Exhaust Manifold W/ Turbocharger Removal

Engine Hybrid System. Land Cruiser. Urj200, 202 Grj200 Vdj200
1Vd-Ftv Intake Exhaust. Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE ENGINE ASSEMBLY

  4. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE (for Bank 1)

  5. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE (for Bank 1)

  6. REMOVE NO. 2 VENTILATION HOSE (for Bank 1)

  7. REMOVE NO. 2 TURBO WATER HOSE (for Bank 1)

  8. REMOVE BREATHER PLUG RH (for Bank 1)

  9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 1)

  10. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE (for Bank 1)

  11. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 1)

  12. REMOVE NO. 1 TURBOCHARGER STAY (for Bank 1)

  13. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)

  14. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH (for Bank 1)

  15. REMOVE NO. 1 INLET COMPRESSOR ELBOW (for Bank 1)

  16. REMOVE NO. 1 TURBO OIL PIPE (for Bank 1)

  17. REMOVE NO. 1 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 1)

  18. REMOVE NO. 3 VENTILATION HOSE (for Bank 2)

  19. REMOVE BREATHER PLUG LH (for Bank 2)

  20. REMOVE NO. 2 TURBO WATER HOSE (for Bank 2)

  21. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 2)

  22. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)

  23. REMOVE FRONT WATER BY-PASS JOINT (for Bank 2)

  24. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)

  25. REMOVE NO. 2 OUTLET TURBO OIL HOSE (for Bank 2)

  26. REMOVE NO. 2 TURBOCHARGER STAY (for Bank 2)

  27. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY (for Bank 2)

  28. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH (for Bank 2)

  29. REMOVE NO. 2 INLET COMPRESSOR ELBOW (for Bank 2)

  30. REMOVE NO. 2 TURBO OIL PIPE (for Bank 2)

  31. REMOVE NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 2)

  32. REPLACE STUD BOLT

Exhaust Manifold W/ Turbocharger -- Removal


NOTICE:
w/ DPF:
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. 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 (Click here).


2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable some systems need to be initialized after the cable is reconnected (Click here).


3. REMOVE ENGINE ASSEMBLY
(Click here)


4. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and No. 1 engine oil level dipstick guide.

  1. Remove the O-ring from the No. 1 engine oil level dipstick.



5. REMOVE NO. 1 INTAKE AIR CONNECTOR PIPE (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 4 connectors.

  1. Using a clip remover, detach the 5 wire harness clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp, and remove the bolt and No. 1 intake air connector pipe.



6. REMOVE NO. 2 VENTILATION HOSE (for Bank 1)


Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal
Text in Illustration
*A
w/ DPF
*B
w/o DPF


7. REMOVE NO. 2 TURBO WATER HOSE (for Bank 1)


Land Cruiser. Urj200, 202 Grj200 Vdj200


8. REMOVE BREATHER PLUG RH (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the hose.

  1. Detach the clamp and remove the breather plug RH.



9. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

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


10. DISCONNECT NO. 1 OUTLET TURBO OIL HOSE (for Bank 1)


Land Cruiser. Urj200, 202 Grj200 Vdj200


11. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the water hose.

  1. Remove the 3 bolts, 2 nuts, No. 1 turbo water pipe and gasket.



12. REMOVE NO. 1 TURBOCHARGER STAY (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and No. 1 turbocharger stay.



13. REMOVE NO. 1 VENTILATION TUBE SUB-ASSEMBLY (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the hose.

  1. Remove the union bolt, bolt, No. 1 ventilation tube and gasket.



14. REMOVE NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the union bolt and gasket, and disconnect the No. 1 inlet turbo oil pipe from the cylinder block.



  1. Remove the 10 nuts, 10 collars and No. 1 turbocharger with exhaust manifold RH.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal


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

  1. Remove the gasket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/ DPF:
    Remove the 4 bolts, No. 1 exhaust manifold pipe and 2 gaskets.



