Land-Cruiser-2009.pdf

2009 ENGINE
Engine Mechanical - Land Cruiser
ENGINE
ON-VEHICLE INSPECTION
1. INSPECT IGNITION TIMING
a. Warm up and stop the engine.
1. Allow the engine to warm up to a normal operating temperature.
b. When using the Techstream:
1. Connect the Techstream to the DLC3.
2. Start the engine and idle it.
3. Turn the Techstream ON.
4. 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)
5. Disconnect the Techstream from the DLC3.
c. When not using the Techstream:
1. Connect the tester probe of a timing light to the wire of the ignition coil connector for the No.
1 cylinder.
Fig. 1: Identifying Timing Light Connection With Wire Of Ignition Coil Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NOTE: Use a timing light that detects primary signals.
2009 Toyota Land Cruiser
2009 ENGINE Engine Mechanical - Land Cruiser
domingo, 8 de diciembre de 2019 10:28:35 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.

2. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST 09843-18040
Fig. 2: Identifying Terminals 13 (TC) And 4 (CG) Of DLC3
3. Using the timing light, check the ignition timing.
switch off)
4. Remove SST from the DLC3.
5. Check the ignition timing.
switch off)
6. Disconnect the timing light from the engine.
Fig. 3: Checking Ignition Timing Using Timing Light
NOTE: l Confirm the terminal numbers before connecting them.
Connecting the wrong terminals can damage the engine.
l Switch off all accessories and the A/C before connecting
the terminals.

2. INSPECT ENGINE IDLE SPEED
b. When using the Techstream:
1. Connect the Techstream to the DLC3.
2. Race the engine at 2500 rpm for approximately 90 seconds.
3. Turn the Techstream ON.
4. 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.
5. Disconnect the Techstream from the DLC3.
c. When not using the Techstream:
1. Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3.
SST 09843-18030
NOTE: Switch off all accessories and the A/C before connecting the
Techstream.
NOTE: l Confirm the terminal number before connecting the probe.
Connecting the probe to the wrong terminal can damage
the engine.
l Switch off all accessories and the A/C before connecting
the probe.

Fig. 4: Identifying Terminal 9 (TAC) Of DLC3
2. Race the engine at 2500 rpm for approximately 90 seconds.
3. 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.
4. Disconnect the tachometer probe from the DLC3.
3. INSPECT COMPRESSION
b. Remove the V-bank cover.
c. Remove the air cleaner hose assembly (See REMOVAL ).
d. Remove the air cleaner assembly (See REMOVAL ).
e. Disconnect the water by-pass pipe assembly (See REMOVAL ).
f. Disconnect the 2 injector connectors and 8 ignition coil connectors.
g. Remove the 8 bolts and 8 ignition coils (See REMOVAL ).
h. Remove the 8 spark plugs (See REMOVAL ).

Fig. 5: Identifying Injector And Ignition Coil Connectors
i. Check the cylinder compression pressure.
1. Insert a compression gauge into the spark plug hole.
2. Fully open the throttle.
3. While cranking the engine, measure the compression pressure.
Fig. 6: Checking Cylinder Compression Pressure
Standard compression pressure:
NOTE: Check the compression pressure of each cylinder in the same way.

1300 kPa (13.3 kgf/cm2 , 189 psi)
Minimum pressure:
1000 kPa (10.2 kgf/cm2 , 145 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm2 , 15 psi) or less
4. 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:
l If adding oil helps boost the compression, it is likely that the piston rings and/or
cylinder bore are worn or damaged.
l If pressure stays low, a valve may be stuck or seated improperly, or there may be
leakage in the gasket.
j. Install the 8 spark plugs (See INSTALLATION ).
k. Install the 8 ignition coils with the 8 bolts (See INSTALLATION ).
l. Connect the 2 injector connectors and 8 ignition coil connectors.
m. Connect the water by-pass pipe assembly (See INSTALLATION ).
n. Install the air cleaner assembly (See INSTALLATION ).
o. Install the air cleaner hose assembly (See INSTALLATION ).
p. 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.
a. Start the engine.
b. Keep the engine speed at 2500 rpm for approximately 180 seconds.
NOTE: l Always use a fully charged battery to obtain an engine
speed of 250 rpm or more.
l This measurement must be done as quickly as possible.

Fig. 7: Identifying Injector And Ignition Coil Connectors
c. Insert the CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe during idling.
d. 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.
e. If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given
below.
1. Check the A/F sensor and heated oxygen sensor operation.
Fig. 8: Checking CO/HC Concentration

2. See the table below for possible causes, and then inspect and correct the applicable causes if
necessary.
TROUBLE SYMPTOM CHART
DRIVE BELT
COMPONENTS
CO HC Symptom Cause
Normal High Rough idle
1. Faulty ignitions:
¡ Incorrect timing
¡ Plugs (contaminated, shorted or gaps
are defective)
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinder
Low High
Rough idle (Fluctuating HC
reading)
1. Vacuum leaks:
¡ PCV hose
¡ Intake manifold
¡ Throttle body
2. Lean mixture causing misfire
High High
Rough idle (Black smoke from
exhaust)
1. Restricted air filter
2. Faulty SFI system:
¡ Faulty pressure regulator
¡ Defective ECT sensor
¡ Faulty ECM
¡ Faulty injectors
¡ Faulty throttle position sensor
¡ Faulty MAF meter

Fig. 9: Identifying Drive Belt Associated Components With Torque Specifications
ON-VEHICLE INSPECTION
1. INSPECT FAN AND GENERATOR V BELT
a. 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.

l The belt is cracked.
l The belt is worn out to the extent that the cords are exposed.
l The belt has chunks missing from the ribs.
b. 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.
Fig. 10: Identifying V-Ribbed Belt Correct And Incorrect Position
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
a. Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a
malfunction exists, replace the tensioner.
REMOVAL
1. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See REMOVAL )
2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See REMOVAL )
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See REMOVAL )
4. REMOVE V-BANK COVER SUB-ASSEMBLY (See REMOVAL )
5. REMOVE FAN AND GENERATOR V BELT
a. 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.
b. Remove the V belt.
Fig. 11: Removing V-Belt
INSTALLATION
1. INSTALL FAN AND GENERATOR V BELT
a. Set the V belt onto every part.
b. While turning the belt tensioner counterclockwise, remove the bar.
NOTE: Make sure that the V belt is properly set to each pulley.

