Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 3UR-FE ENGINE MECHANICAL

After turning the engine 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 ().

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

4. REMOVE UPPER RADIATOR SUPPORT SEAL

Remove the 7 clips and radiator support seal.

Engine Assembly - Removal. 3UR-FE ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

5. REMOVE RADIATOR GRILLE

Put protective tape around the radiator grille assembly.

Text in Illustration
*1	Protective Tape

Remove the 3 screws.

Detach the 2 clips and 8 claws, and remove the radiator grille assembly.

w/ Wide View Front Monitor System:

Disconnect the connector.

6. REMOVE FRONT BUMPER COVER

HINT:

For the front bumper cover with garnish, use the procedure described below.

Put protective tape around the front bumper cover.

Engine Assembly - Removal. 3UR-FE ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*1	Protective Tape	-	-

Using a T30 "TORX" socket, remove the 6 screws.

Engine Assembly - Removal. 3UR-FE ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*A	LH Side	*B	RH Side

Remove the 3 clips, 4 screws and 4 bolts.

Detach the 10 claws and remove the front bumper cover.

Engine Assembly - Removal. 3UR-FE ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

w/ TOYOTA Parking Assist-sensor System or w/ Fog Light:

Disconnect the No. 4 engine room wire connector and remove the front bumper cover.

w/ Headlight Cleaner System:

Disconnect the headlight cleaner hose and remove the front bumper cover.

7. REMOVE TRANSMISSION OIL COOLER AIR DUCT

Remove the 4 bolts and oil cooler air duct.

8. DISCONNECT RADIATOR SIDE DEFLECTOR LH

Using a clip remover, remove the 4 clips and disconnect the side deflector.

9. REMOVE HOOD SUB-ASSEMBLY

Remove the 2 hood support bolts and disconnect the hood supports.

CAUTION:

Remove the hood support assembly while supporting the hood by hand.

Remove the 4 bolts and hood.

10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

()

11. REMOVE FRONT FENDER APRON SEAL LH

Using a clip remover, remove the 3 clips and fender apron seal.

12. REMOVE FRONT FENDER APRON SEAL REAR LH

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

13. REMOVE FRONT FENDER APRON SEAL FRONT RH

Using a clip remover, remove the 3 clips and fender apron seal.

14. REMOVE FRONT FENDER APRON SEAL REAR RH

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

15. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Remove the 3 bolts and screw.

Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly LH.

16. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Remove the 3 bolts and 2 screws.

Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly RH.

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

Remove the 10 bolts and No. 1 engine under cover.

18. REMOVE NO. 2 ENGINE UNDER COVER

Remove the 2 bolts and No. 2 engine under cover.

19. REMOVE OIL PAN PROTECTOR ASSEMBLY

Remove the 4 bolts and oil pan protector assembly.

20. DRAIN ENGINE OIL

Remove the oil filler cap.

Remove the 2 bolts and No. 2 engine under cover seal.

Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

Install a new gasket and the oil pan drain plug.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

21. 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.

Remove the radiator cap. Then drain the coolant from the radiator.

Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine.

Tighten the 2 cylinder block drain cock plugs.

Torque:
13 N*m{ 133 kgf*cm, 10 ft.*lbf}

Engine Assembly - Removal. 3UR-FE ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

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

Tighten the radiator drain cock plug by hand.

22. REMOVE V-BANK COVER SUB-ASSEMBLY

Raise the front of the V-bank cover to detach the 3 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

Text in Illustration
*1	Bracket
*2	Hook
*3	Pin
*4	Grommet

23. REMOVE AIR CLEANER HOSE ASSEMBLY

Disconnect the vacuum hose and No. 2 ventilation hose.

Loosen the 2 hose clamps.

Remove the air cleaner hose.

24. REMOVE AIR CLEANER ASSEMBLY

Remove the 3 bolts and air cleaner.

25. REMOVE NO. 1 RADIATOR HOSE

26. REMOVE NO. 2 RADIATOR HOSE

27. REMOVE FAN SHROUD

Loosen the 4 nuts holding the fluid coupling fan.

Remove the fan and generator V-belt ().

Disconnect the reservoir hose from the upper radiator tank.

Detach the claw to open the flexible hose clamp.

Remove the 2 bolts and disconnect the oil cooler tube from the fan shroud.

Remove the 2 bolts holding the fan shroud.

Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley.

28. REMOVE RADIATOR ASSEMBLY

Disconnect the 2 oil cooler hoses.

Remove the 4 bolts and radiator.

29. DISCONNECT FUEL MAIN AND RETURN HOSE

Remove the fuel pipe clamp.

Disconnect the fuel main and return hoses ().

30. DISCONNECT WIRE HARNESS AND HOSE

Disconnect the purge line hose.

Remove the heater hose.

Disconnect the clamp and ECM connector.

Text in Illustration
*A	w/o Rear Heater
*B	w/ Rear Heater

HINT:

Refer to the following procedures to disconnect the ECM connector ().

Disconnect the 4 connectors and clamp from the connector holder block.

Remove the bolt and disconnect the ground wire.

Remove the nut and disconnect the wire from the positive (+) battery cable.

Disconnect the cable from the positive (+) battery terminal.

