Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1GR-FE INTAKE / EXHAUST

Use a torque wrench with a fulcrum length of 300 mm (11.8 in.). When using a torque wrench with a fulcrum length that is not 300 mm (11.8 in.), calculate the torque specification for the torque wrench and SST based on the "without SST" torque specification ().

Make sure SST and the wrench are connected in a straight line.

2. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

Install a new gasket to the cylinder head.

Text in Illustration
*1	Protrusion
	Front

NOTICE:

Be careful of the installation direction.

Temporarily install the manifold with 6 new nuts.

Tighten the 6 nuts in the sequence shown in the illustration.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Text in Illustration
*A	w/ Secondary Air Injection System
*B	w/o Secondary Air Injection System

Connect the air fuel ratio sensor connector.

3. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with the 3 bolts.

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

4. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)

Install 2 new gaskets.

Text in Illustration
*1	Claw
*2	No. 2 Air Tube

NOTICE:

Make sure the gasket's claws are not caught between the No. 2 emission control valve set and No. 2 air tube.

Install the No. 2 air tube with the 2 bolts and 2 nuts.

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

5. INSTALL NO. 2 MANIFOLD STAY

Install the No. 2 manifold stay with the 3 bolts.

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

6. INSTALL AIR FUEL RATIO SENSOR (for Bank 1 Sensor 1)

Using SST, install the air fuel ratio sensor.

SST
09224-00010

Torque:
without SST:
44 N*m{ 449 kgf*cm, 32 ft.*lbf}
with SST:
40 N*m{ 408 kgf*cm, 30 ft.*lbf}

Text in Illustration
*1	Fulcrum Length

HINT:

Make sure SST and the wrench are connected in a straight line.

7. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

Install a new gasket to the cylinder head.

Text in Illustration
*1	Protrusion
	Front

NOTICE:

Be careful of the installation direction.

Temporarily install the manifold with 6 new nuts.

Tighten the 6 nuts in the sequence shown in the illustration.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Text in Illustration
*A	w/ Secondary Air Injection System
*B	w/o Secondary Air Injection System

Connect the air fuel ratio sensor connector.

8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Install the heat insulator with the 3 bolts.

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

9. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

for Manual Tilt and Manual Telescopic Steering Column: ()

for Power Tilt and Power Telescopic Steering Column: ()

10. INSTALL AIR TUBE (w/ Secondary Air Injection System)

Install 2 new gaskets.

Text in Illustration
*1	Claw
*2	Air Tube

NOTICE:

Make sure the gasket's claws are not caught between the No. 1 emission control valve set and air tube.

Install the air tube with the 2 bolts and 2 nuts.

Torque:
10 N*m{ 102 kgf*cm, 7 in.*lbf}

11. INSTALL MANIFOLD STAY

Install the manifold stay with the 3 bolts.

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

12. INSTALL FRONT EXHAUST PIPE ASSEMBLY

()

13. INSTALL NO. 2 ENGINE UNDER COVER

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

Torque:
29 N*m{ 296 kgf*cm, 21 ft.*lbf}

14. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Install the No. 1 engine under cover with the 10 bolts.

Torque:
29 N*m{ 296 kgf*cm, 21 ft.*lbf}

15. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.

16. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

17. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Install the air cleaner case with the 3 bolts.

Torque:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the air cleaner filter element.

18. INSTALL AIR CLEANER CAP AND HOSE

Install the air cleaner cap and hose.

Text in Illustration
*a	Top
*b	Front
*c	Protrusion (Hose)
*d	Protrusion (Throttle body)

Install the air cleaner cap and hose with the bolt and fasten the 4 hook clamps.

Torque:
5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Tighten the clamp.

Torque:
2.5 N*m{ 25 kgf*cm, 22 in.*lbf}

Attach the 4 clamps and connect the No. 2 PCV hose, vacuum hose and mass air flow meter connector.

HINT:

The direction of the hose clamp is indicated in the illustration.

19. INSTALL V-BANK COVER

Attach the 2 V-bank cover hooks to the bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover to attach the pins.

Text in Illustration
*1	Pin
*2	Hook

20. INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

21. INSTALL FRONT FENDER APRON TRIM PACKING B

w/ KDSS:

Install the front fender apron trim packing B with the 3 clips.

w/o KDSS:

Install the front fender apron trim packing B with the 4 clips.

22. INSTALL FRONT FENDER APRON TRIM PACKING A

Install the front fender apron trim packing A with the 3 clips.

23. INSTALL FRONT FENDER APRON TRIM PACKING D

Install the front fender apron trim packing D with the 4 clips.

24. INSTALL FRONT FENDER APRON TRIM PACKING C

Install the front fender apron trim packing C with the 4 clips.

Exhaust Manifold - Installation

Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - 1GR-FE INTAKE / EXHAUST

EXHAUST MANIFOLD - INSTALLATION