Fig. 12: Routing Of Fan And Generator V-Belt
c. 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.
Fig. 13: Identifying Correct And Incorrect Position Of Drive Belt
2. INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )
3. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (See INSTALLATION )
4. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See INSTALLATION )
5. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See INSTALLATION )
CAMSHAFT
COMPONENTS

Fig. 14: Identifying Camshaft Replacement Components With Torque Specifications (1 Of 17)

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See REMOVAL )

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. REMOVE UPPER RADIATOR SUPPORT SEAL (See REMOVAL )
4. REMOVE RADIATOR GRILLE (See DISASSEMBLY )
5. REMOVE FRONT BUMPER COVER (See REMOVAL )
6. REMOVE TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)
(See REMOVAL )
7. DISCONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)
(See REMOVAL )
8. DISCONNECT RADIATOR SIDE DEFLECTOR LH (See REMOVAL )
9. REMOVE FRONT FENDER MAIN SEAL LH (See REMOVAL )
10. REMOVE FRONT FENDER MAIN SEAL RH (See REMOVAL )
11. REMOVE FRONT WIPER ARM LH (See REMOVAL )
12. REMOVE FRONT WIPER ARM RH (See REMOVAL )
13. REMOVE HOOD TO COWL TOP SEAL (See REMOVAL )
14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See REMOVAL )
18. REMOVE NO. 2 ENGINE UNDER COVER (See REMOVAL )
19. REMOVE FRONT FENDER APRON SEAL LH (See REMOVAL )
20. REMOVE FRONT FENDER APRON SEAL FRONT RH (See REMOVAL )
21. DRAIN ENGINE OIL (See REPLACEMENT )
22. DRAIN ENGINE COOLANT (See REPLACEMENT )
24. REMOVE AIR CLEANER HOSE ASSEMBLY (See REMOVAL )
25. REMOVE AIR CLEANER ASSEMBLY (See REMOVAL )
26. REMOVE NO. 1 RADIATOR HOSE
28. REMOVE FAN SHROUD (See REMOVAL )
29. REMOVE RADIATOR ASSEMBLY (See REMOVAL )
30. DISCONNECT ENGINE WIRE (See REMOVAL )
31. DISCONNECT AIR PUMP HOSE AND WIRE HARNESS (See REMOVAL )
32. DISCONNECT NO. 2 WATER BY-PASS PIPE (See REMOVAL )
33. DISCONNECT COOLER COMPRESSOR ASSEMBLY (See REMOVAL )
CAUTION: Wait at least 90 seconds after disconnecting the cable from the
negative (-) battery terminal to disable the SRS system.

34. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (See REMOVAL )
35. REMOVE OIL FILTER ELEMENT (See REPLACEMENT )
36. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (See REMOVAL )
37. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY (See REMOVAL )
38. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See REMOVAL )
39. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See REMOVAL )
40. REMOVE OIL FILTER BRACKET (w/ Oil Cooler) (See REMOVAL )
41. REMOVE OIL FILTER BRACKET (w/o Oil Cooler) (See REMOVAL )
42. REMOVE INTAKE MANIFOLD (See REMOVAL )
43. DISCONNECT VANE PUMP ASSEMBLY (See REMOVAL )
44. DISCONNECT OIL COOLER PIPE ASSEMBLY (See REMOVAL )
45. REMOVE GENERATOR ASSEMBLY (See REMOVAL )
46. REMOVE NO. 1 WATER BY-PASS HOSE (See REMOVAL )
47. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY (See REMOVAL )
48. REMOVE FRONT WATER BY-PASS JOINT (See REMOVAL )
49. REMOVE NO. 2 ENGINE COVER (See REMOVAL )
51. REMOVE AIR TUBE SUB-ASSEMBLY (See REMOVAL )
52. REMOVE WATER INLET HOUSING (See REMOVAL )
53. REMOVE WATER PUMP PULLEY (See REMOVAL )
54. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (See REMOVAL )
55. REMOVE FLUID COUPLING BRACKET (See REMOVAL )
56. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See REMOVAL )
57. REMOVE IGNITION COIL ASSEMBLY (See REMOVAL )
58. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See REMOVAL )
59. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (See REMOVAL )
60. REMOVE SPARK PLUG TUBE GASKET (See DISASSEMBLY )
61. REMOVE CRANKSHAFT PULLEY (See REMOVAL )
62. DISCONNECT WIRE HARNESS CLAMP BRACKET (See REMOVAL )
63. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See REMOVAL )
64. REMOVE WATER INLET PIPE (See REMOVAL )
65. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See DISASSEMBLY )
66. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH (See DISASSEMBLY
67. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH (See DISASSEMBLY )
68. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH (See DISASSEMBLY )
69. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH (See DISASSEMBLY )
70. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY (See DISASSEMBLY )
71. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH (See DISASSEMBLY )

72. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH (See DISASSEMBLY )
73. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH (See DISASSEMBLY )
74. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH (See DISASSEMBLY )
75. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY (See DISASSEMBLY )
76. REMOVE CRANKSHAFT TIMING GEAR KEY (See DISASSEMBLY )
77. REMOVE CAMSHAFT BEARING CAP LH
a. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
Fig. 31: Identifying Camshaft Knock Pin Position
b. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
Fig. 32: Identifying Bearing Cap Bolts Loosening Sequence
c. 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.

d. Remove the 6 bearing caps.
HINT:
Arrange the removed parts in the correct order.
e. Remove the No. 3 and No. 4 camshafts.
78. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a
screwdriver.
HINT:
Tape the screwdriver tip before use.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and
camshaft housing.

Fig. 34: Locating Screwdriver Position For Removing Camshaft Housing
79. REMOVE CAMSHAFT BEARING CAP RH
a. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
b. Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

c. Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.
d. Remove the 6 bearing caps.
HINT:
Arrange the removed parts in the correct order.
e. Remove the No. 1 and No. 2 camshafts.
80. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
a. Remove the camshaft housing by prying between the cylinder head and camshaft housing with a
screwdriver.
HINT:
NOTE: Uniformly loosen the bolts while keeping the camshaft level.
NOTE: Be careful not to damage the contact surfaces of the cylinder head and
camshaft housing.

INSTALLATION
1. INSTALL CAMSHAFT BEARING CAP RH
a. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
b. Install the No. 1 and No. 2 camshafts to the camshaft housing.
Fig. 38: Locating Screwdriver Position For Removing Camshaft Housing
c. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper
positions and directions.
Fig. 39: Identifying Marks And Numbers On Camshaft Bearing Caps
d. Temporarily install the 10 bolts in the order shown in the illustration.

