Exhaust Pipe (W/ Dpf) - Installation

Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1VD-FTV INTAKE / EXHAUST

EXHAUST PIPE (w/ DPF) - INSTALLATION

  • CAUTION:
Wear protective gloves and protective glasses when installing the exhaust pipe.
The exhaust pipe is extremely hot immediately after the engine has stopped.
Confirm that the exhaust pipe has cooled down before removing it.
1. INSTALL EXHAUST GAS TEMPERATURE SENSOR
  • NOTICE:
  • If the sensor is dropped, replace it with a new one.

Using a 14 mm union nut wrench, install the 2 exhaust gas temperature sensors.

  • Torque:
  • 30 N*m{ 306 kgf*cm, 22 ft.*lbf}
  • NOTICE:
  • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench ().
  • HINT:
  • The identification tape on the exhaust gas temperature sensor is pink.
2. INSTALL NO. 2 EXHAUST GAS TEMPERATURE SENSOR
  • NOTICE:
  • If the sensor is dropped, replace it with a new one.

Using a 14 mm union nut wrench, install the No. 2 exhaust gas temperature sensor.

  • Torque:
  • 30 N*m{ 306 kgf*cm, 22 ft.*lbf}
  • NOTICE:
  • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench ().
  • HINT:
  • The identification tape on the exhaust gas temperature sensor is white.
3. INSTALL NO. 3 EXHAUST GAS TEMPERATURE SENSOR
  • NOTICE:
  • If the sensor is dropped, replace it with a new one.

Using a 14 mm union nut wrench, install the No. 3 exhaust gas temperature sensor.

  • Torque:
  • 30 N*m{ 306 kgf*cm, 22 ft.*lbf}
  • NOTICE:
  • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench ().
  • HINT:
  • The identification tape on the exhaust gas temperature sensor is gray.
4. INSTALL MONOLITHIC CONVERTER ASSEMBLY LH

Install a new gasket to the turbocharger.

  • HINT:
  • Make sure that the claw of the gasket faces downward.
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the monolithic converter LH with 3 new nuts.

  • Torque:
  • 47 N*m{ 479 kgf*cm, 35 ft.*lbf}

Temporarily install the No. 2 manifold stay with the 3 bolts.

Tighten the 2 bolts labeled A in the illustration first, and then tighten the bolt labeled B in the illustration.

  • Torque:
  • 43 N*m{ 438 kgf*cm, 32 ft.*lbf}
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the 4 clamps and connect the 2 exhaust gas temperature sensor connectors.

Text in Illustration
*1Tape
  • HINT:
  • Make sure that the tape is in the position shown in the illustration.
5. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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6. INSTALL MONOLITHIC CONVERTER ASSEMBLY RH

Install a new gasket to the turbocharger.

  • HINT:
  • Make sure that the claw of the gasket faces the transmission.
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the monolithic converter RH with 3 new nuts.

  • Torque:
  • 47 N*m{ 479 kgf*cm, 35 ft.*lbf}

Temporarily install the manifold stay with the 3 bolts.

Tighten the 2 bolts labeled A in the illustration first, and then tighten the bolt labeled B in the illustration.

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

Attach the 4 clamps and connect the 2 exhaust gas temperature sensor connectors.

7. INSTALL NO. 4 EXHAUST GAS TEMPERATURE SENSOR
  • NOTICE:
  • If the sensor is dropped, replace it with a new one.

Using a 14 mm union nut wrench, install the 2 No. 4 exhaust gas temperature sensors.

  • Torque:
  • 30 N*m{ 306 kgf*cm, 22 ft.*lbf}
  • NOTICE:
  • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench ().
  • HINT:
  • The identification tape on the exhaust gas temperature sensor is gold.
8. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY

Install a new gasket and the front No. 2 exhaust pipe to the monolithic converter LH with 3 new nuts.

  • Torque:
  • 48 N*m{ 489 kgf*cm, 35 ft.*lbf}
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the clamp and connect the exhaust gas temperature sensor connector.

Text in Illustration
*1Tape
*2Stopper
*3Clip
*a2 to 7 mm (0.0787 to 0.276 in.)
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200Paint Mark
  • HINT:
  • Make sure that the tape is in the position shown in the illustration.

