spring. Standard free length: 49.39 mm (1.94 in.) If the free length is not as specified, replace the spring. Using a steel square, measure the deviation of the inner compression spring. Maximum deviation: 1.0 mm (0.0394 in.) Maximum angle (reference): 2° If the deviation is more than the maximum, replace the spring.
7. INSPECT VALVE GUIDE BUSH OIL CLEARANCE Using a caliper gauge, measure the inside diameter of the guide bush. Standard bush inside diameter: 5.51 to 5.53 mm (0.217 to 0.218 in.) Subtract the valve stem diameter measurement from the guide bush inside diameter measurement. Standard Oil Clearance STANDARD OIL CLEARANCE REFERENCE Item Specified Condition Intake 0.025 to 0.060 mm (0.000984 to 0.00236 in.) Exhaust 0.030 to 0.065 mm (0.00118 to 0.00256 in.) Maximum Oil Clearance MAXIMUM OIL CLEARANCE REFERENCE Item Specified Condition Intake 0.08 mm (0.00315 in.) Exhaust 0.10 mm (0.00394 in.) If the oil clearance is more than the maximum, replace the valve and guide bush.
8. INSPECT CAMSHAFT THRUST CLEARANCE Inspect the bank 1 camshafts. Install the bank 1 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.135 mm (0.00315 to 0.00531 in.) Maximum thrust clearance: 0.15 mm (0.00591 in.) If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft. Inspect the bank 2 camshafts. Install the bank 2 camshafts. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.08 to 0.135 mm (0.00315 to 0.00531 in.) Maximum thrust clearance: 0.15 mm (0.00591 in.) If the thrust clearance is more than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

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1. REPLACE INTAKE VALVE GUIDE BUSH Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the valve guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Using a caliper gauge, measure the bush bore diameter of the cylinder head side. Standard bush bore diameter: 10.285 to 10.306 mm (0.405 to 0.406 in.) If the bush bore diameter of the cylinder head is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step. If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head. Select a new guide bush (STD or O/S 0.05), and measure its diameter. Machine the bush bore diameter of the cylinder head side to the diameter of the selected guide bush. Bush Bore Diameter BUSH BORE DIAMETER DIMENSION Bush Size Specified Condition STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Standard bush length: 41.3 to 41.7 mm (1.63 to 1.64 in.) Using SST and a hammer, tap in a new guide bush to the standard protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Standard protrusion height: 14.3 to 14.7 mm (0.563 to 0.579 in.) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem. Standard oil clearance: 0.025 to 0.060 mm (0.000984 to 0.00236 in.)
2. REPLACE EXHAUST VALVE GUIDE BUSH Heat the cylinder head to approximately 80 to 100°C (176 to 212°F). Place the cylinder head on wooden blocks. Using SST and a hammer, tap out the valve guide bush. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Using a caliper gauge, measure the bush bore diameter of the cylinder head. Standard bush bore diameter: 10.285 to 10.306 mm (0.405 to 0.406 in.) If the bush bore diameter of the cylinder head is between 10.285 and 10.306 mm (0.405 and 0.406 in.), proceed to the next step. If the bush bore diameter of the cylinder head is 10.356 mm (0.408 in.) or more, replace the cylinder head. Select a new guide bush (STD or O/S 0.05), and measure its diameter. Machine the bush bore diameter of the cylinder head side to the diameter of the selected guide bush. Bush Bore Diameter BUSH BORE DIAMETER DIMENSION Bush Size Specified Condition STD 10.333 to 10.344 mm (0.4068 to 0.4072 in.) O/S 0.05 10.383 to 10.394 mm (0.4088 to 0.4092 in.) Standard bush length: 46.8 to 47.2 mm (1.84 to 1.86 in.) Using SST and a hammer, tap in a new guide bush to the standard protrusion height. SST 09201-10000 (09201-01050), 09950-70010 (09951-07100) Standard protrusion height: 14.3 to 14.7 mm (0.563 to 0.579 in.) Using a sharp 5.5 mm reamer, ream the guide bush to obtain the standard oil clearance between the guide bush and valve stem. Standard oil clearance: 0.030 to 0.065 mm (0.00118 to 0.00256 in.)