Fig. 40: Identifying Bearing Cap Bolts Installing Order
2. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
a. Make sure that the valve rocker arms are installed as shown in the illustration.
Fig. 41: Identifying Installing Position Of Valve Rocker Arms
b. 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: l Remove any oil from the contact surface.
l Install the camshaft housing within 3 minutes and tighten the

Fig. 42: Specifications For Applying Seal Packing
c. 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)
bolts within 15 minutes after applying seal packing.
NOTE: l Do not start the engine for at least 2 hours after the installation.
l Make sure that the knock pin of the camshaft is positioned as
shown in the illustration before installing the camshaft housing.

d. Tighten the 10 bolts in the order shown in the illustration.
Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf)
3. INSTALL CAMSHAFT BEARING CAP LH
a. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.
b. Install the No. 3 and No. 4 camshafts to the camshaft housing.
Fig. 44: Identifying Bearing Caps Bolts Tightening Order
c. Confirm the marks and numbers on the camshaft bearing caps and place them in their proper
positions and directions.
Fig. 45: Identifying Marks And Numbers On Camshaft Bearing Caps
d. Temporarily install the 10 bolts in the order shown in the illustration.
NOTE: Thoroughly wipe clean any seal packing.

Fig. 46: Identifying Bearing Caps Bolts Tightening Order
4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Make sure that the valve rocker arms are installed as shown in the illustration.
Fig. 47: Identifying Installing Position Of Valve Rocker Arms
b. 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: l Remove any oil from the contact surface.
l Install the camshaft housing within 3 minutes and tighten the
bolts within 15 minutes after applying seal packing.

Fig. 48: Specifications For Applying Seal Packing
c. 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)
d. Tighten the 10 bolts in the order shown in the illustration.
NOTE: l Do not start the engine for at least 2 hours after the installation.
l Make sure that the knock pin of the camshaft is positioned as
shown in the illustration before installing the camshaft housing.

Fig. 50: Identifying Bearing Cap Bolts Tightening Order
5. INSTALL CRANKSHAFT TIMING GEAR KEY (See REASSEMBLY )
6. SET NO. 1 CYLINDER TO TDC/COMPRESSION (See REASSEMBLY )
7. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (See REASSEMBLY )
8. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH (See REASSEMBLY )
9. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH (See REASSEMBLY )
10. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH (See REASSEMBLY )
11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH (See REASSEMBLY )
12. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (See REASSEMBLY )
13. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH (See REASSEMBLY )
14. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH (See REASSEMBLY )
15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH (See REASSEMBLY )
16. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH (See REASSEMBLY )
17. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY (See REASSEMBLY )
18. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION (See REASSEMBLY )
19. INSTALL WATER INLET PIPE (See INSTALLATION )
20. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (See INSTALLATION )
21. INSTALL SPARK PLUG TUBE GASKET (See REASSEMBLY )
22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH (See INSTALLATION )
23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH (See INSTALLATION )
24. INSTALL IGNITION COIL ASSEMBLY (See INSTALLATION )
25. INSTALL CRANKSHAFT TIMING GEAR KEY (See REASSEMBLY )
26. INSTALL CRANKSHAFT PULLEY (See INSTALLATION )
27. CONNECT WIRE HARNESS CLAMP BRACKET (See INSTALLATION )
28. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See INSTALLATION )
NOTE: Thoroughly wipe clean any seal packing.

29. INSTALL WATER PUMP PULLEY (See INSTALLATION )
30. INSTALL WATER INLET HOUSING (See INSTALLATION )
31. INSTALL AIR TUBE SUB-ASSEMBLY (See INSTALLATION )
32. INSTALL NO. 1 ENGINE COVER (See INSTALLATION )
33. INSTALL NO. 2 ENGINE COVER (See INSTALLATION )
34. INSTALL FRONT WATER BY-PASS JOINT (See INSTALLATION )
35. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (See INSTALLATION )
36. INSTALL NO. 1 WATER BY-PASS HOSE (See INSTALLATION )
37. INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
38. CONNECT OIL COOLER PIPE ASSEMBLY (See INSTALLATION )
39. CONNECT VANE PUMP ASSEMBLY (See INSTALLATION )
40. INSTALL INTAKE MANIFOLD (See INSTALLATION )
41. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) (See INSTALLATION )
42. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) (See INSTALLATION )
43. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See INSTALLATION )
44. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See
INSTALLATION )
45. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (See REMOVAL )
46. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE (See INSTALLATION )
47. INSTALL OIL FILTER ELEMENT (See REPLACEMENT )
48. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (See INSTALLATION )
49. CONNECT COOLER COMPRESSOR ASSEMBLY (See INSTALLATION )
50. CONNECT NO. 2 WATER BY-PASS PIPE (See INSTALLATION )
51. CONNECT AIR PUMP HOSE AND WIRE HARNESS (See INSTALLATION )
52. CONNECT ENGINE WIRE (See INSTALLATION )
53. INSTALL RADIATOR ASSEMBLY (See INSTALLATION )
54. INSTALL FAN SHROUD (See INSTALLATION )
55. INSTALL NO. 2 RADIATOR HOSE
57. INSTALL AIR CLEANER ASSEMBLY (See INSTALLATION )
58. INSTALL AIR CLEANER HOSE ASSEMBLY (See INSTALLATION )
60. ADD ENGINE OIL (See REPLACEMENT )
61. ADD ENGINE COOLANT (See REPLACEMENT )
62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
63. INSPECT FOR OIL LEAK (See REPLACEMENT )
64. INSPECT FOR COOLANT LEAK (See ON-VEHICLE INSPECTION )
65. INSPECT ENGINE OIL LEVEL (See ON-VEHICLE INSPECTION )

