Egr Valve Removal

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

  1. PRECAUTION

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

  4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

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

  6. REMOVE UPPER RADIATOR SUPPORT SEAL

  7. DRAIN ENGINE COOLANT

  8. REMOVE INTERCOOLER ASSEMBLY

  9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

  10. REMOVE NO. 1 AIR CLEANER HOSE

  11. REMOVE INTAKE AIR CONNECTOR

  12. REMOVE NO. 2 ENGINE OIL DIPSTICK GUIDE

  13. REMOVE AIR TUBE SUB-ASSEMBLY RH

  14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH

  15. DRAIN CLUTCH FLUID (for Manual Transmission)

  16. REMOVE CLUTCH HOSE (for Manual Transmission)

  17. REMOVE AIR TUBE SUB-ASSEMBLY LH

  18. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

  19. REMOVE NO. 1 GAS FILTER

  20. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET

  21. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH

  22. REMOVE NO. 1 AIR HOSE

  23. REMOVE NO. 3 AIR TUBE

  24. REMOVE NO. 2 AIR HOSE

  25. REMOVE NO. 4 AIR TUBE

  26. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

  27. DISCONNECT WATER HOSE SUB-ASSEMBLY

  28. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

  29. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

  30. DISCONNECT FUEL HOSE

  31. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

  32. REMOVE NO. 4 WATER BY-PASS PIPE

  33. DISCONNECT ENGINE WIRE

  34. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

  35. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY

  36. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)

  37. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)

  38. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)

  39. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)

  40. REMOVE INJECTION PIPE LH

  41. REMOVE NO. 2 FUEL PIPE (w/ DPF)

  42. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)

  43. DISCONNECT CONNECTING WIRE (w/ DPF)

  44. REMOVE COMMON RAIL ASSEMBLY LH

  45. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

  46. DISCONNECT FUEL PUMP MOTOR WIRE

  47. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY

  48. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)

  49. REMOVE INJECTION PIPE RH

  50. REMOVE COMMON RAIL ASSEMBLY RH

  51. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)

  52. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

  53. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

  54. REMOVE NO. 4 EGR PIPE

  55. REMOVE INTAKE PIPE

  56. DISCONNECT NO. 2 ENGINE WIRE

  57. REMOVE NO. 3 INTAKE MANIFOLD

  58. REMOVE INTAKE MANIFOLD INSULATOR

  59. REMOVE EGR PIPE INSULATOR

  60. DISCONNECT NO. 5 WATER BY-PASS PIPE

  61. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

  62. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

  63. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER

  64. REMOVE NO. 3 EGR PIPE

  65. REMOVE NO. 9 WATER BY-PASS HOSE AND WATER HOSE

  66. REMOVE NO. 1 EGR VALVE ASSEMBLY

  67. REMOVE NO. 2 EGR VALVE ASSEMBLY

  68. REMOVE EGR COOLER GASKET

Egr Valve -- Removal


NOTICE:
  1. When replacing the injectors (including shuffling the injectors between the cylinders), common rail, cylinder head, or intake manifold, it is necessary to replace the injection pipes with new ones.
  2. w/ DPF:
    When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines.


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 (Click here).


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

  1. Disconnect the cables from the negative (-) main battery and sub-battery terminals.



3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and screw.

  1. Loosen the clip and remove the front fender splash shield LH.



4. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

  1. Remove the 3 bolts and 2 screws.

  1. Loosen the clip and remove the front fender splash shield RH.



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


    Land Cruiser. Urj200, 202 Grj200 Vdj200

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



6. REMOVE UPPER RADIATOR SUPPORT SEAL

  1. Remove the 7 clips and upper radiator support seal.



7. DRAIN ENGINE COOLANT
CAUTION:
Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
HINT:
Collect the coolant in a container and dispose of it according to the regulations in your area.

  1. Loosen the radiator drain cock plug.

  1. Remove the radiator reservoir cap to drain the coolant in the radiator.



  1. Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Tighten the radiator drain cock plug by hand.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Tighten the oil filter bracket drain cock plug.

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


8. REMOVE INTERCOOLER ASSEMBLY
(Click here)


9. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

  1. Detach the 4 clamps and remove the air cleaner cap.



10. REMOVE NO. 1 AIR CLEANER HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the No. 1 air cleaner hose.



11. REMOVE INTAKE AIR CONNECTOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. w/ Viscous Heater:
    Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

    Text in Illustration
    *A
    		w/ Viscous Heater

  1. w/o Viscous Heater:
    Disconnect the connector from the water temperature sensor.

  1. Using a clip remover, detach the 3 wire harness clamps.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.



12. REMOVE NO. 2 ENGINE OIL DIPSTICK GUIDE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.



    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Disconnect the ventilation hose from the cylinder head cover RH.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF

  1. Remove the 2 bolts and No. 2 engine oil level dipstick guide.

  1. Remove the O-ring from the No. 2 engine oil level dipstick guide.



13. REMOVE AIR TUBE SUB-ASSEMBLY RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the air tube from the throttle body.



14. REMOVE DIESEL THROTTLE BODY ASSEMBLY RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the throttle position sensor connector.

