Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1VD-FTV ENGINE MECHANICAL
ENGINE UNIT - REMOVAL
| 1. REMOVE VACUUM PUMP ASSEMBLY (w/ Intercooler) |
Remove the 3 bolts and vacuum pump.
Remove the 2 O-rings.
| 2. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE |
Remove the 2 bolts and No. 1 engine oil level dipstick guide.
Remove the O-ring from the No. 1 engine oil level dipstick.
| 3. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE |
Disconnect the 4 connectors.
Using a clip remover, detach the 5 wire harness clamps.
Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.
| 4. REMOVE GENERATOR ASSEMBLY |
Remove the nut and bolt, and disconnect the generator positive (+) cable.
Remove the 3 bolts, 2 nuts and generator.
| 5. REMOVE NO. 2 VENTILATION HOSE |
| *A | w/ DPF |
| *B | w/o DPF |
| 6. REMOVE NO. 2 TURBO WATER HOSE |
| 7. REMOVE BREATHER PLUG RH |
Disconnect the hose.
Detach the clamp and remove the breather plug RH.
| 8. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR |
Remove the 3 bolts and No. 1 exhaust manifold heat insulator.
| *A | w/ DPF |
| *B | w/o DPF |
| 9. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE |
| 10. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY |
Disconnect the water hose.
Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.
| 11. REMOVE NO. 1 TURBOCHARGER STAY |
Remove the 2 bolts and No. 1 turbocharger stay.
| 12. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY |
Disconnect the hose.
Remove the union bolt, bolt, No. 1 ventilation tube and gasket.
| 13. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH |
Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.
Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.
| *A | w/ DPF | *B | w/o DPF |
Remove the gasket.
w/ DPF:
Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.
Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.
| *A | w/ DPF | *B | w/o DPF |
Remove the gasket from the No. 1 turbocharger.
| 14. REMOVE NO. 3 VENTILATION HOSE |
| *A | w/ DPF |
| *B | w/o DPF |
| 15. REMOVE BREATHER PLUG LH |
Disconnect the hose.
| *A | w/ DPF |
| *B | w/o DPF |
w/o DPF:
Detach the clamp.
Remove the breather plug LH.
| 16. REMOVE NO. 2 TURBO WATER HOSE |
| 17. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR |
Remove the 3 bolts and No. 2 exhaust manifold heat insulator.
| *A | w/ DPF |
| *B | w/o DPF |
| 18. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY |
Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.
| 19. REMOVE FRONT WATER BY-PASS JOINT |
Remove the front water by-pass joint and gasket.
| 20. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY |
Disconnect the water hose.
Remove the union bolt, bolt, No. 2 turbo water pipe and gasket.
| 21. DISCONNECT NO. 2 OUTLET TURBO OIL HOSE |
| 22. REMOVE NO. 2 TURBOCHARGER STAY |
Remove the 2 bolts and No. 2 turbocharger stay.
| 23. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY |
Disconnect the hose.
| *A | w/ DPF | *B | w/o DPF |
Remove the union bolt, bolt, No. 2 ventilation tube and gasket.
| 24. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH |
Disconnect the 2 connectors from the turbocharger.
Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.
Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.
| *A | w/ DPF | *B | w/o DPF |
Remove the gasket.
w/ DPF:
Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.
Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.
| *A | w/ DPF |
| *B | w/o DPF |
Remove the gasket from the turbocharger.
| 25. REMOVE VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater) |
Disconnect the connector and detach the clamp.
Using pliers, grip the claws of the clips and slide the 2 clips.
Disconnect the 2 heater hoses.
Remove the 2 bolts and heater assembly.
| 26. REMOVE NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater) |
Remove the bolt and No. 1 idler pulley bracket.
| 27. REMOVE WATER INLET |
Disconnect the No. 2 oil cooler hose from the water pump and clamp.
Remove the 4 bolts and water inlet.
| 28. REMOVE THERMOSTAT |
Remove the thermostat.
Remove the gasket from the thermostat.
| 29. REMOVE TIMING GEAR COVER INSULATOR (w/ Intercooler) |
w/o Viscous Heater:
Remove the 2 bolts and timing gear cover insulator.
w/ Viscous Heater:
Remove the timing gear cover insulator.
| 30. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY |
Remove the 3 bolts and V-ribbed belt tensioner bracket.
