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

REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

REMOVE OIL FILTER ELEMENT

REMOVE NO. 1 OIL COOLER BRACKET

REMOVE OIL FILTER BRACKET

REMOVE OIL FILLER CAP SUB-ASSEMBLY

REMOVE OIL FILLER CAP HOUSING

REMOVE SPARK PLUG

REMOVE VVT SENSOR

REMOVE CAMSHAFT POSITION SENSOR

REMOVE CRANK POSITION SENSOR PROTECTOR

REMOVE CRANKSHAFT POSITION SENSOR

REMOVE ENGINE OIL LEVEL SENSOR

REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY

REMOVE WATER PUMP PULLEY

REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

REMOVE FLUID COUPLING BRACKET

REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

REMOVE OIL CONTROL VALVE FILTER

REMOVE SPARK PLUG TUBE GASKET

REMOVE CRANKSHAFT PULLEY

REMOVE WATER PUMP ASSEMBLY

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

REMOVE WATER INLET PIPE

REMOVE FRONT CRANKSHAFT OIL SEAL

SET NO. 1 CYLINDER TO TDC/COMPRESSION

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

REMOVE CRANKSHAFT TIMING GEAR KEY

REMOVE CAMSHAFT BEARING CAP LH

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

REMOVE CAMSHAFT BEARING CAP RH

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

REMOVE VALVE LASH ADJUSTER ASSEMBLY

REMOVE VALVE STEM CAP

REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

REMOVE CYLINDER BLOCK WATER JACKET SPACER

REMOVE VENTILATION PIPE GASKET

REMOVE NO. 1 HEAT EXCHANGER COVER

REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

REMOVE NO. 1 OIL PAN BAFFLE PLATE

REMOVE OIL STRAINER SUB-ASSEMBLY

REMOVE ENGINE REAR OIL SEAL RETAINER

REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

REMOVE REAR CRANKSHAFT OIL SEAL

REMOVE RING PIN

REMOVE STUD BOLT

ENGINE UNIT - DISASSEMBLY

1. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

Disconnect the sender gauge connector.

Remove the oil pressure sender gauge.

2. REMOVE OIL FILTER ELEMENT

Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

Text in Illustration
*1	Pipe
*2	Hose

Remove the oil filter drain plug.

Install the pipe to the oil filter cap.

Text in Illustration
*1	Cap
*2	Valve
*3	Pipe
*4	O-Ring
*5	Hose

NOTICE:

If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

HINT:

Use a container to catch the draining oil.

Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

Using SST, remove the oil filter cap.

SST
09228-06501

Text in Illustration
*1	Oil Filter Bracket Clip

NOTICE:

Do not remove the oil filter bracket clip.

Remove the oil filter element and O-ring from the oil filter cap.

Text in Illustration
*1	Oil Filter Element
*2	O-Ring

NOTICE:

Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

3. REMOVE NO. 1 OIL COOLER BRACKET

Remove the 2 nuts and bracket.

Disconnect the ground wire from the cylinder block.

4. REMOVE OIL FILTER BRACKET

Remove the 2 bolts, 2 nuts and filter bracket.

Remove the 2 O-rings.

5. REMOVE OIL FILLER CAP SUB-ASSEMBLY

6. REMOVE OIL FILLER CAP HOUSING

Remove the 2 bolts, filler cap housing and gasket.

7. REMOVE SPARK PLUG

Using a 16 mm plug wrench, remove the 8 spark plugs.

8. REMOVE VVT SENSOR

LH:

Remove the 2 bolts and 2 VVT sensors.

RH:

Remove the 2 bolts and 2 VVT sensors.

9. REMOVE CAMSHAFT POSITION SENSOR

Remove the bolt and camshaft position sensor.

10. REMOVE CRANK POSITION SENSOR PROTECTOR

Remove the 2 bolts and sensor protector.

11. REMOVE CRANKSHAFT POSITION SENSOR

Remove the bolt and crankshaft position sensor.

12. REMOVE ENGINE OIL LEVEL SENSOR

Disconnect the oil level sensor connector.

Remove the 4 bolts and oil level sensor.

Text in Illustration
*1	Cutting Position
*2	Supply Part

Cut off the gasket as shown in the illustration.

Remove the gasket from the oil level sensor.

HINT:

After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

13. REMOVE CAMSHAFT OIL CONTROL VALVE ASSEMBLY

LH:

Remove the 2 bolts and 2 oil control valves.

