ENGINE ASSEMBLY (w/ DPF) REMOVAL


  1. PRECAUTION

    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

  3. REMOVE FRONT WHEEL

  4. DRAIN ENGINE COOLANT

    CAUTION:

    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.


    1. A01KFNQE02
      Text in Illustration
      *1 Radiator Cap
      *2 Engine Drain Plug
      *3 Radiator Drain Plug

      Loosen the radiator drain plug (on the radiator).

    2. Remove the radiator cap.

    3. Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.

    4. Drain the coolant from the reservoir tank.

    5. Tighten the engine drain plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the drain plug from the oil pan and drain the engine oil into a container.

    3. Clean the drain plug.

    4. Install the drain plug with a new gasket.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  6. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH


    1. for Single Cab:

      Remove the 4 bolts and engine side cover LH.

    2. for Double Cab:

      Remove the 3 bolts and engine side cover LH.

  7. REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH


    1. for Single Cab:

      Remove the 4 bolts and engine side cover RH.

    2. for Double Cab:

      Remove the 3 bolts and engine side cover RH.

  8. REMOVE FRONT SEAT ASSEMBLY LH (for Double Cab)


    1. Disconnect the connector.

    2. Remove the 4 bolts and front seat LH.

  9. REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)

    A01KG08

    1. Remove the 4 screws and front door scuff plate LH.

  10. REMOVE PARKING BRAKE HOLE COVER (for Double Cab)

    A01KHZT

    1. Remove the screw and parking brake hole cover.

  11. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Double Cab)

  12. REMOVE FRONT FLOOR PANEL BRACE (for Double Cab)

    A01KFZF

    1. Remove the 3 clips, then remove the floor panel brace with the shifting hole cover.

  13. REMOVE NO. 1 FRONT FLOOR MAT REAR (for Double Cab)

  14. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (for Double Cab)


    1. A01KECI

      Remove the clip.

    2. Remove the nut and washer, and separate the floor shift cable transmission control shift.

  15. SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (for Double Cab)


    1. A01KF9M

      Remove the clip.

    2. Remove the clip and washer, and separate the floor shift cable transmission control select.

  16. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)

    A01KGMH

    1. Remove the 4 bolts and transmission floor shift.

  17. SEPARATE PARKING BRAKE LEVER ASSEMBLY (for Double Cab)

    A01KH1U

    1. Disconnect the connector.

    2. Remove the 4 bolts, and separate the parking brake lever with parking brake cable.

  18. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)

    A01KEH0

    1. Remove the 7 bolts and engine service hole sub cover.

  19. REMOVE REAR DOOR SCUFF PLATE LH (for Double Cab)

    A01KF1Z

    1. Remove the 3 screws and rear door scuff plate.

  20. REMOVE REAR DOOR SCUFF PLATE RH (for Double Cab)

    A01KINS

    1. Remove the 3 screws and rear door scuff plate.

  21. REMOVE REAR FLOOR MAT (for Double Cab)

  22. REMOVE NO. 4 MAT SET PLATE (for Double Cab)

    A01KGPT

    1. Remove the 8 screws and mat set plate.

  23. REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)

    A01KIQM

    1. Remove the 12 bolts and service hole cover.

  24. REMOVE INJECTOR DRIVER

    Click here

  25. REMOVE RADIATOR ASSEMBLY

    Click here

  26. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  27. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  28. REMOVE CLUTCH COVER ASSEMBLY


    1. A01KHECE02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the set bolts, and pull off the clutch cover assembly.

      Note

      Do not drop the clutch disc assembly.

  29. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel sub-assembly away from oil and foreign matter.

  30. REMOVE FLYWHEEL SUB-ASSEMBLY

    A01KEV4E01

    1. Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021
    2. A01KFUT

      Remove the 8 bolts and flywheel.

  31. REMOVE NO. 3 AIR HOSE


    1. A01KFEG

      Disengage the vacuum hose clamp.