Remove the bolt and disconnect the ground wire from the body.

Remove the bolt and disconnect the ground wire from the bracket.

Remove the nut and disconnect the wire and 2 clips from the engine room junction block.

Disconnect the 2 connectors and 2 clips from the engine room junction block.

Disconnect the 2 connectors and clamp.

31. DISCONNECT COOLER COMPRESSOR ASSEMBLY

Remove the 3 bolts, nut and stud bolt, and disconnect the cooler compressor.

HINT:

It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

32. DISCONNECT VANE PUMP ASSEMBLY

Remove the 2 bolts and disconnect the vane pump.

33. REMOVE GENERATOR ASSEMBLY

Disconnect the generator connector.

Open the terminal cap.

Remove the nut and disconnect the generator wire.

Remove the bolt and disconnect the wire harness bracket from the generator.

Remove the 3 bolts, nut and generator.

Remove the stud bolt.

34. REMOVE TAILPIPE ASSEMBLY

Remove the bolt, clamp and gasket.

Remove the tailpipe from the 2 exhaust pipe supports.

Remove the bolt and clamp, and then disconnect the tailpipe from the center exhaust pipe.

35. REMOVE CENTER EXHAUST PIPE ASSEMBLY

Remove the 4 bolts.

Remove the center exhaust pipe from the 3 exhaust pipe supports.

Remove the 2 gaskets from the front exhaust pipe and front No. 2 exhaust pipe.

36. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY

Disconnect the heated oxygen sensor connector.

Remove the bolt and disconnect the wire harness clamp bracket of the oxygen sensor from the transmission.

Remove the 2 nuts, front No. 2 exhaust pipe and gasket from the exhaust manifold LH.

37. REMOVE FRONT EXHAUST PIPE ASSEMBLY

Disconnect the heated oxygen sensor connector.

Remove the bolt and disconnect the wire harness clamp bracket of the oxygen sensor from the transmission.

Remove the 2 nuts, front exhaust pipe and gasket from the exhaust manifold RH.

38. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Disconnect the wire harness clamp.

Remove the dipstick.

Remove the bolt and dipstick guide.

Remove the O-ring from the dipstick guide.

39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

()

40. REMOVE REAR PROPELLER SHAFT ASSEMBLY

()

41. REMOVE PROPELLER SHAFT HEAT INSULATOR

Remove the 2 bolts and heat insulator.

42. REMOVE NO. 2 MANIFOLD STAY

Remove the 3 bolts and No. 2 manifold stay.

43. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Remove the 3 bolts and heat insulator.

44. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

Disconnect the connector and detach the wire harness clamp.

Remove the 8 nuts, exhaust manifold sub-assembly LH and gasket.

45. REMOVE NO. 1 MANIFOLD STAY

Remove the 3 bolts and No. 1 manifold stay.

46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Remove the 3 bolts and heat insulator.

47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

Disconnect the connector and detach the wire harness clamp.

Remove the 8 nuts, exhaust manifold sub-assembly RH and gasket.

48. REMOVE STARTER COVER

Remove the 3 bolts and starter cover.

49. REMOVE STARTER ASSEMBLY

Disconnect the starter connector.

Remove the nut and disconnect the starter wire.

Remove the 2 bolts and starter.

Remove the flywheel housing side cover.

50. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

()

51. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

HINT:

Only perform this procedure when replacement of the engine mounting insulator is necessary.

Remove the 2 bolts and front engine mounting insulator RH.

Remove the 4 bolts and rear engine mounting insulator from the transmission.

52. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Using SST, hold the crankshaft.

SST
09213-70011
09330-00021

Remove the 10 bolts, rear drive plate spacer, drive plate and crankshaft angle sensor rotor.

53. DISCONNECT OIL COOLER PIPE ASSEMBLY

Remove the 2 bolts and disconnect the oil cooler pipe.

54. REMOVE WATER PIPE AND HOSE SUB-ASSEMBLY

Remove the 2 bolts and disconnect the hose. Then remove the water pipe and hose.

55. REMOVE ENGINE ASSEMBLY

Install 2 engine hangers with 2 bolts as shown in the illustration.

Torque:
43 N*m{ 438 kgf*cm, 32 ft.*lbf}

HINT:

Engine hanger	12281-38150
Bolt	90119-14120

Attach an engine sling device and hang the engine with a chain block.

Text in Illustration
*1	Engine Hanger
*2	ENGINE
*a	50° or less

NOTICE:

When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

Remove the 4 engine mounting insulator bolts.

Text in Illustration
*A	RH
*B	LH

Lift the engine out from the vehicle slowly and carefully.

NOTICE:

Make sure the engine is clear of all wiring, hoses and cables.

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

56. INSTALL ENGINE ON ENGINE STAND

Install the engine onto an engine stand with bolts.

Remove the 2 bolts and 2 engine hangers.

57. REMOVE FRONT ENGINE MOUNTING INSULATOR LH

Remove the nut and mounting insulator.

58. REMOVE FRONT ENGINE MOUNTING INSULATOR RH

Remove the nut and mounting insulator.

59. REMOVE NO. 2 FRONT ENGINE MOUNTING BRACKET LH

Remove the bolt and No. 2 front engine mounting bracket LH.