Install 2 new clips to the 2 air hoses.

Connect the 2 air hoses to the front No. 2 exhaust pipe.

  • NOTICE:
Align the paint marks of the front No. 2 exhaust pipe and air hose and push on the air hose until it contacts the stopper.
Make sure the clip is 4 to 10 mm (0.157 to 0.394 in.) from the end of the air hose when installing the clip.
Make sure that there is no slack in the air hose, and that it is not twisted or bent.
Take care not to damage the inner or outer surface of the air hose when installing it. If the air hose is damaged, replace it with a new one.
9. INSTALL NO. 5 EXHAUST PIPE ASSEMBLY

Install a new gasket and the No. 5 exhaust pipe to the front No. 2 exhaust pipe with 2 new nuts.

  • Torque:
  • 48 N*m{ 489 kgf*cm, 35 ft.*lbf}
10. INSTALL FRONT EXHAUST PIPE ASSEMBLY

Install a new gasket and the front exhaust pipe to the monolithic converter RH with 3 new nuts.

  • Torque:
  • 48 N*m{ 489 kgf*cm, 35 ft.*lbf}
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Attach the clamp and connect the exhaust gas temperature sensor connector.

Text in Illustration
*1Tape
*2Stopper
*3Clip
*a2 to 7 mm (0.0787 to 0.276 in.)
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200Paint Mark
  • HINT:
  • Make sure that the tape is in the position shown in the illustration.

Install 2 new clips to the 2 air hoses.

Connect the 2 air hoses to the front exhaust pipe.

  • NOTICE:
Align the paint marks of the front exhaust pipe and air hose and push on the air hose until it contacts the stopper.
Make sure the clip is 4 to 10 mm (0.157 to 0.394 in.) from the end of the air hose when installing the clip.
Make sure that there is no slack in the air hose, and that it is not twisted or bent.
Take care not to damage the inner or outer surface of the air hose when installing it. If the air hose is damaged, replace it with a new one.
11. INSTALL CENTER EXHAUST PIPE ASSEMBLY
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Check the free length.

Using a vernier caliper, measure the free length of the compression spring.

  • Free length:
  • 43 mm (1.69 in.)

If the free length is less than the minimum, replace the compression spring.


Connect the center exhaust pipe to the 3 exhaust pipe supports.

Install 2 new gaskets to the No. 5 exhaust pipe and front exhaust pipe.

Install the center exhaust pipe with the 4 bolts and 2 compression springs.

  • Torque:
  • for center exhaust pipe and front exhaust pipe:
  • 43 N*m{ 438 kgf*cm, 32 ft.*lbf}
  • for center exhaust pipe and No. 5 exhaust pipe:
  • 48 N*m{ 489 kgf*cm, 35 ft.*lbf}
12. INSTALL TAILPIPE ASSEMBLY
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Connect the tailpipe to the 2 exhaust pipe supports.

Text in Illustration
*1Gasket
*aTop
*bLH Side
Exhaust Pipe (W/ Dpf) - Installation. 1VD-FTV INTAKE / EXHAUST. Land Cruiser URJ200 URJ202 GRJ200 VDJ200Front

Install a new gasket to the center exhaust pipe.

Connect the tailpipe to the center exhaust pipe with a new clamp.

  • HINT:
  • Install the clamp within the angle range shown in the illustration.

Tighten the bolt.

  • Torque:
  • 32 N*m{ 326 kgf*cm, 24 ft.*lbf}
13. INSTALL AIR FUEL RATIO SENSOR

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14. INSPECT FOR EXHAUST GAS LEAK
15. INSTALL NO. 2 ENGINE UNDER COVER

Install the No. 2 engine under cover with the 6 bolts.

  • Torque:
  • 29 N*m{ 296 kgf*cm, 21 ft.*lbf}
16. INSTALL FRONT FENDER APRON SEAL REAR LH

Install the front fender apron seal rear LH with the 4 clips.

17. INSTALL FRONT FENDER APRON SEAL REAR RH

Install the front fender apron seal rear RH with the 4 clips.

18. PERFORM CATALYST RECORD OF DPF THERMAL DETERIORATION CLEAR FUNCTION

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