    2. Disconnect the vacuum hose.

    3. Loosen the 2 hose clamps and remove the No. 3 air hose.

  32. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY

    A01KG8D

    1. Remove the 2 bolts and separate the vane pump oil reservoir.

  33. DISCONNECT VANE PUMP ASSEMBLY


    1. Remove the 2 nuts and disconnect the vane pump.

    2. Remove the O-ring.

  34. REMOVE VACUUM PUMP ASSEMBLY


    1. A01KHR8

      Slide the clip and disconnect the 2 vacuum hoses from the vacuum pump union.

    2. A01KHU9

      Remove the 2 nuts and remove the vacuum pump.

    3. Remove the 2 O-rings from the vacuum pump.

  35. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE (for LHD)


    1. Disconnect the wire harness from the wire harness clamp bracket.

    2. A01KI96

      Remove the 2 bolts and wire harness clamp bracket.

    3. A01KG1H

      Remove the bolt and engine oil level dipstick guide.

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

  36. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)

    A01KHTU

    1. Remove the 4 bolts and disconnect the cooler compressor.

  37. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

    A01KELJ

    1. Remove the 4 bolts and No. 1 compressor mounting bracket.

  38. REMOVE GENERATOR ASSEMBLY


    1. A01KETK

      Remove the 2 bolts, disconnect the 2 connector shown in the illustration and separate the engine wire harness.

    2. Remove the engine oil level dipstick sub-assembly.

    3. A01KEPC

      Remove the bolt and engine oil level dipstick guide.

    4. A01KGMT

      Disconnect the generator connector.

    5. Remove the terminal cap.

    6. Remove the nut and disconnect the wire harness from terminal B.

    7. A01KFRT

      Remove the 2 bolts and generator bracket.

    8. A01KFAR

      Remove the bolt and generator assembly.

  39. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    A01KI1F

    1. Remove the 4 bolts and V-ribbed belt tensioner.

  40. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    A01KIH2

    1. Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

  41. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    A01KH9J

    1. Remove the 2 bolts and No. 3 exhaust manifold heat insulator.

  42. REMOVE TURBINE OUTLET ELBOW STAY

    A01KEIN

    1. Remove the 4 bolts and turbine outlet elbow stay.

  43. REMOVE CATALYTIC WITH PIPE CONVERTER ASSEMBLY

    A01KG5U

    1. Remove the 3 nuts and catalytic with pipe converter assembly.

  44. REMOVE NO. 2 FUEL PIPE CLAMP


    1. Loosen the No. 3 fuel pipe union bolt.

    2. Remove the No. 2 fuel pipe clamp bolt, No. 2 fuel pipe clamp and No. 3 fuel pipe clamp bolt.

  45. REMOVE TURBINE OUTLET ELBOW

    A01KIAQ

    1. Disconnect the addition injector connector.

    2. Disconnect the No. 1 turbo water hose.

    3. A01KG26J02
      Text in Illustration
      *1 No. 3 Fuel Pipe
      *2 No. 4 Water By-pass Pipe
      *3 No. 13 Water By-pass Hose

      Remove the No. 4 water by-pass pipe union bolt and gasket.

    4. Remove the No. 3 fuel pipe union bolt and gasket.

    5. Disconnect the No. 4 water by-pass pipe from the No. 13 water by-pass pipe.

    6. Remove the 3 nuts, turbine outlet elbow and gasket.

  46. REMOVE NO. 1 AIR HOSE

    A01KHAW

    1. Loose the hose clamp and disconnect the No. 1 air hose.

  47. REMOVE COMPRESSOR OUTLET ELBOW

    A01KEB4

    1. Loosen the hose clamp.

    2. Remove the bolt and compressor outlet elbow.

  48. REMOVE NO. 2 AIR CLEANER HOSE

    A01KHOK

    1. Disconnect the turbocharger motor connector.

    2. A01KH05

      Loosen the 2 hose clamps and remove the No. 2 air cleaner hose.

  49. DISCONNECT WIRE HARNESS

    A01KEZH

    1. Disconnect the turbocharger stroke sensor connector.

    2. A01KIQT

      Remove the 2 bolts and separate the engine wire harness with bracket.