3. REPLACE SPARK PLUG TUBE HINT: When using a new cylinder head, the spark plug tubes must be replaced. Remove the spark plug tube. Apply adhesive to the end of a new spark plug tube. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent. Standard seal diameter: 15 mm (0.591 in.) NOTE: Install the spark plug tube within 3 minutes after applying adhesive. Be careful not to deform the spark plug tube. Be careful not to expose the seal to coolant for at least 1 hour after installing it. Using a wooden block and hammer, tap in the spark plug tube to the specified protrusion height. Standard protrusion height: 75.1 to 76.1 mm (2.96 to 3.00 in.) NOTE: To avoid tapping in the spark plug tube too far, measure the protrusion height while tapping it.
4. REPLACE RING PIN NOTE: It is not necessary to remove the ring pin unless it is being replaced. Remove the ring pins. Using a plastic-faced hammer, tap in new ring pins to the cylinder head. Standard Protrusion STANDARD PROTRUSION RING PIN Item Specified Condition Ring pin A 5.5 to 6.5 mm (0.217 to 0.256 in.) Ring pin B 3.5 to 6.5 mm (0.138 to 0.256 in.)

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1. INSTALL STUD BOLT Using E7 and E8 "TORX" socket wrenches, install the stud bolts. Torque: for stud bolts A, B, C and D 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL NO. 2 STRAIGHT SCREW PLUG Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs. Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
3. INSTALL NO. 1 STRAIGHT SCREW PLUG Using a 10 mm hexagon wrench, install 6 new gaskets and the 6 straight screw plugs. Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
4. INSTALL VALVE SPRING SEAT Install the valve spring seats to the cylinder head.
5. INSTALL VALVE STEM OIL SEAL Apply a light coat of engine oil to new oil seals. NOTE: Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal into the intake side can cause installation problems later. HINT: The intake valve oil seals are brown and the exhaust valve oil seals are gray. Using SST, push in the oil seals. SST 09201-41020 NOTE: Failure to use SST will cause the seal to be damaged or improperly seated.
6. INSTALL INTAKE VALVE Apply plenty of engine oil to the tip area of the intake valve shown in the illustration. Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the spring and install the retainer locks. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.
7. INSTALL EXHAUST VALVE Apply plenty of engine oil to the tip area of the exhaust valve shown in the illustration. Install the valve, compression spring and spring retainer to the cylinder head. NOTE: Install the same parts in the same combination to their original locations. Using SST and wooden blocks, compress the spring and install the retainer locks. SST 09202-70020 (09202-00010, 09202-01010, 09202-01020) Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit. NOTE: Be careful not to damage the retainer.

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1. REPAIR INTAKE VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Standard width: 1.1 to 1.5 mm (0.0433 to 0.0591 in.) Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.
2. REPAIR EXHAUST VALVE SEAT NOTE: Repair the seat while checking the seating position. Keep the lip free of foreign matter. Using a 45° cutter, resurface the valve seat so that the valve seat width is more than the specification. Using 30° and 60° cutters, correct the valve seat so that the valve contacts the entire circumference of the seat. The contact should be in the center of the valve seat, and the valve seat width should be maintained within the specified range around the entire circumference of the seat. Standard width: 1.1 to 1.5 mm (0.0433 to 0.0591 in.) Hand-lap the valve and valve seat with an abrasive compound. Check the valve seating position.

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Scheme 347

1. INSPECT CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 to 0.55 mm (0.00591 to 0.0217 in.) Maximum thrust clearance: 0.70 mm (0.0276 in.) If the thrust clearance is more than the maximum, replace one or more connecting rods as necessary. If necessary, replace the crankshaft.