66. INSPECT IGNITION TIMING (See ENGINE )
67. INSPECT ENGINE IDLE SPEED (See ON-VEHICLE INSPECTION )
68. INSTALL FRONT FENDER APRON SEAL FRONT RH (See INSTALLATION )
69. INSTALL FRONT FENDER APRON SEAL LH (See INSTALLATION )
70. INSTALL NO. 2 ENGINE UNDER COVER (See INSTALLATION )
74. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See INSTALLATION )
75. INSTALL HOOD TO COWL TOP SEAL (See INSTALLATION )
76. INSTALL FRONT FENDER MAIN SEAL LH (See INSTALLATION )
77. INSTALL FRONT FENDER MAIN SEAL RH (See INSTALLATION )
78. INSTALL FRONT WIPER ARM LH (See INSTALLATION )
79. INSTALL FRONT WIPER ARM RH (See INSTALLATION )
80. CONNECT RADIATOR SIDE DEFLECTOR LH (See INSTALLATION )
81. CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See
INSTALLATION )
82. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)
(See INSTALLATION )
83. INSTALL FRONT BUMPER COVER (See INSTALLATION )
84. INSTALL RADIATOR GRILLE (See INSTALLATION )
85. INSTALL UPPER RADIATOR SUPPORT SEAL (See INSTALLATION )
CYLINDER HEAD GASKET
COMPONENTS

Fig. 51: Identifying Cylinder Head Gasket Replacement Components With Torque Specifications (1 Of
19)

19)

19)
REMOVAL

3. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY
a. Remove the exhaust manifold (See REMOVAL ).
4. REMOVE CAMSHAFT
a. Remove the camshaft (See REMOVAL ).
5. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (See DISASSEMBLY )
6. REMOVE VALVE LASH ADJUSTER ASSEMBLY (See DISASSEMBLY )
7. REMOVE VALVE STEM CAP (See DISASSEMBLY )
8. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH
a. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
Fig. 70: Identifying Cylinder Head Sub-Assembly Bolts Loosening Sequence (LH)
b. 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: l Be careful not to drop washers into the cylinder head.
l Head warpage or cracking could result from removing bolts in
an incorrect order.

Fig. 71: Identifying Cylinder Head Bolts Loosening Sequence (LH)
HINT:
Be sure to arrange the removed parts for each installation position separately.
c. Remove the cylinder head and gasket.
9. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
a. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
Fig. 72: Identifying Cylinder Head Sub-Assembly Bolts Loosening Sequence (RH)
b. 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: l Be careful not to drop washers into the cylinder head.
l Head warpage or cracking could result from removing bolts in
an incorrect order.

Fig. 73: Identifying Cylinder Head Bolts Loosening Sequence (RH)
HINT:
Be sure to arrange the removed parts for each installation position separately.
c. Remove the cylinder head and gasket.
INSTALLATION
1. INSPECT CYLINDER HEAD SET BOLT (See INSPECTION )
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY (See INSPECTION )
3. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
a. Check the piston protrusions for each cylinder.
1. Clean the cylinder block with solvent.
2. Set the piston of the cylinder to be measured to slightly ATDC.
b. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No.
stamp upward.
c. Place the cylinder head on the cylinder block.
NOTE: l Be careful of the installation direction.
l Make sure that no oil is on the front end (indicated by the
arrows) of the cylinder head gasket.

Fig. 74: Position Of Placing Cylinder Head Gasket On Cylinder Block Surface
HINT:
The cylinder head bolts are tightened in 3 progressive steps.
d. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
e. Step 1:
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.
Fig. 75: Identifying Cylinder Head Bolts Tightening Sequence
f. Step 2:
1. Mark each cylinder head bolt head with paint as shown in the illustration.
2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.
g. Step 3:
1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
2. Check that the painting marks are now facing rearward.
NOTE: l Ensure that no oil is on the mounting surface of the cylinder
head.
l Gently place the cylinder head in order not to damage the
gasket with the bottom part of the head.

Fig. 76: Tightening Position Of Cylinder Head Bolts
h. Uniformly install the 2 bolts in the sequence shown in the illustration.
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH
a. Check the piston protrusions for each cylinder.
1. Clean the cylinder block with solvent.
2. Set the piston of the cylinder to be measured to slightly ATDC.
Fig. 77: Identifying Cylinder Head Bolts Tightening Sequence
b. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No.
stamp upward.
c. Place the cylinder head on the cylinder block.
NOTE: l Be careful of the installation direction.
l Make sure that no oil is on the front end (indicated by the
arrows) of the cylinder head gasket.
NOTE: l Ensure that no oil is on the mounting surface of the cylinder
head.

Fig. 78: Position Of Placing Cylinder Head Gasket On Cylinder Block Surface
HINT:
The cylinder head bolts are tightened in 3 progressive steps.
d. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
e. Step 1:
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.
Fig. 79: Identifying Cylinder Head Bolts Tightening Order
f. Step 2:
1. Mark each cylinder head bolt head with paint as shown in the illustration.
2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.
g. Step 3:
1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.
2. Check that the painted marks are now facing rearward.
l Gently place the cylinder head in order not to damage the
gasket with the bottom part of the head.

Fig. 80: Tightening Position Of Cylinder Head Bolts
h. Uniformly install the 2 bolts in the sequence shown in the illustration.
5. INSTALL VALVE STEM CAP (See REASSEMBLY )
6. INSTALL VALVE LASH ADJUSTER ASSEMBLY (See REASSEMBLY )
7. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY (See REASSEMBLY )
8. INSTALL CAMSHAFT
Fig. 81: Identifying Cylinder Head Bolts Installing Order
a. Install the camshaft (See INSTALLATION ).
9. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY
a. Install the exhaust manifold (See INSTALLATION ).
11. INSPECT FOR EXHAUST GAS LEAK (See INSTALLATION )
FRONT CRANKSHAFT OIL SEAL

COMPONENTS
Fig. 82: Identifying Front Crankshaft Oil Seal Replacement Components With Torque Specifications (1
Of 3)

Of 3)

Of 3)
REMOVAL

10. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) (See REMOVAL )
11. DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)
a. Remove the 3 bolts and disconnect the 2 water bypass hoses from the oil cooler.
14. REMOVE CRANKSHAFT PULLEY (See REMOVAL )
Fig. 85: Locating Bolts And Water Bypass Hoses
15. REMOVE CRANKSHAFT TIMING GEAR KEY
a. Remove the crankshaft timing gear key from the crankshaft.

Fig. 86: Identifying Crankshaft Timing Gear Key
16. REMOVE FRONT CRANKSHAFT OIL SEAL
a. Using a screwdriver, pry out the oil seal.
HINT:
Fig. 87: Removing Front Crankshaft Oil Seal Using Screwdriver
INSTALLATION
1. INSTALL FRONT CRANKSHAFT OIL SEAL
a. Apply MP grease to the lip of a new oil seal.
b. 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: Do not damage the surface of the oil seal press fit hole and crankshaft.
NOTE: l Keep the lip free from foreign matter.

