Exhaust Manifold W/ Turbocharger Removal


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE FRONT BUMPER LOWER COVER

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

  4. DRAIN ENGINE COOLANT

  5. REMOVE FRONT EXHAUST PIPE ASSEMBLY

  6. REMOVE FRONT FENDER APRON SEAL RH

  7. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH

  8. REMOVE UPPER RADIATOR SUPPORT SEAL

  9. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)

  10. REMOVE FAN AND GENERATOR V BELT

  11. REMOVE NO. 1 AIR CLEANER HOSE

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

  13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

  15. REMOVE NO. 1 AIR HOSE

  16. REMOVE COMPRESSOR OUTLET ELBOW

  17. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)

  18. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)

  19. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

  20. REMOVE GENERATOR ASSEMBLY

  21. REMOVE GENERATOR BRACKET

  22. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET

  23. REMOVE VENTILATION PIPE

  24. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  25. REMOVE COMPRESSOR INLET ELBOW

  26. REMOVE NO. 1 TURBO INSULATOR

  27. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  28. DISCONNECT NO. 1 TURBO WATER HOSE

  29. REMOVE TURBINE OUTLET ELBOW

  30. REMOVE TURBOCHARGER STAY

  31. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

  32. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

  33. REMOVE TURBOCHARGER SUB-ASSEMBLY

  34. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

Exhaust Manifold W/ Turbocharger -- Removal



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
  1. 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).
  2. When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).


2. REMOVE FRONT BUMPER LOWER COVER

  1. Remove the clip, 5 bolts and front bumper lower cover.



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

  1. 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.

  1. Loosen the radiator drain cock plug.

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


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.



  1. Loosen the cylinder block drain cock plug.


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Kd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal


    Text in Illustration
    *1
    		Radiator Reservoir
    		*2
    		Vent Plug
    *3
    		Radiator Drain Cock Plug
    		*4
    		Cylinder Block Drain Cock Plug


5. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Kd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Remove the 3 nuts and front exhaust pipe.

    Text in Illustration
    *A
    		w/ EGR Cooler
    *B
    		w/o EGR Cooler

  1. Remove the gasket.



6. REMOVE FRONT FENDER APRON SEAL RH

  1. Using a clip remover, remove the 4 clips and front fender apron seal RH.



7. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH

  1. Using a clip remover, remove the 5 clips and front No. 1 fender apron to frame seal RH.



8. REMOVE UPPER RADIATOR SUPPORT SEAL

  1. Remove the 13 clips and upper radiator support seal.



9. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 bolts and front heater bracket.



10. REMOVE FAN AND GENERATOR V BELT

  1. Using the pulley set bolt of the tensioner, rotate the tensioner pulley clockwise to loosen the belt tension. Then remove the V belt.



11. REMOVE NO. 1 AIR CLEANER HOSE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.



12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Kd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. except Cold Area Specification Vehicles:
    Detach the 2 clamps and disconnect the mass air flow meter connector.

    Text in Illustration
    *A
    		except Cold Area Specification Vehicles
    *B
    		for Cold Area Specification Vehicles

  1. for Cold Area Specification Vehicles:
    Detach the 3 clamps and disconnect the mass air flow meter connector.

  1. Detach the 4 clamps and remove the air cleaner cap sub-assembly.



13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 3 bolts and air cleaner case sub-assembly.



15. REMOVE NO. 1 AIR HOSE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Loosen the 2 clamps.

  1. Remove the No. 1 air hose from the inlet pipe and intercooler.



16. REMOVE COMPRESSOR OUTLET ELBOW


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Detach the 3 wire harness clamps.

  1. Remove the bolt and wire harness bracket.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.



17. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)

  1. Disconnect the viscous heater connector.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Disconnect the water by-pass hose and water hose.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 bolts and viscous heater with magnet clutch.



18. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 4 bolts and No. 1 viscous heater bracket.



19. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Disconnect the compressor connector.

  1. Remove the 4 bolts and disconnect the cooler compressor.



20. REMOVE GENERATOR ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Disconnect the generator connector.

  1. Remove the terminal cap.

  1. Remove the nut and disconnect the generator wire.

  1. Remove the 2 bolts and generator.



21. REMOVE GENERATOR BRACKET


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the bolt and generator bracket.



22. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 5 bolts and No. 1 compressor mounting bracket.



23. REMOVE VENTILATION PIPE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Type A
    Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Kd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.

    Text in Illustration
    *A
    		Type A
    *B
    		Type B


24. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  1. Remove the engine oil level dipstick.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 bolts and engine oil level dipstick guide from the cylinder block sub-assembly.

  1. Remove the O-ring from the engine oil level dipstick guide.



25. REMOVE COMPRESSOR INLET ELBOW


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Detach the 3 wire harness clamps.

  1. Remove the bolt and wire harness bracket from the water inlet.



  1. Disconnect the 2 connectors and detach the wire harness clamp.


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Kd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal


    Text in Illustration
    *A
    		Type A
    		*B
    		Type B

  1. Slide the clamp and disconnect the No. 2 turbo water hose from the No. 1 turbo water hose sub-assembly.

  1. Slide the clamp and disconnect the No. 3 turbo water hose from the No. 2 water by-pass pipe.

  1. Remove the 2 nuts, compressor inlet elbow and gasket from the turbocharger sub-assembly.



26. REMOVE NO. 1 TURBO INSULATOR


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 bolts and No. 1 turbo insulator from the turbocharger sub-assembly.



27. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  1. Remove the bolt and No. 1 exhaust manifold heat insulator from the exhaust manifold.



28. DISCONNECT NO. 1 TURBO WATER HOSE


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Disconnect the No. 1 turbo water hose from the No. 1 turbo water pipe sub-assembly.



29. REMOVE TURBINE OUTLET ELBOW


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 3 nuts, turbine outlet elbow and gasket from the turbocharger sub-assembly.



30. REMOVE TURBOCHARGER STAY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 bolts, nut and turbocharger stay from the turbocharger sub-assembly and cylinder block sub-assembly.



31. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Kd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe sub-assembly and 3 gaskets from the turbocharger sub-assembly and cylinder block sub-assembly.

    NOTICE:
    Do not loosen the nut labeled A in the illustration.


32. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 8 nuts, 8 plate washers and 8 collars from the exhaust manifold with turbocharger sub-assembly.

  1. Remove the exhaust manifold with turbocharger and gasket.



33. REMOVE TURBOCHARGER SUB-ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 3 nuts, turbocharger sub-assembly and gasket from the exhaust manifold.



34. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155

  1. Remove the 2 nuts, bolt, No. 1 turbo water pipe sub-assembly and gasket from the turbocharger sub-assembly.