Remove the bolt and No. 1 idler pulley.
Remove the 5 bolts and V-ribbed belt tensioner.
| 31. REMOVE STARTER ASSEMBLY |
Detach the harness clamp and disconnect the wire harness.
Disconnect the starter connector.
Remove the nut and disconnect the starter wire.
Disconnect the 2 starter hoses.
Remove the 2 bolts and starter.
| 32. REMOVE STARTER HOSE BRACKET |
Remove the 2 bolts and starter hose bracket.
| 33. DISCONNECT INLET WATER HOSE |
| 34. REMOVE DIESEL ENGINE COOLANT TEMPERATURE SENSOR |
Disconnect the sensor connector.
Using a 19 mm deep socket wrench, remove the sensor and gasket.
| 35. REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET |
Remove the 2 bolts and No. 2 intercooler support bracket.
| 36. REMOVE WATER OUTLET |
Remove the 2 bolts and gasket and disconnect the water outlet from the No. 2 water hose joint.
| 37. REMOVE WATER OUTLET PIPE |
Remove the 4 bolts, water outlet pipe and 2 gaskets.
| 38. SEPARATE NO. 1 AND NO. 2 WATER OUTLET PIPES AND WATER BY-PASS OUTLET |
Remove the 2 bolts and No. 1 water outlet pipe from the No. 2 water outlet pipe.
Disconnect the No. 2 water outlet pipe from the No. 1 water hose joint.
Disconnect the water by-pass outlet from the No. 1 water hose joint.
| 39. REMOVE CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission) |
Remove the 2 bolts and clutch flexible hose bracket.
| 40. REMOVE NO. 1 GLOW PLUG CONNECTOR |
Remove the 2 screw grommets and 2 nuts, and disconnect the 2 wire harnesses.
Remove the 8 screw grommets, 8 nuts and 2 glow plug connectors.
| *a | RH |
| *b | LH |
| 41. REMOVE GLOW PLUG ASSEMBLY |
Using a 10 mm deep socket wrench, remove the 8 glow plugs.
| *a | RH |
| *b | LH |
- HINT:
- Before removing the glow plugs, thoroughly clean off all dirt, sand, etc.
| 42. REMOVE FUEL PUMP MOTOR WIRE |
Disconnect the 2 connectors and remove the bolt and fuel pump motor wire.
| 43. REMOVE NO. 2 IDLER PULLEY (w/ Viscous Heater) |
Remove the bolt, cover, No. 2 idler pulley and collar.
| 44. REMOVE NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater) |
Remove the 3 bolts and idler pulley bracket.
| 45. REMOVE FAN BRACKET SUB-ASSEMBLY |
Remove the 4 bolts and fan bracket.
| 46. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/o DPF) |
Disconnect the 2 vacuum hoses.
Remove the bolt and vacuum switching valve.
| 47. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o DPF) |
w/ Intercooler:
Disconnect the 2 vacuum hoses.
Remove the 3 bolts and vacuum transmitting pipe.
| 48. REMOVE CYLINDER HEAD COVER SILENCER RH (w/o DPF) |
w/ Intercooler:
Remove the 3 bolts and cylinder head cover silencer RH.
| 49. REMOVE CYLINDER HEAD COVER SILENCER LH (w/o DPF) |
w/ Intercooler:
Remove the 3 bolts and cylinder head cover silencer LH.
| 50. REMOVE REAR CYLINDER HEAD PLATE RH (w/o EGR System) |
Remove the 2 bolts, rear cylinder head plate RH and gasket.
| 51. REMOVE REAR CYLINDER HEAD PLATE LH (w/o EGR System) |
Remove the 2 bolts, rear cylinder head plate LH and gasket.
| 52. REMOVE NO. 1 INTAKE AIR CONNECTOR BRACKET |
Remove the 2 bolts and No. 1 intake air connector bracket.
| 53. REMOVE AIR TUBE SUPPORT |
Remove the 2 bolts and air tube support.
| 54. REMOVE NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY |
Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.
| 55. REMOVE NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler) |
Disconnect the vacuum hose.