Fig. 88: Tapping In Oil Seal Using SST And Hammer
2. INSTALL CRANKSHAFT TIMING GEAR KEY
a. Install the crankshaft timing gear key.
Fig. 89: Identifying Crankshaft Timing Gear Key
3. INSTALL CRANKSHAFT PULLEY (See INSTALLATION )
4. INSTALL OIL FILTER BRACKET (w/ Oil Cooler) (See INSTALLATION )
5. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) (See INSTALLATION )
6. CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)
a. Connect the 2 water by-pass hoses to the oil cooler.
b. Install the 3 by-pass pipe bolts.
l Do not tap the oil seal at an angle.

Fig. 90: Locating Bolts And Water Bypass Hoses
7. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Oil Cooler) (See INSTALLATION )
8. INSTALL OIL FILTER BRACKET (w/o Oil Cooler) (See INSTALLATION )
9. INSTALL OIL PRESSURE SENDER GAUGE ASSEMBLY (See REMOVAL )
REAR CRANKSHAFT OIL SEAL
COMPONENTS

Fig. 91: Identifying Rear Crankshaft Oil Seal Replacement Components With Torque Specifications (1
Of 2)

Fig. 92: Identifying Rear Crankshaft Oil Seal Replacement Components With Torque Specifications (2
Of 2)
REMOVAL
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
a. Remove the automatic transmission (See REMOVAL ).
3. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See REMOVAL )
4. REMOVE REAR CRANKSHAFT OIL SEAL
a. Using a knife, cut off the lip of the oil seal.
b. Using a screwdriver, pry out the oil seal.

Fig. 93: Removing Rear Crankshaft Oil Seal Using Screw Driver
HINT:
INSTALLATION
1. INSTALL REAR CRANKSHAFT OIL SEAL
a. Apply MP grease to the lip of a new oil seal.
b. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer
edge.
Fig. 94: Tapping In Oil Seal Using SST And Hammer
SST 09223-56010
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See INSTALLATION )
NOTE: Do not damage the surface of the oil seal press fit hole and crankshaft.
NOTE: l Keep the lip free from foreign matter.
l Do not tap on the oil seal at an angle.

3. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
a. Install the automatic transmission (See INSTALLATION ).
ENGINE ASSEMBLY
COMPONENTS

Fig. 95: Identifying Engine Assembly Replacement Components With Torque Specifications (1 Of 12)

REMOVAL
3. REMOVE UPPER RADIATOR SUPPORT SEAL (See REMOVAL )
4. REMOVE RADIATOR GRILLE (See DISASSEMBLY )
5. REMOVE FRONT BUMPER COVER (See REMOVAL )
6. REMOVE TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)
(See REMOVAL )

7. DISCONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)
(See REMOVAL )
8. DISCONNECT RADIATOR SIDE DEFLECTOR LH (See REMOVAL )
9. REMOVE HOOD SUB-ASSEMBLY
a. Remove the 2 hood support bolts and disconnect the hood supports.
b. Remove the 4 bolts and hood.
Fig. 107: Locating Hood Support Bolts
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
a. Remove the cowl top ventilator louver (See REMOVAL ).
11. REMOVE FRONT FENDER APRON SEAL LH (See REMOVAL )
12. REMOVE FRONT FENDER APRON SEAL REAR LH (See REMOVAL )
13. REMOVE FRONT FENDER APRON SEAL FRONT RH (See REMOVAL )
14. REMOVE FRONT FENDER APRON SEAL REAR RH (See REMOVAL )
17. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
a. Remove the 10 bolts and No. 1 engine under cover.
CAUTION: Remove the hood support assembly while supporting the hood
by hand.

Fig. 108: Locating No. 1 Engine Under Cover Bolts
18. REMOVE NO. 2 ENGINE UNDER COVER
a. Remove the 2 bolts and No. 2 engine under cover.
19. REMOVE OIL PAN PROTECTOR ASSEMBLY (See REMOVAL )
20. DRAIN ENGINE OIL (See REPLACEMENT )
22. REMOVE V-BANK COVER SUB-ASSEMBLY
a. 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 )

Fig. 110: Identifying V-Bank Cover Hooks And Bracket
24. REMOVE AIR CLEANER ASSEMBLY
a. Remove the 3 bolts and air cleaner.
Fig. 111: Locating Air Cleaner Mounting Bolts
28. REMOVE RADIATOR ASSEMBLY (See REMOVAL )
29. DISCONNECT FUEL MAIN AND RETURN HOSE
a. Remove the fuel pipe clamp.
b. Disconnect the fuel main and return hoses (See FUEL SYSTEM ).

Fig. 112: Locating Fuel Main And Return Hoses
30. DISCONNECT WIRE HARNESS AND HOSE
a. Disconnect the purge line hose.
Fig. 113: Locating Purge Line Hose
b. Disconnect the 4 heater hoses.
Fig. 114: Locating Heater Hoses
c. Disconnect the clamp and ECM connector.
HINT:

Refer to the following procedures to disconnect the ECM connector (See REMOVAL ).
d. Disconnect the 4 connectors and clamp from the connector holder block.
Fig. 115: Locating Connectors On Connector Holder Block
e. Disconnect the 2 air pump connectors and 3 clamps.
f. Remove the nut and connector bracket.
g. Remove the bolt and disconnect the ground wire.
h. Disconnect the 2 air injection system hoses.
Fig. 116: Locating Air Pump Connectors And Clamps
i. Remove the nut and disconnect the wire from the positive (+) battery cable.
j. Disconnect the cable from the positive (+) battery terminal.
k. Remove the bolt and disconnect the ground wire from the body.
l. Remove the bolt and disconnect the ground wire from the air injection control bracket.
m. Disconnect the 4 air injection control driver connectors.
n. Remove the nut and disconnect the wire and 2 clips from the engine room junction block.
o. Disconnect the 2 connectors and 2 clips from the engine room junction block.
p. Disconnect the 2 connectors and clamp.

