Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 3UR-FE ENGINE MECHANICAL
ENGINE UNIT - DISASSEMBLY
| 1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY |
Disconnect the sender gauge connector.
Remove the oil pressure sender gauge.
| 2. REMOVE OIL FILTER ELEMENT |
Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.
| *1 | Pipe |
| *2 | Hose |
Remove the oil filter drain plug.
Install the pipe to the oil filter cap.
| *1 | Cap |
| *2 | Valve |
| *3 | Pipe |
| *4 | O-Ring |
| *5 | Hose |
- NOTICE:
- If the O-ring is removed with the drain plug, install the O-ring together with the pipe.
- HINT:
- Use a container to catch the draining oil.
Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.
Using SST, remove the oil filter cap.
- SST
- 09228-06501
| *1 | Oil Filter Bracket Clip |
- NOTICE:
- Do not remove the oil filter bracket clip.
Remove the oil filter element and O-ring from the oil filter cap.
| *1 | Oil Filter Element |
| *2 | O-Ring |
- NOTICE:
- Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.
| 3. REMOVE NO. 1 OIL COOLER BRACKET |
Remove the 2 nuts and bracket.
Disconnect the ground wire from the cylinder block.
| 4. REMOVE OIL FILTER BRACKET |
Remove the 2 bolts, 2 nuts and filter bracket.
Remove the 2 O-rings.
| 5. REMOVE OIL FILLER CAP SUB-ASSEMBLY |
| 6. REMOVE OIL FILLER CAP HOUSING |
Remove the 2 bolts, filler cap housing and gasket.
| 7. REMOVE SPARK PLUG |
Using a 16 mm plug wrench, remove the 8 spark plugs.
| 8. REMOVE VVT SENSOR |
LH:
Remove the 2 bolts and 2 VVT sensors.
RH:
Remove the 2 bolts and 2 VVT sensors.
| 9. REMOVE CAMSHAFT POSITION SENSOR |
Remove the bolt and camshaft position sensor.
| 10. REMOVE CRANK POSITION SENSOR PROTECTOR |
Remove the 2 bolts and sensor protector.
| 11. REMOVE CRANKSHAFT POSITION SENSOR |
Remove the bolt and crankshaft position sensor.
| 12. REMOVE ENGINE OIL LEVEL SENSOR |
Disconnect the oil level sensor connector.
Remove the 4 bolts and oil level sensor.
| *1 | Cutting Position |
| *2 | Supply Part |
Cut off the gasket as shown in the illustration.
Remove the gasket from the oil level sensor.
- HINT:
- After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.
| 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 |
Using SST, hold the water pump pulley.
- SST
- 09960-10010(09962-01000,09963-01000)
Remove the 4 bolts and water pump pulley.
| 15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY |
Remove the bolt and idler pulley.
| 16. REMOVE FLUID COUPLING BRACKET |
Remove the 4 bolts and fluid coupling bracket.
| 17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY |
Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.
| 18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH |
Remove the 14 bolts, seal washer, cylinder head cover and gasket.
- HINT:
- Make sure the removed parts are returned to the same places they were removed from.
Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).
| 19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH |
Remove the bolt and noise filter.
Remove the 14 bolts, seal washer, cylinder head cover and gasket.
- HINT:
- Make sure the removed parts are returned to the same places they were removed from.
Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).
| 20. REMOVE OIL CONTROL VALVE FILTER |
LH:
Remove the 3 bolts, cylinder head cover spacer, gasket and filter.
| *1 | Cylinder Head Cover Spacer |
| *2 | Gasket |
| *3 | Filter |
RH:
Remove the 3 bolts, cylinder head cover spacer, gasket and filter.
| *1 | Cylinder Head Cover Spacer |
| *2 | Gasket |
| *3 | 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.
| *1 | Tape |
 | Pry |
- NOTICE:
- HINT:
- Tape the screwdriver tip before use.
| 22. REMOVE CRANKSHAFT PULLEY |
Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.