Remove the 2 bolts and No. 4 vacuum transmitting pipe.
| 56. REMOVE ENGINE MOUNTING BRACKET RH |
Remove the 4 bolts and engine mounting bracket RH.
| 57. REMOVE NO. 1 CYLINDER BLOCK INSULATOR |
| 58. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET |
Detach the 2 wire harness clamps.
Remove the bolt and No. 2 intake air connector bracket.
| 59. REMOVE TURBOCHARGER WIRE |
Detach the 3 wire harness clamps.
Remove the 2 bolts and turbocharger wire.
| 60. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY |
w/ Intercooler:
Disconnect the vacuum hose.
Remove the 2 bolts and No. 3 vacuum transmitting pipe.
| 61. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY |
Remove the union bolt, 2 bolts, No. 2 water by-pass pipe and gasket.
| 62. REMOVE ENGINE MOUNTING BRACKET LH |
Remove the 4 bolts and engine mounting bracket LH.
| 63. REMOVE NO. 2 CYLINDER BLOCK INSULATOR |
| 64. REMOVE OIL TANK BRACKET |
Remove the bolt and oil tank bracket.
| 65. REMOVE NO. 1 INTERCOOLER SUPPORT BRACKET |
Remove the 2 bolts and No. 1 intercooler support bracket.
| 66. REMOVE NO. 3 ENGINE HANGER |
Remove the 2 bolts and No. 3 engine hanger.
| 67. REMOVE OIL FILTER BRACKET DRAIN COCK ASSEMBLY |
Remove the oil filter drain cock plug.
Remove the oil filter drain cock body.
- HINT:
- If the drain cock is deformed or clogged, replace or repair it.
| 68. REMOVE OIL PRESSURE REGULATOR ASSEMBLY |
Using a 26 mm wrench, remove the oil pressure regulator and gasket.
Remove the O-ring from the oil pressure regulator body.
Hold the oil pressure regulator body in a vise between aluminum plates.
- NOTICE:
- Be careful not to damage the oil pressure regulator body.
Using a 10 mm hexagon wrench, remove the oil pump relief valve plug labeled A and gasket.
- CAUTION:
- When removing the plug, be careful as the spring will be jumped out.
Remove the 2 springs labeled B.
Remove the oil pump relief valve labeled C.
| 69. REMOVE STIFFENER INSULATOR RH (w/ Intercooler) |
Remove the 2 bolts and stiffener insulator RH.
| 70. SET NO. 1 CYLINDER TO TDC/COMPRESSION |
Align the timing mark of the crankshaft pulley and the chain cover and compressor bracket.
| *1 | Timing Mark |
| 71. REMOVE COMPRESSOR BRACKET |
Remove the bolt and compressor bracket.
| 72. REMOVE EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (w/ DPF) |
Disconnect the 2 exhaust fuel addition injector connectors.
| *A | for Bank 1 |
| *B | for Bank 2 |
Remove the 2 bolts, 2 washers and 2 nozzle holder clamps.
| *A | for Bank 1 |
| *B | for Bank 2 |
| *1 | Washer |
| *2 | Nozzle Holder Clamp |
Remove the 2 exhaust fuel addition injectors and 2 gaskets.
| 73. REMOVE FUEL INJECTOR SEAL (w/ DPF) |
Remove the 2 fuel injector seals.
| *1 | Fuel Injector Seal |
| 74. REPLACE FLYWHEEL RING GEAR |
- CAUTION:
- When torching the flywheel:
- HINT:
- If the flywheel ring gear is deformed or the gear teeth are damaged, replace it.
Using a torch, heat the ring gear evenly to approximately 200°C (392°F).
Install 8 10 mm x 1.25 pitch bolts with a length of 70 mm or more to the flywheel.
Uniformly tighten the 8 bolts in the order shown in the illustration.
Remove the ring gear from the flywheel.
Using a torch, heat a new ring gear evenly to approximately 200°C (392°F).
| *a | No Clearance |
- NOTICE:
- Be careful not to overheat the ring gear.
Using a brass bar, tap the ring gear onto the flywheel with its chamfered gear teeth facing the block.
- NOTICE:
| 75. REPLACE FLYWHEEL STRAIGHT PIN |
- HINT:
- It is not necessary to remove the straight pin unless it is being replaced.
Replace the flywheel straight pin.