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

After turning the engine 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 ().

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected ().

4. REMOVE UPPER RADIATOR SUPPORT SEAL

Remove the 7 clips and radiator support seal.

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

5. REMOVE RADIATOR GRILLE

Put protective tape around the radiator grille assembly.

Text in Illustration
*1	Protective Tape

Remove the 3 screws.

Detach the 2 clips and 8 claws, and remove the radiator grille assembly.

w/ Wide View Front Monitor System:

Disconnect the connector.

6. REMOVE FRONT BUMPER COVER

HINT:

For the front bumper cover with garnish, use the procedure described below.

Put protective tape around the front bumper cover.

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

Text in Illustration
*1	Protective Tape	-	-

Using a T30 "TORX" socket, remove the 6 screws.

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

Text in Illustration
*A	LH Side	*B	RH Side

Remove the 3 clips, 4 screws and 4 bolts.

Detach the 10 claws and remove the front bumper cover.

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

w/ TOYOTA Parking Assist-sensor System or w/ Fog Light:

Disconnect the No. 4 engine room wire connector and remove the front bumper cover.

w/ Headlight Cleaner System:

Disconnect the headlight cleaner hose and remove the front bumper cover.

7. REMOVE TRANSMISSION OIL COOLER AIR DUCT

Remove the 4 bolts and oil cooler air duct.

8. DISCONNECT RADIATOR SIDE DEFLECTOR LH

Using a clip remover, remove the 4 clips and disconnect the side deflector.

9. REMOVE FRONT FENDER MAIN SEAL LH

Using a clip remover, detach the 3 clips and remove the fender main seal.

10. REMOVE FRONT FENDER MAIN SEAL RH

HINT:

Use the same procedure described for the LH side.

11. REMOVE FRONT WIPER ARM LH

Remove the nut, wiper arm and blade.

12. REMOVE FRONT WIPER ARM RH

Remove the nut, wiper arm and blade.

13. REMOVE HOOD TO COWL TOP SEAL

Using a clip remover, detach the 12 clips, 4 clamps and remove the hood to cowl top seal.

14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Remove the washer hose.

Remove the 2 clips.

Detach the 17 claws and remove the cowl top ventilator louver sub-assembly.

15. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Remove the 3 bolts and screw.

Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly LH.

16. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Remove the 3 bolts and 2 screws.

Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly RH.

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

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

18. REMOVE NO. 2 ENGINE UNDER COVER

Remove the 2 bolts and No. 2 engine under cover.

19. REMOVE FRONT FENDER APRON SEAL LH

Using a clip remover, remove the 3 clips and fender apron seal.

20. REMOVE FRONT FENDER APRON SEAL FRONT RH

Using a clip remover, remove the 3 clips and fender apron seal.

21. DRAIN ENGINE OIL

Remove the oil filler cap.

Remove the 2 bolts and No. 2 engine under cover seal.

Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

Install a new gasket and the oil pan drain plug.

Torque:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

22. DRAIN ENGINE COOLANT

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Loosen the radiator drain cock plug.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Remove the radiator cap. Then drain the coolant from the radiator.

Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine.

Tighten the 2 cylinder block drain cock plugs.

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

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

Text in Illustration
*1	Radiator Reservoir	*2	Radiator Cap
*3	Radiator Drain Cock Plug	*4	Cylinder Block Drain Cock Plug

Tighten the radiator drain cock plug by hand.

23. REMOVE V-BANK COVER SUB-ASSEMBLY

Raise the front of the V-bank cover to detach the 3 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

Text in Illustration
*1	Bracket
*2	Hook
*3	Pin
*4	Grommet

24. REMOVE AIR CLEANER HOSE ASSEMBLY

Disconnect the vacuum hose and No. 2 ventilation hose.

Loosen the 2 hose clamps.

Remove the air cleaner hose.

25. REMOVE AIR CLEANER ASSEMBLY

Remove the 3 bolts and air cleaner.

26. REMOVE NO. 1 RADIATOR HOSE

27. REMOVE NO. 2 RADIATOR HOSE

28. REMOVE FAN SHROUD

Loosen the 4 nuts holding the fluid coupling fan.

Remove the fan and generator V-belt ().

Disconnect the reservoir hose from the upper radiator tank.

Detach the claw to open the flexible hose clamp.

Remove the 2 bolts and disconnect the oil cooler tube from the fan shroud.

Remove the 2 bolts holding the fan shroud.

Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley.

29. REMOVE RADIATOR ASSEMBLY

Disconnect the 2 oil cooler hoses.

Remove the 4 bolts and radiator.

30. DISCONNECT ENGINE WIRE

Engine Room LH Side:

Remove the engine room relay block cover.

Disconnect the 2 connectors and 2 clips from the engine room junction block.

Disconnect the injector connector.

Disconnect the 4 ignition coil connectors.

Disconnect the 2 VVT sensor connectors.

Disconnect the 4 clamps.

Remove the 2 bolts and ground wire.