  1. Remove the 2 nuts and bolt, and separate the No. 1 turbocharger and exhaust manifold RH.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal


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

  1. Remove the gasket from the No. 1 turbocharger.



15. REMOVE NO. 1 INLET COMPRESSOR ELBOW (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts, No. 1 inlet compressor elbow and gasket.



16. REMOVE NO. 1 TURBO OIL PIPE (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts, No. 1 turbo oil pipe and gasket.



17. REMOVE NO. 1 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 1)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the union bolt, bolt, No. 1 inlet turbo oil pipe and gasket.



18. REMOVE NO. 3 VENTILATION HOSE (for Bank 2)


Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal
Text in Illustration
*A
w/ DPF
*B
w/o DPF


19. REMOVE BREATHER PLUG LH (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Disconnect the hose.

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

  1. w/o DPF:
    Detach the clamp.

  1. Remove the breather plug LH.



20. REMOVE NO. 2 TURBO WATER HOSE (for Bank 2)


Land Cruiser. Urj200, 202 Grj200 Vdj200


21. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

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


22. REMOVE NO. 3 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts, union bolt, No. 3 turbo water pipe and gasket.



23. REMOVE FRONT WATER BY-PASS JOINT (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the front water by-pass joint and gasket.



24. REMOVE NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the water hose.

  1. Remove the union bolt, bolt, No. 2 turbo water pipe and gasket.



25. REMOVE NO. 2 OUTLET TURBO OIL HOSE (for Bank 2)


Land Cruiser. Urj200, 202 Grj200 Vdj200


26. REMOVE NO. 2 TURBOCHARGER STAY (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and No. 2 turbocharger stay.



27. REMOVE NO. 2 VENTILATION TUBE SUB-ASSEMBLY (for Bank 2)


  1. Disconnect the hose.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal


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

  1. Remove the union bolt, bolt, No. 2 ventilation tube and gasket.



28. REMOVE NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 connectors from the turbocharger.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the union bolt and gasket, and disconnect the No. 2 inlet turbo oil pipe from the No. 1 oil pan.



  1. Remove the 10 nuts, 10 collars and No. 2 turbocharger with exhaust manifold LH.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal


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

  1. Remove the gasket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/ DPF:
    Remove the 4 bolts, No. 2 exhaust manifold pipe and 2 gaskets.



    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. Remove the 3 nuts, and separate the No. 2 turbocharger and exhaust manifold LH.

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

  1. Remove the gasket from the turbocharger.



29. REMOVE NO. 2 INLET COMPRESSOR ELBOW (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts, No. 2 inlet compressor elbow and gasket.



30. REMOVE NO. 2 TURBO OIL PIPE (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts, No. 2 turbo oil pipe and gasket.



31. REMOVE NO. 2 INLET TURBO OIL PIPE SUB-ASSEMBLY (for Bank 2)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the union bolt, bolt, No. 2 inlet turbo oil pipe and gasket.



32. REPLACE STUD BOLT
HINT:
If a stud bolt is deformed or its threads are damaged, replace it.


  1. For No. 1 Turbocharger:

    1. Using an E10 "TORX" wrench, replace the stud bolts labeled A and B shown in the illustration below.

      Torque:
      20 N*m{204 kgf*cm, 15 ft.*lbf}


    2. Replace the stud bolts labeled C shown in the illustration below.

      Torque:
      6.0 N*m{61 kgf*cm, 53 in.*lbf}


      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal



    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. For No. 2 Turbocharger:
    Using an E10 "TORX" wrench, replace the stud bolt.

    Torque:
    20 N*m{204 kgf*cm, 15 ft.*lbf}


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Intake Exhaust.Intake System.Exhaust Manifold W/ Turbocharger Removal

  1. For Exhaust Manifold LH:

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF
    Using an E10 "TORX" wrench, replace the stud bolt.
    Torque:
    20 N*m{204 kgf*cm, 15 ft.*lbf}