When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Start the engine.

Turn the A/C switch on.

Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

Stop the engine.

Recover the refrigerant from the A/C system using a refrigerant recovery unit.

2. PRECAUTION

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work ().

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable some systems need to be initialized after the cable is reconnected ().

4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

()

5. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Remove the 2 nuts and No. 1 engine cover.

6. REMOVE UPPER RADIATOR SUPPORT SEAL

Remove the 7 clips and upper radiator support seal.

7. REMOVE MAIN BATTERY

8. REMOVE SUB-BATTERY

9. REMOVE FRONT WHEEL

10. REMOVE HOOD SUB-ASSEMBLY

Remove the 2 hood stay bolts. Then disconnect the 2 hood supports.

NOTICE:

Avoid touching the stroke portions of the rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing.

Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks.

Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed.

Remove the hood support while supporting the hood by hand.

Remove the 4 bolts and hood.

11. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Remove the 3 bolts and screw.

Loosen the clip and remove the front fender splash shield LH.

12. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Remove the 3 bolts and 2 screws.

Loosen the clip and remove the front fender splash shield RH.

13. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Remove the 10 bolts and No. 1 engine under cover.

14. REMOVE NO. 2 ENGINE UNDER COVER

Remove the 2 bolts and No. 2 engine under cover.

15. REMOVE OIL PAN PROTECTOR ASSEMBLY

Remove the 4 bolts and oil pan protector.

16. DRAIN ENGINE COOLANT

CAUTION:

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

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Loosen the radiator drain cock plug.

Remove the radiator reservoir cap to drain the coolant in the radiator.

Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Tighten the radiator drain cock plug by hand.

Tighten the oil filter bracket drain cock plug.

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

17. DRAIN ENGINE OIL

Remove the oil filler cap.

Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

Install a new gasket and the oil pan drain plug.

Torque:
38 N*m{ 387 kgf*cm, 28 ft.*lbf}

18. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

()

19. REMOVE NO. 3 ENGINE ROOM WIRE

Disconnect the 4 wire harness clamps.

Remove the 2 nuts and No. 3 engine room wire.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

Loosen the hose clamp.

Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

Detach the 4 clamps and remove the air cleaner cap.

21. REMOVE AIR CLEANER FILTER ELEMENT

22. REMOVE AIR CLEANER CASE

Using a clip remover, detach the wire harness clamp.

Remove the 3 bolts and air cleaner case.

23. REMOVE NO. 1 AIR CLEANER HOSE

Loosen the hose clamp and remove the No. 1 air cleaner hose.

24. REMOVE INTAKE AIR CONNECTOR

w/ Viscous Heater:

Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

Text in Illustration
*A	w/ Viscous Heater

w/o Viscous Heater:

Disconnect the connector from the water temperature sensor.

Using a clip remover, detach the 3 wire harness clamps.

Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

25. REMOVE VANE PUMP OIL RESERVOIR ASSEMBLY

Insert a screwdriver between the reservoir and oil reservoir bracket, push the claw, and then disconnect the reservoir by pulling it upwards.

26. REMOVE NO. 1 OIL RESERVOIR BRACKET

Remove the 2 bolts and bracket.

27. REMOVE RADIATOR RESERVOIR ASSEMBLY

Disconnect the 2 hoses.

Remove the 3 bolts and radiator reservoir.

28. REMOVE VANE PUMP ASSEMBLY

w/ DPF: ()

w/o DPF: ()

29. DISCONNECT NO. 1 RADIATOR HOSE

30. DISCONNECT NO. 2 RADIATOR HOSE

31. REMOVE V-RIBBED BELT (w/ Viscous Heater)

Loosen the lock nut and turn the bolt counterclockwise.

Remove the V-ribbed belt.

32. REMOVE NO. 1 IDLER PULLEY (w/ Viscous Heater)

Remove the bolt, cover, No. 1 idler pulley and collar.

33. REMOVE NO. 3 IDLER PULLEY (w/ Viscous Heater)

Remove the nut and No. 3 idler pulley.

34. REMOVE V-RIBBED BELT

Using a wrench to the V-ribbed belt tensioner bracket, turn the wrench clockwise and remove the V-ribbed belt.

