Egr Cooler -- Removal |
- NOTICE:
- When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
- When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.
| 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- 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 (LandCruiser RM000003YMD00TX.html).
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).
| 2. REMOVE FRONT BUMPER LOWER COVER |
Remove the clip, 5 bolts and front bumper lower cover.
| 3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 engine under cover.
| 4. DRAIN ENGINE COOLANT |
- CAUTION:
- Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Loosen the radiator drain cock plug.
- HINT:
- Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
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Loosen the cylinder block drain cock plug.
Text in Illustration *1 Radiator Reservoir *2 Vent Plug *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug
| 5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY |
Remove the cowl top ventilator louver (LandCruiser RM000001OV305GX_01_0012.html).
| 6. REMOVE DIESEL THROTTLE BODY ASSEMBLY |
Remove the diesel throttle body (LandCruiser RM0000013ZD02OX_01_0004.html).
| 7. DISCONNECT NO. 3 WATER BY-PASS HOSE |
Remove the clamp.
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Disconnect the No. 3 water by-pass hose from the EGR cooler.
| 8. DISCONNECT NO. 4 WATER BY-PASS HOSE |
Disconnect the No. 4 water by-pass hose from the EGR cooler.
| 9. REMOVE INJECTION PIPE |
- NOTICE:
- After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating the injector inlet.
Remove the 2 nuts and No. 3 injection pipe clamp.
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Remove the 2 bolts and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a for Injector Side *b for Common Rail Side
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| 10. REMOVE AIR CONNECTOR STAY |
Remove the 3 bolts and air connector stay.
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| 11. DISCONNECT ENGINE WIRE (for LHD) |
Remove the 2 bolts.
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Detach the clamp and disconnect the engine wire.
| 12. DISCONNECT ENGINE WIRE (for RHD) |
Remove the bolt and disconnect the engine wire.
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| 13. REMOVE EGR VALVE BRACKET |
Remove the 2 nuts and EGR valve bracket.
| 14. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY |
Disconnect the 2 connectors from the electric EGR control valve and E-VRV.
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Detach the wire harness clamp.
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Disconnect the 5 vacuum hoses.
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Remove the bolt and gas filter together with the gas filter bracket.
Remove the 2 bolts and E-VRV bracket together with the EGR vacuum damper.
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| 15. REMOVE NO. 2 INTAKE AIR CONNECTOR |
Remove the 3 nuts, No. 2 intake air connector and gasket.
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| 16. REMOVE INTAKE AIR CONNECTOR |
Remove the 3 bolts, intake air connector and 2 gaskets.
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| 17. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER |
Disconnect the No. 3 vacuum transmitting hose from the No. 2 EGR valve.
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Remove the bolt, 2 nuts, electric EGR control valve together with the No. 2 EGR valve and EGR cooler.
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Remove the gasket from the cylinder block.
| 18. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY |
Remove the 2 bolts, electric EGR control valve and gasket.
Text in Illustration *A w/ EGR Cooler *B w/o EGR Cooler
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| 19. REMOVE EGR VALVE ADAPTER |
Using a 6 mm hexagon wrench, remove the 3 hexagon bolts, 3 plate washers, EGR valve adapter and gasket.
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| 20. REMOVE NO. 2 EGR VALVE ASSEMBLY |
Using a 5 mm hexagon wrench, remove the hexagon bolt, No. 2 EGR valve and gasket.
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| 21. REMOVE EGR COOLER |
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