Intake Manifold Removal


  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE EGR COOLER ASSEMBLY

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

  5. DISCONNECT NO. 2 FUEL PIPE

  6. REMOVE WIRING HARNESS CLAMP BRACKET

  7. REMOVE MANIFOLD STAY

  8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

  9. REMOVE NO. 3 FUEL PIPE

  10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY

  11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

  12. REMOVE VACUUM CONTROL VALVE SET

  13. REMOVE INTAKE MANIFOLD

Intake Manifold -- Removal


NOTICE:
  1. When replacing the parts in the following chart (A), replace the No. 1 injection pipe subassembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones

    Replaced Parts (A)
    		Pipes Requiring New Replacement
    1. Injector assembly (including shuffling the injector assemblies between the cylinders)
    2. Common rail assembly
    3. Injection pipe sub-assembly or Supply pump assembly
    1. No. 1 injection pipe sub-assembly
    2. No. 2 injection pipe sub-assembly
    1. Common rail assembly
    2. Injection pipe sub-assembly or Supply pump assembly
    3. Cylinder block sub-assembly
    4. Cylinder head sub-assembly
    5. Cylinder head gasket
    6. Timing chain case assembly or Belt cover sub-assembly
    1. No. 1 injection pipe sub-assembly
    2. No. 2 injection pipe sub-assembly
    3. Fuel inlet pipe sub-assembly
  2. After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.


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 (LandCruiser RM000003YMD00TX.html).


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


3. REMOVE EGR COOLER ASSEMBLY
(LandCruiser RM000005UJV000X_01_0017.html)


4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


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

  1. Remove the engine oil level dipstick.

  1. Remove the bolt and engine oil level dipstick guide.

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



5. DISCONNECT NO. 2 FUEL PIPE


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

  1. Remove the bolt and disconnect the No. 2 fuel pipe.



6. REMOVE WIRING HARNESS CLAMP BRACKET


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

  1. Disconnect the diesel throttle body assembly connector and pre-stroke control valve connector.



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

  1. Detach the 2 wire harness clamps.

  1. Remove the bolt and wiring harness clamp bracket.



7. REMOVE MANIFOLD STAY


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

  1. Remove the bolt and disconnect the wiring harness clamp bracket from the intake manifold stay.



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

  1. Remove the 2 bolts and manifold stay.



8. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY


Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Text in Illustration
Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Union Bolt
Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Bolt

  1. Disconnect the No. 4 fuel pipe sub-assembly from the No. 1 fuel pipe (LandCruiser RM0000028RU05SX.html).

  1. Remove the bolt from the intake manifold.

  1. Remove the 2 union bolts and 2 gaskets from the supply pump assembly and fuel filter.



9. REMOVE NO. 3 FUEL PIPE


Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Text in Illustration
Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Union Bolt
Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155
Supply Pump Hollow Screw

  1. Remove the union bolts, supply pump hollow screw and 2 gaskets from the supply pump assembly and fuel filter.

  1. Remove the 2 fuel pipe clamps from the No. 3 fuel pipe and fuel filter.



10. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Intake Exhaust.Intake System.Intake Manifold Removal
Text in Illustration
*a
Common Rail Assembly Side
*b
Fuel Supply Pump Assembly Side

  1. Remove the 2 bolts, No. 1 injection pipe clamp and No. 2 injection pipe clamp.



    Land Cruiser, Land Cruiser Prado. Grj150 Trj150,155 Kdj150,155 Lj150, Gdj150,155.1Gd-Ftv Intake Exhaust.Intake System.Intake Manifold Removal

  1. Text in Illustration
    *a
    		SST
    Using SST, loosen the fuel inlet pipe sub-assembly union nut of the common rail assembly side.
    SST
    09245-11010
    NOTICE:
    If the No. 1 or No. 2 injection pipe clamp is removed from the inlet pipe sub-assembly, replace the No. 1 or No. 2 injection clamp with a new one.

  1. Using a 19 mm union nut wrench, loosen the inlet pipe sub-assembly union nut of the fuel supply pump assembly side.



11. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


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

  1. Slide the clamps and remove the No. 4 fuel hose from the No. 2 nozzle leakage pipe assembly and common rail assembly.

  1. Slide the 2 clamps and remove the No. 5 fuel hose from the No. 1 nozzle leakage pipe assembly and No. 2 nozzle leakage pipe assembly.



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

  1. Slide the clamp and disconnect the No. 6 fuel hose from the No. 3 nozzle leakage pipe assembly.

  1. Remove the 2 bolts and No. 2 nozzle leakage pipe assembly.



12. REMOVE VACUUM CONTROL VALVE SET


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

  1. Disconnect the wire harness clamp and vacuum control valve set connector.

  1. Disconnect the 2 vacuum hoses from the swirl control valve actuator and vacuum transmitting pipe sub-assembly.

  1. Remove the bolt and vacuum control valve set from the intake manifold.



13. REMOVE INTAKE MANIFOLD


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

  1. Remove the bolt and disconnect the wire harness bracket.

  1. Remove the 7 bolts, 2 nuts, intake manifold and gasket.