35. REMOVE FRONT FENDER APRON SEAL FRONT RH

Remove the 3 clips and front fender apron seal front RH.

36. REMOVE FRONT FENDER APRON SEAL REAR RH

Remove the 4 clips and front fender apron seal rear RH.

37. REMOVE FRONT FENDER APRON SEAL FRONT LH

w/o KDSS:

Remove the 4 clips and front fender apron seal front LH.

w/ KDSS:

Remove the 3 clips and front fender apron seal front LH.

38. REMOVE FRONT FENDER APRON SEAL REAR LH

Remove the 4 clips and front fender apron seal rear LH.

39. REMOVE OIL COOLER TUBE (for Automatic Transmission)

Disconnect the inlet and outlet No. 1 oil cooler hose.

Disconnect the inlet No. 2 and No. 3 oil cooler hoses.

Disconnect the inlet No. 4 oil cooler hose.

Remove the 2 bolts and transmission oil cooler tube.

40. REMOVE FAN SHROUD WITH FAN

Loosen the 4 nuts holding the fluid coupling fan.

Remove the 2 bolts holding the fan shroud.

Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the fluid coupling fan.

41. REMOVE FAN PULLEY

42. REMOVE FRONT BUMPER WINCH COVER (w/ Winch)

Detach the 2 claws.

Detach the 3 guides and remove front bumper winch cover sub-assembly.

43. REMOVE RADIATOR GRILLE

Put protective tape around the radiator grille assembly.

Text in Illustration
*1	Protective Tape

Remove the 3 screws.

Detach the 2 clips and 8 claws, and remove the radiator grille assembly.

w/ Wide View Front Monitor System:

Disconnect the connector.

44. REMOVE FRONT BUMPER COVER

HINT:

For the front bumper cover with garnish, use the procedure described below.

Put protective tape around the front bumper cover.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*1	Protective Tape	-	-

Using a T30 "TORX" socket, remove the 6 screws.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*A	LH Side	*B	RH Side

Remove the 3 clips, 4 screws and 4 bolts.

Detach the 10 claws and remove the front bumper cover.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

w/ TOYOTA Parking Assist-sensor System or w/ Fog Light:

Disconnect the No. 4 engine room wire connector and remove the front bumper cover.

w/ Headlight Cleaner System:

Disconnect the headlight cleaner hose and remove the front bumper cover.

45. REMOVE TRANSMISSION OIL COOLER AIR DUCT (for Automatic Transmission)

Remove the 4 bolts and oil cooler air duct.

46. DISCONNECT RADIATOR SIDE DEFLECTOR RH (for Manual Transmission)

Using a clip remover, remove the 4 clips, and remove the side deflector.

47. DISCONNECT RADIATOR SIDE DEFLECTOR LH

Using a clip remover, remove the 4 clips, and remove the side deflector.

48. REMOVE RADIATOR ASSEMBLY

Remove the 4 bolts and radiator.

49. DISCONNECT FRONT DIFFERENTIAL BREATHER TUBE

50. DISCONNECT FUEL TUBE

w/ DPF:

Disconnect the 2 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

w/o DPF:

Disconnect the 3 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

51. REMOVE NO. 1 COOL AIR INLET (w/o Intercooler)

Loosen the No. 1 air hose clamp.

Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

Remove the 3 nuts, bolt and No. 1 cool air inlet.

Remove the gasket from the air tube RH.

52. REMOVE NO. 2 COOL AIR INLET (w/o Intercooler)

Loosen the No. 2 air hose clamp.

Remove the 3 nuts, bolt and No. 2 cool air inlet.

Remove the gasket from the air tube LH.

53. DISCONNECT WATER HOSE SUB-ASSEMBLY

Text in Illustration
*A	w/ Rear Heater
*B	w/o Rear Heater

54. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

Disconnect the ventilation hose from the cylinder head cover RH.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Remove the 2 bolts and No. 2 engine oil level dipstick guide.

Remove the O-ring from the No. 2 engine oil level dipstick guide.

55. REMOVE AIR TUBE SUB-ASSEMBLY RH

Loosen the hose clamp.