Fig. 117: Locating Air Injection Control Driver Connectors And Clips
31. DISCONNECT COOLER COMPRESSOR ASSEMBLY (See REMOVAL )
32. DISCONNECT VANE PUMP ASSEMBLY (See REMOVAL )
33. REMOVE GENERATOR ASSEMBLY (See REMOVAL )
34. REMOVE TAILPIPE ASSEMBLY (See REMOVAL )
35. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See REMOVAL )
36. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (See REMOVAL )
37. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See REMOVAL )
38. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
a. Disconnect the wire harness clamp.
b. Remove the dipstick.
c. Remove the bolt and dipstick guide.
d. Remove the O-ring from the dipstick guide.
39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
a. Remove the front propeller shaft (See REMOVAL ).
40. REMOVE REAR PROPELLER SHAFT ASSEMBLY
a. Remove the rear propeller shaft (See REMOVAL ).

Fig. 118: Locating Engine Oil Level Dipstick Guide With Bolt
41. REMOVE PROPELLER SHAFT HEAT INSULATOR (See REMOVAL )
42. REMOVE NO. 2 MANIFOLD STAY (See REMOVAL )
43. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See REMOVAL )
44. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (See REMOVAL )
45. REMOVE NO. 1 MANIFOLD STAY (See REMOVAL )
46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See REMOVAL )
47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See REMOVAL )
48. REMOVE STARTER COVER (See REMOVAL )
49. REMOVE STARTER ASSEMBLY (See DISASSEMBLY )
50. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
a. Remove the automatic transmission (See REMOVAL ).
51. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT:
Only perform this procedure when replacement of the engine mounting insulator is necessary.
a. Remove the 2 bolts and front engine mounting insulator RH.
b. Remove the 4 bolts and rear engine mounting insulator from the transmission.
Fig. 119: Locating Engine Mounting Insulator Bolts

52. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
Fig. 120: Holding Crankshaft Using SST
b. Remove the 10 bolts, rear drive plate spacer, drive plate and crankshaft angle sensor rotor.
53. DISCONNECT OIL COOLER PIPE ASSEMBLY (See REMOVAL )
Fig. 121: Locating Drive Plate Bolts
54. REMOVE NO. 2 WATER BY-PASS PIPE
a. Remove the 2 bolts and disconnect the 2 hoses. Then remove the water by-pass pipe.

Fig. 122: Locating Bolts And Water By-Pass Hoses
55. REMOVE ENGINE ASSEMBLY
a. Install 2 engine hangers with 2 bolts as shown in the illustration.
Engine Hanger Part No.
ENGINE HANGER PART NO REFERENCE
b. Attach an engine sling device and hang the engine with a chain block.
Fig. 123: Locating Engine Hanger Bolts
c. Remove the 4 engine mounting insulator bolts.
Item Part No.
Engine hanger 12281-38030
Bolt 90119-14120

d. Lift the engine out from the vehicle slowly and carefully.
Fig. 124: Identifying Engine Mounting Insulator Bolts
56. REMOVE FRONT ENGINE MOUNTING INSULATOR LH
a. Remove the nut and mounting insulator.
Fig. 125: Locating Front Engine Mounting Insulator Nut (LH)
57. REMOVE FRONT ENGINE MOUNTING INSULATOR RH
a. Remove the nut and mounting insulator.
NOTE: Make sure the engine is clear of all wiring, hoses and cables.

Fig. 126: Locating Front Engine Mounting Insulator Nut (RH)
58. REMOVE NO. 2 FRONT ENGINE MOUNTING BRACKET LH
a. Remove the bolt and No. 2 front engine mounting bracket LH.
Fig. 127: Identifying No. 2 Front Engine Mounting Bracket LH
59. INSTALL ENGINE ON ENGINE STAND
a. Install the engine onto an engine stand with bolts.
b. Remove the 2 bolts and 2 engine hangers.
INSTALLATION
1. REMOVE ENGINE STAND
a. 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

Fig. 128: Locating Engine Hanger Bolts
b. Attach an engine sling device and hang the engine with a chain block.
c. Remove the bolts and engine assembly from the engine stand.
2. INSTALL NO. 2 FRONT ENGINE MOUNTING BRACKET LH
a. Install the No. 2 front engine mounting bracket LH with the bolt.
Fig. 129: Identifying No. 2 Front Engine Mounting Bracket LH
3. INSTALL FRONT ENGINE MOUNTING INSULATOR RH
a. Install the mounting insulator with the nut.

Fig. 130: Locating Front Engine Mounting Insulator Nut (RH)
4. INSTALL FRONT ENGINE MOUNTING INSULATOR LH
a. Install the mounting insulator with the nut.
5. INSTALL ENGINE ASSEMBLY
a. Slowly lower the engine assembly into the engine compartment.
b. Attach the engine mounting insulators to the vehicle.
Fig. 131: Locating Front Engine Mounting Insulator Nut (LH)
c. Install the 4 engine mounting insulator bolts.
d. Remove the 2 bolts and 2 engine hangers.
NOTE: Make sure that the engine is clear of all wiring and hoses.

Fig. 132: Identifying Engine Mounting Insulator Bolts
6. INSTALL NO. 2 WATER BY-PASS PIPE
a. Connect the 2 hoses and install the water by-pass pipe with the 2 bolts.
7. CONNECT OIL COOLER PIPE ASSEMBLY (See INSTALLATION )
Fig. 133: Locating Bolts And Water By-Pass Hoses

8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
b. Install the crankshaft angle sensor rotor, drive plate and rear drive plate spacer to the crankshaft.
Fig. 134: Holding Crankshaft Using SST
c. Install and uniformly tighten 10 new bolts in the sequence shown in the illustration.
Fig. 135: Locating Flywheel Installation Bolts
d. Mark the upside of each flywheel installation bolt with paint.
e. Tighten the flywheel installation bolts 90° as shown in the illustration.
NOTE: l Do not reuse the flywheel installation bolts.
l Do not strike or damage the flywheel installation bolts. Be sure
to handle them carefully.

f. Check that the painted marks are now at a 90° angle to the upside.
Fig. 136: Tightening Flywheel Installation Bolts
9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
a. Install the rear engine mounting insulator to the transmission with the 4 bolts.
b. Install the front engine mounting insulator RH with the 2 bolts.
Fig. 137: Locating Engine Mounting Insulator Bolts
10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
a. Install the automatic transmission (See INSTALLATION ).
11. INSTALL STARTER ASSEMBLY (See INSTALLATION )
12. INSTALL STARTER COVER (See INSTALLATION )
13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See INSTALLATION )
14. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See INSTALLATION )
15. INSTALL NO. 1 MANIFOLD STAY (See INSTALLATION )
16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See INSTALLATION )