  50. REMOVE VENTILATION PIPE SUB-ASSEMBLY

    A01KGFJ

    1. Remove the bolt and ventilation pipe sub-assembly.

  51. REMOVE NO. 1 TURBO INSULATOR

    A01KFXV

    1. Remove the 2 bolts and No. 1 turbo insulator.

  52. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A01KHYL

    1. Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  53. REMOVE TURBOCHARGER STAY

    A01KFD3

    1. Remove the 2 bolts, nut and the turbocharger stay.

  54. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY

    A01KH75E01

    1. Remove the 2 bolts, 2 nuts, union bolt then remove the turbo oil inlet pipe and 3 gaskets.

      Note

      Do not loosen the nut labeled A. If the nut is mistakenly loosened, replace the turbocharger.

  55. REMOVE TURBOCHARGER SUB-ASSEMBLY

    A01KGJR

    1. Disconnect the 3 turbo water hoses.

    2. A01KF0L

      Remove the 3 nuts, turbocharger and gasket.

  56. REMOVE EXHAUST MANIFOLD

    A01KHVE

    1. Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

  57. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    A01KHFIE01

    1. Remove the cotter pin and nut.

    2. Using SST, disconnect the tie rod end from the steering knuckle arm.

      SST
      09610-20012

  58. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Remove the RH side using the same procedures as the LH side.

  59. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH

    A01KF92

    1. Remove the bolt and nut, disconnect the front shock absorber LH from the suspension lower arm.

  60. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Separate the RH side using the same procedures as the LH side.

  61. SEPARATE FRONT STABILIZER BAR

    A01KHO7

    1. Remove the 4 bolts and separate the front stabilizer bar.

  62. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH


    1. Remove the cotter pin and castle nut.

    2. A01KF50E01
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, disconnect the lower ball joint from suspension lower arm.

      SST
      09628-62011

  63. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Separate the RH side using the same procedures as the LH side.

  64. REMOVE STEERING TORQUE SHAFT ASSEMBLY


    1. Remove the 3 bolts, steering link protector UPR and steering link protector LWR.

    2. Remove the 2 bolts.

    3. A01KHJHE01
      Text in Illustration
      *a Matchmark

      Shift the sliding yoke and place the matchmarks to the sliding yoke and steering gear.

    4. Remove the bolt.

    5. A01KEEOE01
      Text in Illustration
      *a Matchmark

      Shift the torque shaft and place the matchmarks to the torque shaft and bevel gear.

    6. Remove the torque shaft.

  65. SEPARATE STEERING GEAR OUTLET RETURN TUBE

    A01KIMS

    1. Remove the bolt (LHD steering position type only).

    2. A01KEK0

      Remove the clip and disconnect the return hose.

    3. A01KFQW

      Remove the return tube.

  66. SEPARATE PRESSURE FEED TUBE ASSEMBLY

    A01KGVN

    1. Remove the union bolt and gasket, and disconnect the feed tube.

  67. SEPARATE ENGINE WIRE

  68. REMOVE FRONT SUSPENSION MEMBER ASSEMBLY


    1. A01KGIFE02
      Text in Illustration
      *1 Front Suspension Damper

      Set a jack under the front suspension member.

    2. Remove the 2 nuts and the 2 suspension dampers.

    3. Remove the 4 bolts and front suspension member.

  69. REMOVE ENGINE ASSEMBLY


    1. Using an engine lifter, hold the engine assembly.

    2. A01KGZ3E02
      Text in Illustration
      *1 Upper No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers in the correct direction.

      Tech Tips

      Part name Part No.

      No. 1 engine hanger

      Bolt

      12284-30020

      91512-81025

      No. 2 engine hanger

      Bolt

      12282-67030

      91642-81030
      Torque:
      Upper No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
    3. A01KFLI

      Remove the 4 bolts, 6 nuts and engine mount insulators.