Disconnect the noise filter connector.

Disconnect the engine coolant temperature sensor connector.

Disconnect the 2 camshaft timing oil control valve connectors.

Disconnect the camshaft position sensor connector.

Disconnect the 3 clamps.

Disconnect the cooler compressor connector.

Engine Room RH Side:

Disconnect the 2 camshaft timing oil control valve connectors.

Disconnect the 4 ignition coil connectors.

Disconnect the injector connector.

Disconnect the 2 VVT sensor connectors.

Disconnect the noise filter connector.

Remove the 2 bolts and ground wire.

Disconnect the throttle position sensor and throttle control motor connector.

Disconnect the 5 clamps.

Disconnect the 2 clamps and power steering oil pressure switch connector.

31. DISCONNECT WATER PIPE AND HOSE SUB-ASSEMBLY

Disconnect the 3 hoses.

Remove the 2 bolts and disconnect the water pipe and hose from the cylinder head cover.

32. DISCONNECT COOLER COMPRESSOR ASSEMBLY

Remove the 3 bolts, nut and stud bolt, and disconnect the cooler compressor.

HINT:

It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

33. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

Remove the 2 bolts and disconnect the fuel tube.

Text in Illustration
*A	LH Side
*B	RH Side

34. 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.

35. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Disconnect the wire harness clamp.

Remove the dipstick.

Remove the bolt and dipstick guide.

Remove the O-ring from the dipstick guide.

36. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

Disconnect the sender gauge connector.

Remove the oil pressure sender gauge.

37. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

Remove the 3 bolts.

Disconnect the 4 hoses and remove the water by-pass pipe.

38. REMOVE NO. 1 OIL COOLER BRACKET

Remove the 2 nuts and bracket.

Disconnect the ground wire from the cylinder block.

39. REMOVE OIL FILTER BRACKET

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.

40. REMOVE INTAKE MANIFOLD

Disconnect the ventilation hose from the ventilation pipe of the cylinder head cover LH and RH.

Disconnect the 2 water by-pass hoses.

Disconnect the throttle body connector.

Disconnect the No. 1 ventilation hose.

Disconnect the purge VSV connector.

Disconnect the purge line hose from the purge VSV.

Disconnect the vacuum switching valve connector (for ACIS).

Remove the No. 1 engine cover sub-assembly.

Remove the No. 3 engine cover.

Disconnect the 3 wire clamps from the 3 wire brackets.

Remove the bolt and wire bracket from the intake manifold.

Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets.

41. DISCONNECT VANE PUMP ASSEMBLY

Remove the 2 bolts and disconnect the vane pump.

42. DISCONNECT OIL COOLER PIPE ASSEMBLY

Remove the 2 bolts and disconnect the oil cooler pipe.

43. REMOVE GENERATOR ASSEMBLY

Disconnect the generator connector.

Open the terminal cap.

Remove the nut and disconnect the generator wire.

Remove the bolt and disconnect the wire harness bracket from the generator.

Remove the 3 bolts, nut and generator.

Remove the stud bolt.

44. REMOVE NO. 1 WATER BY-PASS HOSE

Remove the No. 1 water by-pass hose by disconnecting the hose from the water inlet housing and front water by-pass joint.

45. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

Disconnect the 2 hoses.

Remove the 2 bolts and water by-pass pipe.

46. REMOVE FRONT WATER BY-PASS JOINT

Disconnect the No. 2 water by-pass hose from the water by-pass joint.

Remove the 4 nuts, water by-pass joint and 2 gaskets.

47. REMOVE NO. 2 ENGINE COVER

48. REMOVE NO. 1 ENGINE COVER

49. REMOVE WATER INLET HOUSING

Remove the 3 bolts, water inlet housing and gasket.

50. 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.

51. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

Remove the bolt and idler pulley.

52. REMOVE FLUID COUPLING BRACKET

Remove the 4 bolts and fluid coupling bracket.

53. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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

54. REMOVE IGNITION COIL ASSEMBLY

Remove the 8 bolts and 8 ignition coils.

55. 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).

56. 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).

57. 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.

58. 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

59. DISCONNECT WIRE HARNESS CLAMP BRACKET

Remove the bolt and disconnect the bracket.

60. 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.

61. REMOVE WATER INLET PIPE

Remove the water inlet pipe.

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

62. 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.

Camshaft - Removal. 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°

63. 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.

64. REMOVE NO. 1 CHAIN TENSIONER SLIPPER LH

65. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH

Remove the 2 bolts and chain vibration damper.

66. 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.

67. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

Remove the 2 bolts and chain tensioner.

68. 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.

69. REMOVE NO. 1 CHAIN TENSIONER SLIPPER RH

70. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH

Remove the 2 bolts and vibration damper.

71. 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.

72. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

Remove the 2 bolts and chain tensioner.

73. REMOVE CRANKSHAFT TIMING GEAR KEY

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

74. 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.

75. 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.

76. 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.

77. 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.