2. INSPECT CONNECTING ROD OIL CLEARANCE Check that the front mark on the connecting rod and cap are aligned to ensure correct reassembly. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Check the crank pin and bearing for pitting and scratches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. Clean the crank pin and bearing. Lay a strip of Plastigage on the crank pin. Place the connecting rod cap on the connecting rod with the front mark facing forward. Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) NOTE: Do not turn the crankshaft. Mark the front side of each connecting rod cap bolt with paint. Tighten the cap bolts 90° as shown in the illustration. Check that the painted marks are now at a 90° angle to the front. NOTE: Do not turn the crankshaft. Remove the 2 connecting rod cap bolts. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted to the connecting rod cap. Measure the Plastigage at its widest point. Standard oil clearance: 0.025 to 0.050 mm (0.000984 to 0.00197 in.) Maximum oil clearance: 0.070 mm (0.00276 in.) If the oil clearance is more than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number as its respective connecting rod cap. The standard thickness of each bearing is indicated by a 1, 2, 3 or 4 mark on its surface. Select the correct bearing by adding together the number marks imprinted on the connecting rod big end and crank pin. Example: Connecting rod "1" + Crank pin "2" = 3 (Use bearing "3") Reference: Standard Sized Bearing Center Wall Thickness STANDARD SIZED BEARING CENTER WALL THICKNESS REFERENCE CHART Mark Thickness 2 1.489 to 1.492 mm (0.0586 to 0.0587 In.) 3 1.492 to 1.495 mm (0.0587 to 0.0589 in.) 4 1.495 to 1.498 mm (0.0589 to 0.0590 in.) 5 1.498 to 1.501 mm (0.0590 to 0.0591 in.) 6 1.501 to 1.504 mm (0.0591 to 0.0592 in.) 7 1.504 to 1.507 mm (0.0592 to 0.0593 in.) Connecting Rod Big End Inside Diameter CONNECTING ROD BIG END INSIDE DIAMETER THICKNESS REFERENCE CHART Mark Thickness 1 59.000 to 59.006 mm (2.32283 to 2.32307 in.) 2 59.006 to 59.012 mm (2.32307 to 2.32330 in.) 3 59.012 to 59.018 mm (2.32330 to 2.32354 in.) 4 59.018 to 59.024 mm (2.32354 to 2.32377 in.) Crankshaft Pin Diameter CRANKSHAFT PIN DIAMETER THICKNESS REFERENCE CHART Mark Thickness 1 55.994 to 56.000 mm (2.20448 to 2.20472 in.) 2 55.988 to 55.994 mm (2.20425 to 2.20448 in.) 3 55.982 to 55.988 mm (2.20401 to 2.20425 in.) Completely remove the Plastigage. Perform the inspection above for each cylinder.
3. REMOVE PISTON AND CONNECTING ROD Using a ridge reamer, remove all the carbon from the top of the cylinder. Remove the 16 cap bolts, 8 connecting rod caps and 8 lower bearings. Push the 8 pistons and 8 connecting rods through the top of the cylinder block. HINT: Keep the bearing, connecting rod and cap together. Arrange the piston and connecting rods in the correct order.
4. REMOVE CONNECTING ROD BEARING Remove the connecting rod bearings from the connecting rods and connecting rod caps. HINT: Arrange the removed parts in the correct order.
5. INSPECT CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 to 0.220 mm (0.000787 to 0.00866 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is more than the maximum, replace the thrust washers as a set. If necessary, replace the crankshaft. Standard thrust washer thickness: 2.44 to 2.49 mm (0.0961 to 0.0980 in.)
6. REMOVE CRANKSHAFT Uniformly loosen and remove the 10 bearing cap bolts and 10 seal washers in several steps in the sequence shown in the illustration. Uniformly loosen and remove the 20 bearing cap bolts in several steps in the sequence shown in the illustration. Using a screwdriver, slightly pry up the 5 main bearing caps. NOTE: Be careful not to damage the joint surface of the cylinder block and main bearing caps. Pry up the left and right side of the cap little by little. HINT: Tape the screwdriver tip before use. Using the 2 inside position crankshaft bearing cap bolts, loosen each crankshaft bearing cap by moving it forward and backward, and remove each crankshaft bearing cap. Remove the crankshaft.