Remove the air tube from the throttle body.

56. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket from the intake pipe.

57. DRAIN CLUTCH FLUID (for Manual Transmission)

58. REMOVE CLUTCH HOSE (for Manual Transmission)

Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

NOTICE:

Do not bend or damage the flexible hose tubes.

Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

Remove the 2 clips.

Remove the bolt and clutch hose.

59. REMOVE AIR TUBE SUB-ASSEMBLY LH

Loosen the hose clamp.

Remove the air tube from the throttle body.

60. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

NOTICE:

Do not bend or damage the flexible hose tube.

Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.

Remove the 2 bolts and tube connector to flexible hose tube.

61. REMOVE NO. 1 GAS FILTER

Disconnect the hose from the intake pipe.

Remove the No. 1 gas filter.

62. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

for Manual Transmission:

Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.

Remove the 2 bolts and No. 3 intercooler support bracket.

63. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket from the intake pipe.

64. REMOVE NO. 1 AIR HOSE

Loosen the hose clamp and remove the No. 1 air hose.

65. REMOVE NO. 3 AIR TUBE

Disconnect the wire harness from the clamp.

Remove the nut and ground wire.

Remove the bolt and disconnect the wire harness bracket.

Loosen the hose clamp and remove the bolt and No. 3 air tube.

66. REMOVE NO. 1 AIR TUBE ASSEMBLY

Remove the bolt and No. 1 air tube.

Remove the O-ring.

67. REMOVE NO. 2 AIR HOSE

Loosen the hose clamp and remove the No. 2 air hose.

68. REMOVE NO. 4 AIR TUBE

Remove the bolt and disconnect the suction hose.

Loosen the hose clamp and remove the bolt and No. 4 air tube.

69. REMOVE NO. 2 AIR TUBE ASSEMBLY

Remove the bolt and No. 2 air tube.

Remove the O-ring.

70. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

Disconnect the ventilation hose from the oil separator.

Loosen the hose clamp.

Remove the bolt and No. 2 air cleaner pipe.

71. REMOVE NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

Remove the bolt and disconnect the discharge hose from the cooler compressor.

Remove the O-ring from the discharge hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

72. REMOVE SUCTION HOSE SUB-ASSEMBLY

Remove the bolt and disconnect the suction hose from the cooler compressor.

Remove the O-ring from the suction hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

73. REMOVE COOLER COMPRESSOR ASSEMBLY

Disconnect the 4 connectors.

Using a clip remover, detach the 3 wire harness clamps.

Remove the 4 bolts and cooler compressor.

74. REMOVE NO. 2 INTAKE AIR CONNECTOR PIPE

w/ Intercooler:

Disconnect the vacuum hose.

Loosen the hose clamp, and remove the bolt and No. 2 intake air connector pipe.

75. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

76. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

Loosen the hose clamp.

Remove the bolt and No. 1 air cleaner pipe.

77. DISCONNECT FUEL HOSE

w/ DPF:

Text in Illustration
*a	for Fuel Filter with Heater
*b	for Fuel Filter without Heater

w/o DPF:

Text in Illustration
*a	for Fuel Filter with Heater
*b	for Fuel Filter without Heater

78. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

79. REMOVE NO. 4 WATER BY-PASS PIPE

w/ EGR System:

Remove the 2 bolts and nut.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*A	w/ DPF	*B	w/o DPF

w/ DPF:

Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

w/o DPF:

Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.

w/o EGR System:

Remove the 2 bolts and nut.

Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

80. DISCONNECT ENGINE WIRE

LH Side:

w/ DPF:

Disconnect the 7 connectors from the injector driver.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

w/o DPF:

Disconnect the 4 connectors from the injector driver.

Disconnect the 4 connectors and detach the wire harness holder from the relay block.

Remove the bolt and disconnect the ground wire.

Disconnect the wire harness from the wire harness clamp holder.

Remove the bolt and disconnect the ground wire from the body panel.

Using a clip remover, detach the ground wire clamp labeled A from the relay block side.

Disconnect the wire harness from the wire harness clamp holder labeled B.

Remove the nut and detach the generator positive (+) cable holder from the relay block.