- SST
- 09213-70011
09330-00021
| *a | Hold |
| Turn |
Using the pulley set bolt and SST, remove the crankshaft pulley.
- SST
- 09950-50013(09951-05010,09952-05010,09953-05010,09954-05011)
| *a | Hold |
| Turn |
| 23. REMOVE WATER PUMP ASSEMBLY |
Remove the 8 bolts, water pump and gasket.
| 24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY |
Remove the 28 bolts and nut shown in the illustration.
| Bolt |
 | Nut |
Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver as shown in the illustration.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.
- HINT:
- Tape the screwdriver tip before use.
Remove the oil pump gasket from the cylinder block.
Remove the O-ring from the oil pan.
| 25. REMOVE WATER INLET PIPE |
Remove the water inlet pipe.
Remove the 2 O-rings from the water inlet pipe.
| 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.
| *1 | Wooden Block |
- NOTICE:
- 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.
| *1 | Timing Mark | *2 | Timing Mark Position |
| *3 | Knock Pin Position | *4 | Key |
| *a | Toward Ceiling | *b | Approximately 2° |
| *c | Approximately 45° | *d | Approximately 16° |
| *e | Approximately 18° | *f | Approximately 32° |
| 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.
| *1 | Plunger |
| *2 | Stopper Plate |
Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.
| *1 | Plunger |
| *2 | Stopper Plate |
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 1.0 mm (0.0394 in.) into the hole to fix it in place.
| *1 | Pin |
| *2 | Plunger |
| *a | Push |
Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
| *a | Hold |
| Turn |
- NOTICE:
Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
| *a | Hold |
| Turn |
- NOTICE:
- 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.
| *1 | Plunger |
| *2 | Stopper Plate |
Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.
| *1 | Plunger |
| *2 | Stopper Plate |
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 1.0 mm (0.0394 in.) into the hole to fix it in place.
| *1 | Pin |
| *2 | Plunger |
| *a | Push |
Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
| *a | Hold |
| Turn |
- NOTICE:
Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.
| *a | Hold |
| Turn |
- NOTICE:
- 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 |
Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
| *1 | IN |
| *2 | EX |
| *3 | Knock Pin |
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.
- NOTICE:
- 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.
- HINT:
- Arrange the removed parts in the correct order.
| 40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH |
Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
- HINT:
- Tape the screwdriver tip before use.
| 41. REMOVE CAMSHAFT BEARING CAP RH |
Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
| *1 | EX |
| *2 | IN |
| *3 | Knock Pin |
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.
- NOTICE:
- 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.
- HINT:
- Arrange the removed parts in the correct order.
| 42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH |
Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.
- HINT:
- Tape the screwdriver tip before use.
| 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 |
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.
- NOTICE:
- HINT:
- Be sure to arrange the removed parts for each installation position separately.
Remove the cylinder head and gasket.
| 47. 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.
- NOTICE:
- HINT:
- Be sure to arrange the removed parts for each installation position separately.
Remove the cylinder head and gasket.
| 48. REMOVE CYLINDER BLOCK WATER JACKET SPACER |
Remove the 2 water jacket spacers from the cylinder block.
- NOTICE:
- 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.
| Bolt |
| Nut |
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 |
Remove the 14 bolts and 2 nuts.
| Bolt |
| Nut |
Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.
- NOTICE:
- 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.
| Bolt |
| Nut |
- 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.
| *A | LH Side |
| *B | RH Side |
- NOTICE:
- 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.
| *1 | Wooden Block |
Using a screwdriver and hammer, tap out the oil seal.
| 58. REMOVE RING PIN |
- NOTICE:
- It is not necessary to remove the ring pin unless it is being replaced.
| 59. REMOVE STUD BOLT |
- NOTICE:
- If the stud bolt is deformed or its threads are damaged, replace it.