Fuel Cooler (For Engine Room Side) Removal

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

  1. REMOVE COMMON RAIL ASSEMBLY LH AND RH

  2. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  3. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  4. REMOVE INTAKE PIPE

  5. DISCONNECT NO. 2 ENGINE WIRE

  6. REMOVE NO. 3 INTAKE MANIFOLD

  7. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)

  8. REMOVE EGR PIPE INSULATOR (w/ EGR System)

  9. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

  10. REMOVE EGR COOLER INSULATOR (w/ EGR System)

  11. REMOVE NO. 3 NOZZLE LEAKAGE PIPE

  12. REMOVE NO. 4 NOZZLE LEAKAGE PIPE

  13. DISCONNECT NO. 6 WATER BY-PASS HOSE

  14. DISCONNECT NO. 3 FUEL HOSE

  15. REMOVE FUEL COOLER ASSEMBLY

  16. DISCONNECT NO. 7 WATER BY-PASS HOSE

Fuel Cooler (For Engine Room Side) -- Removal



1. REMOVE COMMON RAIL ASSEMBLY LH AND RH
(Click here)


2. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)


Land Cruiser. Urj200, 202 Grj200 Vdj200


3. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)


Land Cruiser. Urj200, 202 Grj200 Vdj200


4. REMOVE INTAKE PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/ EGR System:
    Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/o EGR System:
    Remove the 2 nuts, 4 bolts, intake pipe and gasket.



5. DISCONNECT NO. 2 ENGINE WIRE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.



6. REMOVE NO. 3 INTAKE MANIFOLD


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.



7. REMOVE INTAKE MANIFOLD INSULATOR (w/ EGR System)


Land Cruiser. Urj200, 202 Grj200 Vdj200


8. REMOVE EGR PIPE INSULATOR (w/ EGR System)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and EGR pipe insulator.



9. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the No. 5 water by-pass hose from the water by-pass outlet.



10. REMOVE EGR COOLER INSULATOR (w/ EGR System)


Land Cruiser. Urj200, 202 Grj200 Vdj200


11. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the No. 1 fuel hose from the fuel cooler.

  1. Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

    NOTICE:
    After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.


12. REMOVE NO. 4 NOZZLE LEAKAGE PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the No. 2 fuel hose from the fuel cooler.

  1. Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

    NOTICE:
    After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.


13. DISCONNECT NO. 6 WATER BY-PASS HOSE


Land Cruiser. Urj200, 202 Grj200 Vdj200


14. DISCONNECT NO. 3 FUEL HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the fuel hose from the fuel cooler.



15. REMOVE FUEL COOLER ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and fuel cooler.



16. DISCONNECT NO. 7 WATER BY-PASS HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the water by-pass hose from the fuel cooler.