7. REMOVE CRANKSHAFT BEARING Remove the crankshaft bearings from the bearing caps and cylinder block. HINT: Arrange the removed parts in the correct order.
8. REMOVE CRANKSHAFT THRUST WASHER SET Remove the thrust washer set from the cylinder block and No. 3 bearing cap.
9. REMOVE NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, remove the 4 bolts and 4 oil nozzles.
10. REMOVE PISTON RING SET HINT: Arrange the piston rings in the correct order. Using a piston ring expander, remove the 2 compression rings. Remove the 2 side rails and oil ring expander by hand.
11. REMOVE PISTON WITH PIN SUB-ASSEMBLY Disconnect the connecting rod from the piston. Using a small screwdriver, pry off the 2 snap rings from the piston. Gradually heat the piston to approximately 80°C (176°F). Using a brass bar and plastic-faced hammer, lightly tap out the piston pin. Then remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order. Clean the piston. Using a gasket scraper, remove the carbon from the piston top. Using a groove cleaning tool or broken ring, clean the piston ring grooves. Using solvent and a brush, thoroughly clean the piston. NOTE: Do not use a wire brush.
12. REMOVE STUD BOLT NOTE: If the stud bolt is deformed or its threads are damaged, replace it.

Scheme 348

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Scheme 354

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Scheme 371

1. INSPECT NO. 1 OIL NOZZLE SUB-ASSEMBLY Push the check valve with a pin to check if it is stuck. If stuck, replace the No. 1 oil nozzle sub-assembly. Push the check valve with a pin to check if it moves smoothly. If it does not move smoothly, clean or replace the No. 1 oil nozzle sub-assembly. While covering A, apply air into B. Check that air does not leak through C. Perform the check again while covering B and applying air into A. If air leaks, clean or replace the No. 1 oil nozzle sub-assembly. Push the check valve while covering A, and apply air into B. Check that air passes through C. Perform the check again while covering B, pushing the check valve and applying air into A. If air does not pass through C, clean or replace the No. 1 oil nozzle sub-assembly.
2. CHECK CYLINDER BLOCK SUB-ASSEMBLY Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all 8 cylinders. If necessary, replace the cylinder block.
3. INSPECT CYLINDER BLOCK FOR WARPAGE Using a precision straightedge and feeler gauge, measure the warpage of the surfaces where the cylinder head gaskets contact the cylinder block. Maximum warpage: 0.07 mm (0.00276 in.) If the warpage is more than the maximum, replace the cylinder block.
4. INSPECT CYLINDER BORE Using a cylinder gauge, measure the cylinder bore diameter at positions A and B in the thrust and axial directions. Standard diameter: 94.000 to 94.012 mm (3.7008 to 3.7013 in.) Maximum diameter: 94.200 mm (3.7087 in.) If the diameter is more than the maximum, replace the cylinder block.
5. INSPECT PISTON SUB-ASSEMBLY WITH PIN Using a micrometer, measure the piston diameter at a position that is 15.0 mm (0.591 in.) from the bottom of the piston (Scheme 354) Standard diameter: 93.950 to 93.960 mm (3.6988 to 3.6992 in.) Minimum diameter: 93.815 mm (3.6935 in.) If the diameter is less than the minimum, replace the piston.
6. INSPECT PISTON OIL CLEARANCE Measure the cylinder bore diameter in the thrust direction. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.020 to 0.072 mm (0.000787 to 0.00283 in.) Maximum oil clearance: 0.385 mm (0.0152 in.) If the oil clearance is more than the maximum, replace all the pistons. If necessary, replace the cylinder block.
7. INSPECT RING GROOVE CLEARANCE Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove. Standard Ring Groove Clearance STANDARD RING GROOVE CLEARANCE REFERENCE Item Specified Condition No. 1 ring 0.020 to 0.070 mm (0.000787 to 0.00276 in.) No. 2 ring 0.020 to 0.060 mm (0.000787 to 0.00236 in.) Oil ring expander 0.070 to 0.145 mm (0.00276 to 0.00571 in.) If the clearance is not as specified, replace the piston.