  1. Disconnect the throttle motor connector.

  1. Remove the 2 bolts, 2 nuts and throttle body.

  1. Remove the gasket from the intake pipe.



15. DRAIN CLUTCH FLUID (for Manual Transmission)


16. REMOVE CLUTCH HOSE (for Manual Transmission)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

    NOTICE:
    1. Do not bend or damage the flexible hose tubes.
    2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.

  1. Remove the 2 clips.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and clutch hose.



17. REMOVE AIR TUBE SUB-ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the air tube from the throttle body.



18. REMOVE TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

    NOTICE:
    1. Do not bend or damage the flexible hose tube.
    2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and tube connector to flexible hose tube.



19. REMOVE NO. 1 GAS FILTER


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the hose from the intake pipe.

  1. Remove the No. 1 gas filter.



20. REMOVE NO. 3 INTERCOOLER SUPPORT BRACKET


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. for Manual Transmission:

    1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and No. 3 intercooler support bracket.



21. REMOVE DIESEL THROTTLE BODY ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the throttle position sensor connector.

  1. Disconnect the throttle motor connector.

  1. Remove the 2 bolts, 2 nuts and throttle body.

  1. Remove the gasket from the intake pipe.



22. REMOVE NO. 1 AIR HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the No. 1 air hose.



23. REMOVE NO. 3 AIR TUBE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the wire harness from the clamp.

  1. Remove the nut and ground wire.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

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



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the bolt and No. 3 air tube.



24. REMOVE NO. 2 AIR HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the No. 2 air hose.



25. REMOVE NO. 4 AIR TUBE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the suction hose.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp and remove the bolt and No. 4 air tube.



26. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the ventilation hose from the oil separator.

  1. Loosen the hose clamp.

  1. Remove the bolt and No. 2 air cleaner pipe.



27. DISCONNECT WATER HOSE SUB-ASSEMBLY


Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal
Text in Illustration
*A
w/ Rear Heater
*B
w/o Rear Heater


28. REMOVE HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.



29. REMOVE NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Loosen the hose clamp.

  1. Remove the bolt and No. 1 air cleaner pipe.



30. DISCONNECT FUEL HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. w/ DPF:

    Text in Illustration
    *a
    		for Fuel Filter with Heater
    *b
    		for Fuel Filter without Heater


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. w/o DPF:

    Text in Illustration
    *a
    		for Fuel Filter with Heater
    *b
    		for Fuel Filter without Heater


31. REMOVE NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.



32. REMOVE NO. 4 WATER BY-PASS PIPE


  1. w/ EGR System:



    1. Remove the 2 bolts and nut.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal


      Text in Illustration
      *A
      		w/ DPF
      		*B
      		w/o DPF

    2. w/ DPF:
      Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.

    3. w/o DPF:
      Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.



  1. w/o EGR System:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Remove the 2 bolts and nut.

    2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.



33. DISCONNECT ENGINE WIRE


  1. LH Side:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Disconnect the 4 connectors.

    2. Using a clip remover, detach the 3 wire harness clamps.



      3. Land Cruiser. Urj200, 202 Grj200 Vdj200

    3. Disconnect the 2 connectors.

    4. Using a clip remover, detach the 3 wire harness clamps.



    5. Disconnect the 8 connectors.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal


      Text in Illustration
      *A
      		w/ DPF
      		*B
      		w/o DPF

    6. Remove the bolt and engine wire harness bracket labeled B.

    7. Using a clip remover, detach the wire harness clamp labeled D.

    8. Remove the 2 bolts and disconnect the engine wire protector labeled A.

    9. for RHD:
      Disconnect the wire harness from the wire harness clamp holder labeled C.



  1. RH Side:



    1. Disconnect the 7 connectors.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal


      Text in Illustration
      *A
      		w/ DPF
      		*B
      		w/o DPF

    2. Using a clip remover, detach the wire harness clamp.

    3. Remove the 3 bolts and disconnect the wire harness protector labeled A.

    4. Remove the bolt and wire harness bracket labeled B.

    5. Remove the screw grommet, nut and glow plug wire harness labeled C.



      6. Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

    6. for RHD:
      Disconnect the wire harness from the wire harness clamp holder.

      Text in Illustration
      *A
      		w/ DPF
      *B
      		w/o DPF

    7. for RHD:
      Remove the bolt and wire harness clamp holder.



  1. Rear Side:



      Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

    1. Using a clip remover, detach the wire harness clamp.

      Text in Illustration
      *A
      		w/ DPF
      *B
      		w/o DPF

    2. Remove the 2 bolts and 2 ground wires labeled C.

    3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.

    4. w/ DPF:
      Disconnect the 3 connectors.

    5. w/o DPF:
      Disconnect the connector.

    6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.



34. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)
NOTICE:
  1. After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel pipe ends, cover the fuel pipe ends with plastic bags.
  2. After removing a fuel pipe, to prevent dirt or foreign objects from entering the fuel supply pump hole, cover the hole with protective tape.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

  1. Remove the bolt and No. 2 injection pipe clamp.

  1. Remove the union bolt and gasket.

  1. Remove the bolt, nut and No. 2 fuel pipe.



35. REMOVE NO. 6 INJECTION PIPE SUB-ASSEMBLY
NOTICE:
After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes, cover the holes with protective tape.