17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See INSTALLATION )
18. INSTALL NO. 2 MANIFOLD STAY (See INSTALLATION )
19. INSTALL PROPELLER SHAFT HEAT INSULATOR (See INSTALLATION )
20. INSTALL REAR PROPELLER SHAFT ASSEMBLY
a. Install the rear propeller shaft (See INSTALLATION ).
21. INSTALL FRONT PROPELLER SHAFT ASSEMBLY
a. Install the front propeller shaft (See INSTALLATION ).
22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
a. Apply a light coat of engine oil to a new O-ring.
b. Install the O-ring to the guide.
c. Install the dipstick guide with the bolt.
d. Install the dipstick.
e. Connect the wire harness clamp.
23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See INSTALLATION )
Fig. 138: Locating Engine Oil Level Dipstick Guide With Bolt
24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY (See INSTALLATION )
25. INSTALL CENTER EXHAUST PIPE ASSEMBLY (See INSTALLATION )
26. INSTALL TAILPIPE ASSEMBLY (See INSTALLATION )
27. INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
28. CONNECT VANE PUMP ASSEMBLY (See INSTALLATION )
29. CONNECT COOLER COMPRESSOR ASSEMBLY (See INSTALLATION )
30. CONNECT WIRE HARNESS AND HOSE
a. Connect the clamp and 2 connectors.
b. Connect the 2 connectors and 2 clips to the engine room junction block.
c. Install the engine wire with the nut. Then connect the 2 clips.

d. Connect the 4 air injection control driver connectors.
e. Install the ground wire to the air injection control bracket with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
f. Install the ground wire to the body with the bolt.
g. Connect the cable to the positive (+) battery terminal.
h. Install the wire to the positive (+) battery cable with the nut.
Fig. 139: Locating Air Injection Control Driver Connectors And Clips
i. Connect the 2 air injection system hoses.
j. Install the ground wire with the bolt.
k. Connect the 3 clamps and 2 air pump connectors.
l. Install the connector bracket with the nut.

Fig. 140: Locating Air Pump Connectors And Clamps
m. Connect the clamp and 4 connectors to the connector holder block.
Fig. 141: Locating Connectors On Connector Holder Block
n. Connect the 4 heater hoses.
o. Connect the ECM connector and clamp.
HINT:
Refer to the following procedures to connect the ECM connector (See INSTALLATION ).
Fig. 142: Locating Heater Hoses

p. Connect the purge line hose.
Fig. 143: Locating Purge Line Hose
31. CONNECT FUEL MAIN AND RETURN HOSE
a. Connect the fuel main and return hoses (See FUEL SYSTEM ).
b. Install the fuel pipe clamp.
Fig. 144: Locating Fuel Main And Return Hoses
32. INSTALL RADIATOR ASSEMBLY (See INSTALLATION )
36. INSTALL AIR CLEANER ASSEMBLY
a. Install the air cleaner with the 3 bolts.

Fig. 145: Locating Air Cleaner Mounting Bolts
37. INSTALL AIR CLEANER HOSE ASSEMBLY (See INSTALLATION )
38. ADD ENGINE OIL (See REPLACEMENT )
43. INSPECT FOR EXHAUST GAS LEAK (See INSTALLATION )
44. INSPECT FOR FUEL LEAK (See INSTALLATION )
45. INSPECT SHIFT LEVER POSITION (See ON-VEHICLE INSPECTION )
46. INSTALL V-BANK COVER SUB-ASSEMBLY
a. 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.
Fig. 146: Identifying V-Bank Cover Hooks And Bracket

47. INSTALL OIL PAN PROTECTOR ASSEMBLY (See INSTALLATION )
48. INSTALL NO. 2 ENGINE UNDER COVER
a. Install the No. 2 engine under cover with the 2 bolts.
49. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
a. Install the No. 1 engine under cover with the 10 bolts.
50. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH (See REMOVAL )
51. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See REMOVAL )
52. INSTALL FRONT FENDER APRON SEAL REAR RH (See INSTALLATION )
53. INSTALL FRONT FENDER APRON SEAL FRONT RH (See INSTALLATION )
54. INSTALL FRONT FENDER APRON SEAL REAR LH (See INSTALLATION )
55. INSTALL FRONT FENDER APRON SEAL LH (See INSTALLATION )
56. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

a. Install the cowl top ventilator louver (See INSTALLATION ).
57. INSTALL HOOD SUB-ASSEMBLY
a. Install the hood with the 4 bolts.
b. Connect the 2 hood supports with the 2 hood support bolts.
Fig. 149: Locating Hood Support Bolts
58. ADJUST HOOD SUB-ASSEMBLY (See ADJUSTMENT )
59. CONNECT RADIATOR SIDE DEFLECTOR LH (See INSTALLATION )
60. CONNECT RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler) (See
INSTALLATION )
61. INSTALL TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)
(See INSTALLATION )
62. INSTALL FRONT BUMPER COVER (See INSTALLATION )
63. INSTALL RADIATOR GRILLE (See INSTALLATION )
64. INSTALL UPPER RADIATOR SUPPORT SEAL (See INSTALLATION )
67. INSPECT CO/HC (See ON-VEHICLE INSPECTION )
69. INSPECT ENGINE COOLANT LEVEL (See ON-VEHICLE INSPECTION )
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.

ENGINE UNIT
COMPONENTS
Fig. 150: Identifying Engine Unit Replacement Components With Torque Specifications (1 Of 12)

REMOVAL
1. REMOVE ENGINE WIRE

a. Engine LH Side:
1. Disconnect the 2 camshaft timing control valve connectors.
2. Disconnect the 4 ignition coil connectors.
3. Disconnect the 2 VVT sensor connectors.
4. Disconnect the camshaft position sensor connector.
5. Disconnect the vacuum switching valve connector (for ACIS).
6. Disconnect the purge VSV connector.
7. Disconnect the engine coolant temperature sensor connector.
8. Disconnect the fuel injector connector.
9. Disconnect the noise filter connector.
10. Remove the bolt and disconnect the 7 clamps.
Fig. 162: Locating Camshaft Timing Control Valve, Ignition Coil And VVT Sensor
Connectors (LH)
b. Engine RH Side:
1. Disconnect the 2 camshaft timing control valve connectors.
2. Disconnect the 4 ignition coil connectors.
3. Disconnect the 2 VVT sensor connectors.
4. Disconnect the fuel injector connector.
5. Disconnect the noise filter connector.
6. Disconnect the throttle sensor connector.
7. Disconnect the oil pressure sender gauge connector.
8. W/ Oil Level Sensor:
Disconnect the oil level sensor connector.