8. INSPECT PISTON RING END GAP Insert the piston ring into the cylinder bore. Using a piston, push the piston ring a little beyond the bottom of the ring travel, 60 mm (2.36 in.) from the top of the cylinder block. Using a feeler gauge, measure the end gap. Standard End Gap STANDARD END GAP Item Specified Condition No. 1 ring 0.25 to 0.35 mm (0.00984 to 0.0138 in.) No. 2 ring 0.40 to 0.50 mm (0.0157 to 0.0197 in.) Oil ring expander 0.10 to 0.40 mm (0.00394 to 0.0157 in.) Maximum End Gap MAXIMUM END GAP Item Specified Condition No. 1 ring 0.42 mm (0.0165 in.) No. 2 ring 0.55 mm (0.0217 in.) Oil ring expander 0.45 mm (0.0177 in.) If the end gap is more than the maximum, replace the piston ring. If the end gap is more than the maximum even with a new piston ring, replace the cylinder block.
9. INSPECT PISTON PIN OIL CLEARANCE Check each mark on the piston, piston pin and connecting rod. Using a caliper gauge, measure the inside diameter of the piston pin hole. Standard Piston Pin Hole Inside Diameter PISTON PIN HOLE DIMENSION Mark Specified Condition A 21.998 to 22.001 mm (0.86606 to 0.86618 in.) B 22.001 to 22.004 mm (0.86618 to 0.86630 in.) C 22.004 to 22.007 mm (0.86630 to 0.86642 in.) Using a micrometer, measure the piston pin diameter. Standard Piston Pin Diameter STANDARD PISTON PIN DIAMETER Mark Specified Condition A 21.997 to 22.000 mm (0.86602 to 0.86614 in.) B 22.000 to 22.003 mm (0.86614 to 0.86626 in.) C 22.003 to 22.006 mm (0.86626 to 0.86638 in.) Subtract the piston pin diameter measurement from the piston pin hole diameter measurement. Standard oil clearance: -0.002 to 0.004 mm (-0.0000787 to 0.000157 in.) Maximum oil clearance: 0.015 mm (0.000591 in.) If the oil clearance is more than the maximum, replace the piston and piston pin as a set. Using a caliper gauge, measure the inside diameter of the connecting rod bush. Standard Bush Inside Diameter STANDARD BUSH INSIDE DIAMETER Mark Specified Condition A 22.005 to 22.008 mm (0.86634 to 0.86645 in.) B 22.008 to 22.011 mm (0.86645 to 0.86657 in.) C 22.011 to 22.014 mm (0.86657 to 0.86669 in.) Subtract the piston pin diameter measurement from the bush inside diameter measurement. Standard oil clearance: 0.005 to 0.011 mm (0.000197 to 0.000433 in.) Maximum oil clearance: 0.03 mm (0.00118 in.) If the oil clearance is more than the maximum, replace the connecting rod, and replace the piston and pin as a set.
10. INSPECT CONNECTING ROD SUB-ASSEMBLY Using a rod aligner and feeler gauge, check the connecting rod alignment. Check for bend. Maximum bend: 0.05 mm (0.00197 in.) per 100 mm (3.94 in.) If the bend is more than the maximum, replace the connecting rod. Check for twist. Maximum twist: 0.15 mm (0.00591 in.) per 100 mm (3.94 in.) If the twist is more than the maximum, replace the connecting rod.
11. INSPECT CONNECTING ROD BOLT Using a vernier caliper, measure the tension portion diameter of the bolt. Standard diameter: 8.5 to 8.6 mm (0.335 to 0.339 in.) Minimum diameter: 8.3 mm (0.327 in.) If the diameter is less than the minimum, replace the bolt.