RH:

Remove the 2 bolts and 2 oil control valves.

14. REMOVE WATER PUMP PULLEY

Using SST, hold the water pump pulley.

SST
09960-10010(09962-01000,09963-01000)

Remove the 4 bolts and water pump pulley.

15. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

Remove the bolt and idler pulley.

16. REMOVE FLUID COUPLING BRACKET

Remove the 4 bolts and fluid coupling bracket.

17. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

Remove the 14 bolts, seal washer, cylinder head cover and gasket.

HINT:

Make sure the removed parts are returned to the same places they were removed from.

Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).

19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

Remove the bolt and noise filter.

Remove the 14 bolts, seal washer, cylinder head cover and gasket.

HINT:

Make sure the removed parts are returned to the same places they were removed from.

Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).

20. REMOVE OIL CONTROL VALVE FILTER

LH:

Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

Text in Illustration
*1	Cylinder Head Cover Spacer
*2	Gasket
*3	Filter

RH:

Remove the 3 bolts, cylinder head cover spacer, gasket and filter.

Text in Illustration
*1	Cylinder Head Cover Spacer
*2	Gasket
*3	Filter

21. REMOVE SPARK PLUG TUBE GASKET

Bend the 4 ventilation baffle plate claws on the cylinder head cover to an angle of 90° or more.

Using a screwdriver, pry out the gaskets.

Text in Illustration
*1	Tape
	Pry

NOTICE:

Be careful not to damage the cylinder head cover.

Be careful not to damage the gasket when removing it, as the removed gasket needs to be used when installing a new one.

HINT:

Tape the screwdriver tip before use.

22. REMOVE CRANKSHAFT PULLEY

Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

SST
09213-70011
09330-00021

Text in Illustration
*a	Hold
	Turn

Using the pulley set bolt and SST, remove the crankshaft pulley.

SST
09950-50013(09951-05010,09952-05010,09953-05010,09954-05011)

Text in Illustration
*a	Hold
	Turn

23. REMOVE WATER PUMP ASSEMBLY

Remove the 8 bolts, water pump and gasket.

24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

Remove the 28 bolts and nut shown in the illustration.

Text in Illustration
	Bolt
	Nut

Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver as shown in the illustration.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT:

Tape the screwdriver tip before use.

Remove the oil pump gasket from the cylinder block.

Remove the O-ring from the oil pan.

25. REMOVE WATER INLET PIPE

Remove the water inlet pipe.

Remove the 2 O-rings from the water inlet pipe.

26. REMOVE FRONT CRANKSHAFT OIL SEAL

Place the timing chain cover on wooden blocks.

Using a screwdriver and wooden block, pry out the oil seal.

Text in Illustration
*1	Wooden Block

NOTICE:

Do not damage the surface of the oil seal press fit hole.

HINT:

Tape the screwdriver tip before use.

27. SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the crankshaft pulley bolt.

Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

HINT:

If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

Engine Unit - Disassembly. 3UR-FE ENGINE MECHANICAL. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Text in Illustration
*1	Timing Mark	*2	Timing Mark Position
*3	Knock Pin Position	*4	Key
*a	Toward Ceiling	*b	Approximately 2°
*c	Approximately 45°	*d	Approximately 16°
*e	Approximately 18°	*f	Approximately 32°

28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

Text in Illustration
*1	Plunger
*2	Stopper Plate

Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

Text in Illustration
*1	Plunger
*2	Stopper Plate

Remove the 2 bolts, chain tensioner and gasket.

29. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

30. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

Remove the 2 bolts and chain vibration damper.

31. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

Text in Illustration
*1	Pin
*2	Plunger
*a	Push

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration
*a	Hold
	Turn

NOTICE:

Be careful not to damage the cylinder head with the wrench.

Do not disassemble the camshaft timing gear.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration
*a	Hold
	Turn

NOTICE:

Be careful not to damage the cylinder head with the wrench.

Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

Remove the No. 1 and No. 2 chains from the gears.

32. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

Remove the 2 bolts and chain tensioner.

33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

Text in Illustration
*1	Plunger
*2	Stopper Plate

Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

Text in Illustration
*1	Plunger
*2	Stopper Plate

Remove the 2 bolts and chain tensioner.

34. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

35. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

Remove the 2 bolts and vibration damper.

36. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

Text in Illustration
*1	Pin
*2	Plunger
*a	Push

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration
*a	Hold
	Turn

NOTICE:

Be careful not to damage the cylinder head with the wrench.

Do not disassemble the camshaft timing gear.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration
*a	Hold
	Turn

NOTICE:

Be careful not to damage the cylinder head with the wrench.

Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

Remove the No. 1 and No. 2 chains from the gears.

37. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

Remove the 2 bolts and chain tensioner.

38. REMOVE CRANKSHAFT TIMING GEAR KEY

Using a screwdriver, remove the 2 timing gear keys from the crankshaft.

39. REMOVE CAMSHAFT BEARING CAP LH

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Text in Illustration
*1	IN
*2	EX
*3	Knock Pin

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 6 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 3 and No. 4 camshafts.

HINT:

Arrange the removed parts in the correct order.

40. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT:

Tape the screwdriver tip before use.

41. REMOVE CAMSHAFT BEARING CAP RH

Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Text in Illustration
*1	EX
*2	IN
*3	Knock Pin

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 6 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 1 and No. 2 camshafts.

HINT:

Arrange the removed parts in the correct order.

42. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT:

Tape the screwdriver tip before use.

43. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Remove the 32 valve rocker arms from the cylinder heads.

HINT:

Arrange the removed parts in the correct order.

44. REMOVE VALVE LASH ADJUSTER ASSEMBLY

Remove the 32 valve lash adjusters from the cylinder heads.

HINT:

Arrange the removed parts in the correct order.

45. REMOVE VALVE STEM CAP

Remove the 32 valve stem caps from the cylinder heads.

HINT:

Arrange the removed parts in the correct order.

46. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cracking could result from removing bolts in an incorrect order.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the cylinder head and gasket.

47. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 cylinder head bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

Be careful not to drop washers into the cylinder head.

Head warpage or cracking could result from removing bolts in an incorrect order.

HINT:

Be sure to arrange the removed parts for each installation position separately.

Remove the cylinder head and gasket.

48. REMOVE CYLINDER BLOCK WATER JACKET SPACER

Remove the 2 water jacket spacers from the cylinder block.

NOTICE:

Be sure to remove the water jacket spacers. If not, they may fall and become damaged when the cylinder block is inverted.

49. REMOVE VENTILATION PIPE GASKET

Using a screwdriver, pry out the ventilation pipe gasket.

HINT:

Tape the screwdriver tip before use.

50. REMOVE NO. 1 HEAT EXCHANGER COVER

Remove the 12 bolts and 2 nuts.

Text in Illustration
	Bolt
	Nut

Remove the heat exchanger by prying between the heat exchanger and cylinder block with a screwdriver.

HINT:

Tape the screwdriver tip before use.

51. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

Remove the 14 bolts and 2 nuts.

Text in Illustration
	Bolt
	Nut

Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.

NOTICE:

Be careful not to damage the contact surfaces of the oil pans.

52. REMOVE NO. 1 OIL PAN SUB-ASSEMBLY

Remove the 14 bolts and 2 nuts.

Text in Illustration
	Bolt
	Nut

HINT:

Be sure to clean the bolts and stud bolts, and check the threads for cracks or other damage.

Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

Text in Illustration
*A	LH Side
*B	RH Side

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT:

Tape the screwdriver tip before use.

53. REMOVE NO. 1 OIL PAN BAFFLE PLATE

Remove the 7 bolts and baffle plate.

54. REMOVE OIL STRAINER SUB-ASSEMBLY

Remove the 2 bolts, oil strainer and O-ring.

55. REMOVE ENGINE REAR OIL SEAL RETAINER

Remove the 6 bolts and oil seal retainer.

Using a screwdriver, pry out the oil seal retainer.

HINT:

Tape the screwdriver tip before use.

56. REMOVE OIL DRAIN PIPE SUB-ASSEMBLY

Remove the bolt and oil drain pipe.

Remove the O-ring.

57. REMOVE REAR CRANKSHAFT OIL SEAL

Place the oil seal retainer on wooden blocks.

Text in Illustration
*1	Wooden Block

Using a screwdriver and hammer, tap out the oil seal.

58. REMOVE RING PIN

NOTICE:

It is not necessary to remove the ring pin unless it is being replaced.

59. REMOVE STUD BOLT

NOTICE:

If the stud bolt is deformed or its threads are damaged, replace it.