9. Disconnect the 10 clamps.
Fig. 163: Locating Camshaft Timing Control Valve, Ignition Coil And VVT Sensor
Connectors (RH)
c. Engine Rear Side:
1. Disconnect the 2 air switching valve connectors.
Fig. 164: Locating Air Switching Valve Connectors And Clamps
2. Disconnect the 5 clamps.
3. Remove the 3 bolts.
d. Remove the engine wire.
2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See REMOVAL )
4. REMOVE NO. 1 FUEL HOSE
a. Remove the fuel hose (See FUEL SYSTEM ).
5. DISCONNECT NO. 2 FUEL TUBE (See REMOVAL )

6. DISCONNECT NO. 1 FUEL TUBE (See REMOVAL )
7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY LH (See REMOVAL )
8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY RH (See REMOVAL )
Fig. 165: Identifying Fuel Hose
9. REMOVE FUEL INJECTOR ASSEMBLY (See REMOVAL )
10. REMOVE INTAKE MANIFOLD
a. Disconnect the ventilation hose from the ventilation pipe of the cylinder head cover LH and RH.
Fig. 166: Identifying Ventilation Hose
b. Disconnect the 2 water by-pass hoses.

Fig. 167: Locating Water By-Pass Hoses
c. Disconnect the No. 1 ventilation hose.
Fig. 168: Locating No. 1 Ventilation Hose
d. Remove the bolt and wire bracket from the intake manifold.
Fig. 169: Locating Bolt On Wire Bracket
e. Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets.

Fig. 170: Locating Intake Manifold Nuts And Bolts
11. REMOVE NO. 2 FUEL TUBE
a. Remove the 2 bolts and No. 2 fuel tube.
Fig. 171: Locating No. 2 Fuel Tube With Bolts
12. REMOVE NO. 1 FUEL TUBE
15. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) (See REMOVAL )
16. REMOVE NO. 1 WATER BY-PASS HOSE (See REMOVAL )
17. REMOVE FRONT WATER BY-PASS JOINT (See REMOVAL )

Fig. 172: Identifying No. 1 Fuel Tube
18. REMOVE AIR PIPE SUB-ASSEMBLY
a. Remove the 2 bolts, air pipe and 2 No. 1 air hoses.
19. REMOVE WATER INLET HOUSING (See REMOVAL )
Fig. 173: Locating Air Pipe Sub-Assembly Bolts
20. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Remove the 2 bolts and water by-pass pipe.
21. REMOVE AIR SWITCHING VALVE ASSEMBLY (See REMOVAL )
22. REMOVE NO. 2 AIR TUBE (See REMOVAL )
23. REMOVE NO. 3 AIR TUBE (See REMOVAL )
Fig. 174: Locating Water By-Pass Pipe Sub-Assembly Bolts
24. REMOVE ENGINE WIRE
a. Disconnect the 4 knock sensor connectors.
b. Disconnect the 3 clamps. Then remove the engine wire.

Fig. 175: Locating Knock Sensor Connectors
25. REMOVE SEPARATOR CASE
a. Remove the 4 bolts and separator case.
Fig. 176: Locating Separator Case Bolts
26. REMOVE KNOCK SENSOR
a. Remove the 4 bolts and 4 knock sensors.

Fig. 177: Locating Knock Sensor Bolts
27. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the 2 water drain cock plugs from the water drain cocks.
b. Remove the 2 water drain cocks from the cylinder block.
Fig. 178: Locating Water Drain Cock Plugs
28. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and mounting bracket.

Fig. 179: Locating Front No. 1 Engine Mounting Bracket Bolts (RH)
29. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
a. Remove the 4 bolts and mounting bracket.
Fig. 180: Locating Front No. 1 Engine Mounting Bracket Bolts (LH)
30. REMOVE IGNITION COIL ASSEMBLY
a. Remove the 8 bolts and 8 ignition coils.
31. REMOVE NOISE FILTER
a. LH:
Remove the bolt and noise filter from the cylinder head cover.
b. RH:
Remove the bolt and noise filter from the cylinder head cover.

Fig. 181: Locating Ignition Coils With Bolts
DISASSEMBLY
2. REMOVE OIL FILTER ELEMENT (See REPLACEMENT )
6. REMOVE OIL FILLER CAP SUB-ASSEMBLY
7. REMOVE OIL FILLER CAP HOUSING
a. Remove the 2 bolts, filler cap housing and gasket.
8. REMOVE SPARK PLUG
a. Using a 16 mm plug wrench, remove the 8 spark plugs.
Fig. 182: Locating Oil Filler Cap Housing Bolts
9. REMOVE VVT SENSOR
a. LH:
Remove the 2 bolts and 2 VVT sensors.

Fig. 183: Locating VVT Sensor Bolts (LH)
b. RH:
Remove the 2 bolts and 2 VVT sensors.
Fig. 184: Locating VVT Sensor Bolts (RH)
10. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the bolt and camshaft position sensor.
Fig. 185: Locating Camshaft Position Sensor Bolt
11. REMOVE CRANK POSITION SENSOR PROTECTOR

a. Remove the 2 bolts and sensor protector.
Fig. 186: Locating Crank Position Sensor Protector Bolts
12. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt and crankshaft position sensor.
Fig. 187: Locating Crankshaft Position Sensor Bolts
13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY
a. LH:
Remove the 2 bolts and 2 oil control valves.

Fig. 188: Locating Oil Control Valves Bolts (LH)
b. RH:
Remove the 2 bolts and 2 oil control valves.
14. REMOVE WATER PUMP PULLEY (See REMOVAL )
15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (See REMOVAL )
16. REMOVE FLUID COUPLING BRACKET (See REMOVAL )
17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See REMOVAL )
Fig. 189: Locating Oil Control Valves Bolts (RH)
18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See REMOVAL )
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH (See REMOVAL )
20. REMOVE OIL CONTROL VALVE FILTER
a. LH:
Remove the 3 bolts, cylinder head cover spacer, gasket and filter.
Fig. 190: Identifying Bolts, Cylinder Head Cover Spacer, Gasket And Filter (LH)

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Land-Cruiser-2009.pdf