12. INSPECT CRANKSHAFT Inspect circle runout. Place the crankshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.00236 in.) If the circle runout is more than the maximum, replace the crankshaft. Inspect the main journals. Using a micrometer, measure the diameter of each main journal. Standard journal diameter: 66.988 to 67.000 mm (2.6373 to 2.6378 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each main journal for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.000787 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft. Inspect the crank pins. Using a micrometer, measure the diameter of each crank pin. Standard crank pin diameter: 55.982 to 56.000 mm (2.2040 to 2.2047 in.) If the diameter is not as specified, check the oil clearance. If necessary, replace the crankshaft. Check each crank pin for taper and out-of-round as shown in the illustration. Maximum taper and out-of-round: 0.02 mm (0.000787 in.) If the taper and out-of-round is more than the maximum, replace the crankshaft.
13. INSPECT CRANKSHAFT OIL CLEARANCE Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearing. Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Install the crankshaft bearing caps (See «REASSEMBLY»(/toyota/land-cruiser/200-2007-2012/remont/mechanical/#engine-mechanical) ). Remove the 30 bolts and bearing caps. Measure the Plastigage at its widest point. Standard Oil Clearance STANDARD OIL CLEARANCE REFERENCE Number Mark Specified Condition No. 1 and No. 5 journals 0.017 to 0.030 mm (0.000669 to 0.00118 in.) Other journals 0.024 to 0.037 mm (0.000945 to 0.00146 in.) Maximum Oil Clearance MAXIMUM OIL CLEARANCE REFERENCE Number Mark Specified Condition No. 1 and No. 5 journals 0.050 mm (0.00197 in.) Other journals 0.060 mm (0.00236 in.) If the oil clearance is more than the maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If replacing a bearing, replace it with one that has the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft. (Scheme 370)for the appropriate bearing number. There are 6 sizes of standard bearings. For the No. 1 and No. 5 position bearings, use bearings marked 4, 5, 6, 7, 8 or 9. For other bearings, use bearings marked 3, 4, 5, 6, 7 or 8. Example: Cylinder block "07" + Crankshaft "06" = Total number 13 (Use upper bearing "6" and lower bearing "7") HINT: A = Cylinder block number mark B = Crankshaft number mark Standard Bearing Center Wall Thickness No. 1 and No. 5 Journals BEARING CENTER WALL THICKNESS CHART (A) + (B) Upper Bearing Lower Bearing Number Mark Specified Condition Number Mark Specified Condition 00 to 02 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 03 to 05 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 06 to 08 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 09 to 11 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 12 to 14 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 15 to 17 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 18 to 20 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 21 to 23 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 24 to 26 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 9 2.500 to 2.503 (0.0984 to 0.0985 in.) 27 to 28 9 2.516 to 2.519 (0.0991 to 0.0992 in.) 9 2.500 to 2.503 (0.0984 to 0.0985 in.) Other Journals BEARING CENTER WALL THICKNESS CHART (A) + (B) Upper Bearing Lower Bearing Number Mark Specified Condition Number Mark Specified Condition 00 to 02 3 2.482 to 2.485 (0.0977 to 0.0978 in.) 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 03 to 05 4 2.485 to 2.488 (0.0978 to 0.0980 in.) 4 2.501 to 2.504 (0.0985 to 0.0986 in.) 06 to 08 4 2.485 to 2.488 (0.0978 to 0.0980 in.) 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 09 to 11 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 5 2.504 to 2.507 (0.0986 to 0.0987 in.) 12 to 14 5 2.488 to 2.491 (0.0980 to 0.0981 in.) 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 15 to 17 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 6 2.507 to 2.510 (0.0987 to 0.0988 in.) 18 to 20 6 2.491 to 2.494 (0.0981 to 0.0982 in.) 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 21 to 23 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 7 2.510 to 2.513 (0.0988 to 0.0989 in.) 24 to 26 7 2.494 to 2.497 (0.0982 to 0.0983 in.) 8 2.513 to 2.516 (0.0989 to 0.0991 in.) 27 to 28 8 2.497 to 2.500 (0.0983 to 0.0984 in.) 8 2.513 to 2.516 (0.0989 to 0.0991 in.) Completely remove the Plastigage.