  1. w/ EGR System:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Using a union nut wrench, loosen the No. 6 injection pipe ends.

    2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.

    3. Remove the No. 6 injection pipe.



  1. w/o EGR System:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Using a union nut wrench, loosen the No. 6 injection pipe ends.

    2. Remove the nut and No. 2 injection pipe clamp.

    3. Remove the bolt and No. 6 injection pipe.



36. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 vacuum hoses.

  1. Remove the bolt and vacuum switching valve.



37. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the 2 vacuum hoses.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 3 bolts and vacuum transmitting pipe.



38. REMOVE CYLINDER HEAD COVER SILENCER LH (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and cylinder head cover silencer.



39. REMOVE NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the fuel hose.

  1. Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.



40. REMOVE INJECTION PIPE LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. w/ Intercooler:
    Remove the 2 nuts and 4 injection pipe clamps.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Using a union nut wrench, remove the 4 injection pipes.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF
    NOTICE:
    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.


41. REMOVE NO. 2 FUEL PIPE (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the No. 4 fuel hose.

  1. Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.



42. REMOVE NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)


  1. w/ DPF:

    1. Disconnect the fuel hose.



      2. Land Cruiser. Urj200, 202 Grj200 Vdj200

    2. Remove the union bolt, gasket and No. 5 nozzle leakage pipe.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. w/o DPF:
    Remove the union bolt, gasket and No. 5 nozzle leakage pipe.



43. DISCONNECT CONNECTING WIRE (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the 2 clamps and remove the connecting wire.



44. REMOVE COMMON RAIL ASSEMBLY LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Remove the 2 bolts and common rail.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF
    NOTICE:
    1. Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.
    2. w/ DPF:
      Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.


45. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY


  1. w/ DPF:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Remove the bolt and No. 2 injection pipe clamp.

    2. Disconnect the fuel hose.

    3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.



  1. w/o DPF:



      Land Cruiser. Urj200, 202 Grj200 Vdj200

    1. Disconnect the 2 hoses from the fuel pipe.

    2. Remove the bolt and fuel filter to injection pump fuel pipe.



46. DISCONNECT FUEL PUMP MOTOR WIRE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the connector from the fuel supply pump.



47. REMOVE NO. 5 INJECTION PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Using a union nut wrench, remove the No. 5 injection pipe.

    NOTICE:
    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.


48. REMOVE CYLINDER HEAD COVER SILENCER RH (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts and cylinder head cover silencer.



49. REMOVE INJECTION PIPE RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. w/ Intercooler:
    Remove the 2 nuts and 4 injection pipe clamps.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Using a union nut wrench, remove the 4 injection pipes.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF
    NOTICE:
    After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.


50. REMOVE COMMON RAIL ASSEMBLY RH


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Remove the 2 bolts and common rail.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF
    NOTICE:
    Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.


51. REMOVE NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.



52. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


Land Cruiser. Urj200, 202 Grj200 Vdj200


53. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR


Land Cruiser. Urj200, 202 Grj200 Vdj200


54. REMOVE NO. 4 EGR PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts, No. 4 EGR pipe and 2 gaskets.



55. REMOVE INTAKE PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts, 2 nuts and intake pipe.

  1. Remove the gasket.



56. 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.



57. REMOVE NO. 3 INTAKE MANIFOLD


    Land Cruiser. Urj200, 202 Grj200 Vdj200

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



58. REMOVE INTAKE MANIFOLD INSULATOR


Land Cruiser. Urj200, 202 Grj200 Vdj200


59. REMOVE EGR PIPE INSULATOR


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 bolts and EGR pipe insulator.



60. DISCONNECT NO. 5 WATER BY-PASS PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the bolt and disconnect the 2 hoses to disconnect the No. 5 water by-pass pipe.



61. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts, No. 1 EGR pipe and 2 gaskets.



62. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 4 bolts, No. 2 EGR pipe and 2 gaskets.



63. REMOVE EGR VALVE ASSEMBLY WITH EGR COOLER


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Remove the 6 bolts and EGR valve with EGR cooler.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF


64. REMOVE NO. 3 EGR PIPE


    Land Cruiser. Urj200, 202 Grj200 Vdj200.1Vd-Ftv Emission Control.Emission Control System.Egr Valve Removal

  1. Remove the 4 nuts, 4 bolts and No. 3 EGR pipe.

    Text in Illustration
    *A
    		w/ DPF
    *B
    		w/o DPF

  1. Remove the 2 gaskets.

  1. w/ DPF:
    Remove the O-ring from the No. 3 water by-pass pipe.



65. REMOVE NO. 9 WATER BY-PASS HOSE AND WATER HOSE


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the No. 9 water by-pass hose.

  1. Disconnect the 2 water hoses.



66. REMOVE NO. 1 EGR VALVE ASSEMBLY


67. REMOVE NO. 2 EGR VALVE ASSEMBLY


68. REMOVE EGR COOLER GASKET