Disconnect the generator positive (+) cable from the 2 clamps.

Disconnect the 2 connectors.

Using a clip remover, detach the 3 wire harness clamps.

for RHD:

Disconnect the 4 connectors and detach the wire harness tab labeled A from the relay block.

for RHD:

Disconnect the ECM connector.

for RHD:

Disconnect the wire harness from the wire harness clamp holder.

Disconnect the 8 connectors.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*A	w/ DPF	*B	w/o DPF

Remove the bolt and the engine wire harness bracket labeled B.

Using a clip remover, detach the wire harness clamp labeled D.

Remove the 2 bolts and disconnect the engine wire protector labeled A.

for RHD:

Disconnect the wire harness from the wire harness clamp holder labeled C.

RH Side:

for LHD:

Disconnect the 4 connectors, and detach the wire harness holder from the relay block labeled A.

for LHD:

Disconnect the ECM connector.

for LHD:

Disconnect the wire harness from the wire harness clamp holder.

Disconnect the 7 connectors.

Engine Assembly - Removal. 1VD-FTV ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*A	w/ DPF	*B	w/o DPF

Using a clip remover, detach the wire harness clamp.

Remove the 3 bolts and disconnect the engine wire protector labeled A.

Remove the bolt and the wire harness bracket labeled B.

Remove the screw grommet, nut and the glow plug wire harness labeled C.

for RHD:

Disconnect the wire harness from the wire harness clamp holder.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

for RHD:

Remove the bolt and wire harness clamp holder.

w/ Winch:

Remove the bolt and disconnect the ground wire.

Rear Side:

Using a clip remover, detach the wire harness clamp.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Remove the 2 bolts and 2 ground wires labeled C.

Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

w/ DPF:

Disconnect the 3 connectors.

w/o DPF:

Disconnect the connector.

Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.

81. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

NOTICE:

After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.

After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.

Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

Remove the bolt and No. 2 injection pipe clamp.

Remove the union bolt and gasket.

Remove the bolt, nut and No. 2 fuel pipe.

82. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.

w/ EGR System:

Using a union nut wrench, loosen the No. 6 injection pipe ends.

Remove the 2 nuts and 2 No. 2 injection pipe clamps.

Remove the No. 6 injection pipe.

w/o EGR System:

Using a union nut wrench, loosen the No. 6 injection pipe ends.

Remove the nut and No. 2 injection pipe clamp.

Remove the bolt and No. 6 injection pipe.

83. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

Disconnect the 2 vacuum hoses.

Remove the bolt and vacuum switching valve.

84. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

Disconnect the 2 vacuum hoses.

Remove the 3 bolts and vacuum transmitting pipe.

85. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)

Remove the 4 bolts and cylinder head cover silencer.

86. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)

Disconnect the fuel hose.

Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

87. REMOVE INJECTION PIPE LH

w/ Intercooler:

Remove the 2 nuts and 4 injection pipe clamps.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Using a union nut wrench, remove the 4 injection pipes.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

88. REMOVE NO. 2 FUEL PIPE (w/ DPF)

Remove the No. 4 fuel hose.

Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.

89. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)

w/ DPF:

Disconnect the fuel hose.

Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

w/o DPF:

Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

90. REMOVE COMMON RAIL ASSEMBLY LH

Remove the 2 bolts and common rail.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

NOTICE:

Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.

w/ DPF:
Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.

91. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

w/ DPF:

Remove the bolt and No. 2 injection pipe clamp.

Disconnect the fuel hose.

Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.

w/o DPF:

Disconnect the 2 hoses from the fuel pipe.

Remove the bolt and fuel filter to injection pump fuel pipe.

92. DISCONNECT FUEL PUMP MOTOR WIRE

Remove the bolt and disconnect the connector from the fuel supply pump.

93. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

Using a union nut wrench, remove the No. 5 injection pipe.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.

94. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)

Remove the 4 bolts and cylinder head cover silencer.

95. REMOVE INJECTION PIPE RH

w/ Intercooler:

Remove the 2 nuts and 4 injection pipe clamps.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Using a union nut wrench, remove the 4 injection pipes.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

96. REMOVE COMMON RAIL ASSEMBLY RH

Remove the 2 bolts and common rail.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

NOTICE:

Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.

97. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

98. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

99. REMOVE CONNECTING WIRE (w/ DPF)

Detach the 2 clamps and remove the connecting wire.

100. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)

Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

101. REMOVE INTAKE PIPE

w/ EGR System:

Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

w/o EGR System:

Remove the 2 nuts, 4 bolts, intake pipe and gasket.

102. DISCONNECT NO. 2 ENGINE WIRE

Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

103. REMOVE NO. 3 INTAKE MANIFOLD

Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

104. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

105. REMOVE EGR PIPE INSULATOR (w/ EGR System)

Remove the 2 bolts and EGR pipe insulator.

106. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

107. REMOVE EGR COOLER INSULATOR (w/ EGR System)

108. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)

Disconnect the No. 1 fuel hose from the fuel cooler.

Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

NOTICE:

After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

109. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)

Disconnect the No. 2 fuel hose from the fuel cooler.

Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

NOTICE:

After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

110. DISCONNECT NO. 6 WATER BY-PASS HOSE (w/o DPF)

111. REMOVE FUEL COOLER ASSEMBLY (w/o DPF)

Remove the 2 bolts and fuel cooler.

112. REMOVE NO. 2 FUEL INJECTOR PROTECTOR (w/ DPF)

Detach the hose clamp.

Remove the bolt and No. 2 fuel injector protector.

113. REMOVE NO. 1 FUEL INJECTOR PROTECTOR (w/ DPF)

Remove the bolt and No. 1 fuel injector protector.

114. REMOVE FUEL TUBE SUB-ASSEMBLY (w/ DPF)

Disconnect the 3 fuel tube connectors ().

Detach the 3 clamps and remove the fuel tube.

115. REMOVE NO. 1 WATER BY-PASS PIPE

Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

116. REMOVE NO. 2 NOZZLE LEAKAGE PIPE (w/ DPF)

Remove the 4 injector hollow screws and 4 gaskets.

Text in Illustration
	Injector Hollow Screw
	Bolt

Remove the 2 bolts and No. 2 nozzle leakage pipe.

NOTICE:

When removing the nozzle leakage pipe, place a cushion under the pipe.

Be careful not to deform or scratch the union seal surface.

After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

117. REMOVE NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)

Remove the 4 injector hollow screws and 4 gaskets.

Text in Illustration
	Injector Hollow Screw
	No. 2 Check Valve
	Union Bolt

Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

Remove the union bolt and No. 1 nozzle leakage pipe.

NOTICE:

When removing the nozzle leakage pipe, place a cushion under the pipe.

Be careful not to deform or scratch the union seal surface.

After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.

118. REMOVE FUEL HOSE BRACKET (w/ DPF)

Remove the bolt and fuel hose bracket.

119. REMOVE NO. 1 FUEL PIPE CLAMP (w/ DPF)

Remove the 2 bolts and 2 No. 1 fuel pipe clamps.

Text in Illustration
*a	RH Side
*b	LH Side

120. REMOVE NO. 1 INTAKE MANIFOLD

Remove the 9 bolts, No. 1 intake manifold and gasket.

121. REMOVE NO. 2 INTAKE MANIFOLD

Remove the 9 bolts, No. 2 intake manifold and gasket.

122. INSTALL NO. 1 AND NO. 2 ENGINE HANGER

Install the No. 1 and No. 2 engine hangers to the cylinder head RH and LH with the 4 bolts as shown in the illustration.

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

HINT:

No. 1 engine hanger	12281-51040
No. 2 engine hanger	12282-51040
Bolt	91671-80825

Text in Illustration
*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger
*a	RH
*b	LH

123. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

()

124. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

()

125. REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transmission)

Remove the bolt and clutch release cylinder to flexible hose tube.

126. REMOVE ENGINE ASSEMBLY

Attach an engine sling device and hang the engine with a chain block.

Remove the 4 bolts from the engine mounting RH and LH side.

Lift the engine out of the vehicle carefully.

NOTICE:

Make sure the engine is clear of all wiring and hoses.

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

Place the engine onto a work bench.

127. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)