14. INSPECT CRANKSHAFT BEARING CAP SET BOLT Using a vernier caliper, measure the minimum diameter of the elongated thread at the measuring point. Measuring point: 54.5 mm (2.15 in.) Standard Diameter BOLT DIMENSION Item Specified Condition Bolt A 10.5 to 11.0 mm (0.413 to 0.433 in.) Bolt B 9.5 to 10.0 mm (0.374 to 0.394 in.) Minimum Diameter BOLT DIMENSION Item Specified Condition Bolt A 10.4 mm (0.409 in.) Bolt B 9.4 mm (0.370 in.) If the diameter is less than the minimum, replace the bolt.

Scheme 372

1. REPLACE STRAIGHT PIN NOTE: It is not necessary to remove the straight pin unless it is being replaced. Remove the straight pins. Using a plastic-faced hammer, tap in new straight pins to the cylinder block. Standard Protrusion PIN DIAMETER CHART Item Pin Diameter Specified Condition Pin A 10 mm (0.394 in.) 23 mm (0.906 in.) Pin B 10 mm (0.394 in.) 11 mm (0.433 in.) Pin C 8 mm (0.315 in.) 9 mm (0.354 in.) Pin D 4 mm (0.157 in.) 6 mm (0.236 in.)

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Scheme 395

1. INSTALL STUD BOLT Using an E8 "TORX" socket wrench, install the stud bolts. Torque: for stud bolt A 20 N*m (204 kgf*cm, 15 ft.*lbf) for stud bolt B 9.0 N*m (92 kgf*cm, 80 in.*lbf)
2. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY Using a 5 mm hexagon wrench, install the 4 oil nozzles with the 4 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
3. INSTALL PISTON WITH PIN SUB-ASSEMBLY Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the service hole of the piston. Gradually heat the piston to approximately 80°C (176°F). Coat the piston pin and connecting rod with engine oil. Align the front marks of the piston and connecting rod as shown in the illustration. Then push in the piston pin with your thumb until the piston pin contacts the snap ring. NOTE: For the LH side, perform the assembly so that the front marks of the piston and connecting rod are on the same side. For the RH side, perform the assembly so that the front marks of the piston and connecting rod are on opposite sides. HINT: The piston and pin are a matched set. Check the fitting condition between the piston and piston pin. Move the connecting rod back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. Rotate the piston back and forth on the piston pin. Check the fitting condition. If abnormal movement is felt, replace the piston and pin as a set. Using a small screwdriver, install a new snap ring at the other end of the piston pin hole. HINT: Be sure that the end gap of the snap ring is not aligned with the service hole of the piston.
4. INSTALL PISTON RING SET Install the oil ring expander and 2 side rails by hand. Using a piston ring expander, install the 2 compression rings so that the paint marks are positioned as shown in the illustration. Paint Mark PISTON PIN PAINT MARK CHART Piston Ring Paint Mark No. 1 Blue No. 2 Orange
5. INSTALL CRANKSHAFT BEARING Clean the main journal and both surfaces of the bearing. Install the upper bearing. NOTE: Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions. Install the upper bearing to the cylinder block as shown in the illustration. NOTE: Do not apply engine oil to the bearings and the contact surfaces. Both sides of the oil groove in the cylinder block should be visible through the oil feed holes in the bearing. The amount visible on each side of the holes should be equal. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one. Install the lower bearing. NOTE: Be sure to install the selected bearing. Main bearings come in widths of 21 mm (0.827 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the main bearing caps. Install the 21 mm (0.827 in.) bearings in the No. 2, No. 3 and No. 4 positions. Install the lower bearings to the crankshaft bearing caps. Using a vernier caliper, measure the distance between the crankshaft bearing cap edge and the lower bearing edge. Dimension A - B or B - A: 0 to 0.7 mm (0 to 0.0276 in.) NOTE: Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
6. INSTALL CRANKSHAFT THRUST WASHER SET Apply engine oil to the thrust washer set. Install the 4 thrust washers to the No. 3 journal position of the cylinder block and crankshaft bearing cap with the oil grooves facing outward.
7. INSTALL CRANKSHAFT Apply engine oil to the upper bearing and lower bearing, then place the crankshaft on the cylinder block. Confirm the front marks and numbers of the crankshaft bearing caps, and install the crankshaft bearing caps on the cylinder block. HINT: A number is marked on each main bearing cap to indicate the installation position. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts. Temporarily install the 10 crankshaft bearing cap bolts to the inside positions. Push the crankshaft bearing cap by hand until the clearance between the crankshaft bearing cap and cylinder block is less than 6 mm (0.236 in.). Bolt length: 91 mm (3.58 in.) Using a plastic-faced hammer, lightly tap the crankshaft bearing cap to ensure a proper fit. Apply a light coat of engine oil to the threads and under the heads of the 10 crankshaft bearing cap bolts. Temporarily install the 10 crankshaft bearing cap bolts to the outside positions. Bolt length: 79.5 mm (3.13 in.) HINT: The main bearing cap bolts are tightened in 2 progressive steps. Step 1: Uniformly tighten the 20 crankshaft bearing cap bolts in the sequence shown in the illustration. Torque: for inside position 61 N*m (622 kgf*cm, 45 ft.*lbf) for outside position 27 N*m (275 kgf*cm, 20 ft.*lbf) If any of the main bearing cap bolts does not meet the specified torque, replace it. Step 2: Mark the front of the bearing cap bolts with paint. Tighten the bearing cap bolts 90° in the order shown in step 1. Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly. Install and uniformly tighten the 10 crankshaft bearing cap bolts and 10 new seal washers in several steps in the sequence shown in the illustration. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) Check that the crankshaft turns smoothly.
8. INSTALL CONNECTING ROD BEARING Install the connecting rod bearings to the connecting rods and bearing caps. Using a vernier caliper, measure the distance between the connecting rod and bearing cap edges, and each connecting rod bearing edge. Dimension A - B or B - A: 0 to 0.7 mm (0 to 0.0276 in.) NOTE: Do not apply engine oil to the bearings and the contact surfaces. Do not allow coolant to come into contact with the bearing inner surface. If any coolant comes into contact with the bearing inner surface, replace the bearing with a new one.
9. INSTALL PISTON AND CONNECTING ROD Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings. Position the piston rings so that the ring ends are as shown in the illustration. NOTE: Do not align the ring ends. HINT: The expander ends can be placed anywhere. Using a hammer handle and piston ring compressor, push the correctly numbered piston and connecting rod into the cylinder with the front mark of the piston facing forward. Place the connecting rod cap on the connecting rod. Match the numbered connecting rod cap with the connecting rod. Place the connecting rod cap on the connecting rod, and check that the front mark of the connecting rod cap is facing the direction indicated in the chart below. Front Mark FRONT MARK REFERENCE CHART Item Front Mark Bank 1 Front side Bank 2 Rear side Apply a light coat of engine oil to the threads and under the heads of the connecting rod cap bolts. Temporarily install the connecting rod cap bolts. HINT: The connecting rod cap bolts are tightened in 2 progressive steps. Step 1: Install and alternately tighten the bolts of the connecting rod cap in several steps. Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) Step 2: Mark the front side of each connecting rod cap bolt with paint. Tighten the cap bolts 90° as shown in the illustration in the order in step 1. Check that the painted marks are now at a 90° angle to the front. Check that the crankshaft turns smoothly.

See also:
• REMOVAL
• REMOVAL
• INSTALLATION
• REMOVAL
• REMOVAL
• REMOVAL
• REMOVAL
• REMOVAL
• REPLACEMENT
• REMOVAL
• REMOVAL
• REMOVAL
• INSTALLATION
• INSTALLATION
• REMOVAL
• REMOVAL
• REMOVAL
• INSTALLATION
• ADJUSTMENT
• REMOVAL
• INSTALLATION
• REMOVAL