    4. Using a chain block and engine sling device, hang up the engine assembly so as not tilt it.

      CAUTION:

      Do not attempt to hang the engine by hooking the chain to any other part.

  70. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  71. REMOVE NO. 1 TIMING BELT COVER

    A01KER2

    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. Remove the 6 bolts and timing belt cover.

  72. REMOVE TIMING BELT

    A01KFPKE06

    1. Set No. 1 cylinder to TDC/compression.


      1. Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

        Text in Illustration
        *a Matchmarks
        *b Timing Marks

        Tech Tips

        If reusing the timing belt, draw a direction arrow on the belt (in the direction of engine revolution) and place matchmarks on the pulleys and belt as shown in the illustration.

    2. A01KHZHE01

      Alternately loosen the 2 bolts, and remove the timing belt tensioner.

    3. A01KGB9E02

      Remove the timing belt.

      Tech Tips


      • When turning the camshaft with the timing belt removed first, turn the crankshaft 90° counterclockwise to lower the piston.

      • When installing the timing belt, first return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks.

  73. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    1. A01KFZL

      Using a socket hexagon wrench 10 mm, remove the bolt, No. 1 timing belt idler and washer.

  74. REMOVE CRANKSHAFT POSITION SENSOR


    1. TYPE A:

      A01KHI0E01
      Text in Illustration
      *1 Clamp *2 Wire Harness Clamps (A)
      *3 Wire Harness Clamps (B) - -

      1. Detach the 2 wire harness clamps (A, B).

      2. Disconnect the crankshaft position sensor connector.

      3. Detach the crankshaft position sensor connector from the No. 1 vacuum transmitting pipe.

      4. Remove the clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Do not reuse the clamp.

      5. Remove the bolt and crankshaft position sensor.

    2. TYPE B:

      A01KFKIE01
      Text in Illustration
      *1 Clamp *2 Bracket (Clamp)
      *3 Wire Harness Clamps (A) *4 Wire Harness Clamps (B)

      1. Detach the 2 wire harness clamps (A, B).

      2. Disconnect the crankshaft position sensor connector.

      3. Detach the crankshaft position sensor connector from the No. 1 vacuum transmitting pipe.

      4. Remove the clamp.

        Note


        • Make sure that no portion of the clamp remains in the clamp installation hole. If there is any portion of the clamp remaining, remove it.

        • Do not reuse the clamp.

      5. Remove the bolt and bracket (clamp).

      6. Remove the bolt and crankshaft position sensor.

      7. Detach the 2 wire harness clamps from the bracket (clamp).

  75. REMOVE CAMSHAFT POSITION SENSOR


    1. A01KFV3

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and remove the camshaft position sensor.

  76. REMOVE OIL PRESSURE SWITCHING VALVE ASSEMBLY


    1. Disconnect the oil pressure switching valve connector.

    2. A01KHBA

      Remove the bolt and oil pressure switching valve.

  77. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. A01KG92

      Disconnect the 2 diesel throttle body connectors.

    2. Remove the 2 bolts, 2 nuts, diesel throttle body and gasket.

  78. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. A01KFS8

      Loosen the hose clamp and disconnect the No. 4 water by-pass hose.

  79. DISCONNECT NO. 7 WATER BY-PASS HOSE


    1. Loosen the hose clamp and disconnect the No. 7 water by-pass hose.

  80. SEPARATE EMISSION CONTROL VALVE WIRE


    1. A01KFVH

      Disconnect the emission control valve wire connector.

    2. Disengage the wire harness clamp and separate the emission control valve wire.

  81. REMOVE EGR VALVE BRACKET


    1. A01KHHH

      Remove the 2 bolts and EGR valve bracket.

  82. REMOVE EGR VALVE ADAPTER


    1. A01KERE

      Remove the 2 nuts and 3 bolts, remove the EGR valve adapter.

  83. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01KGR3

      Remove the electric EGR control valve assembly.

    2. Disconnect the emission control valve wire.

  84. REMOVE WATER BY-PASS HOSE ASSEMBLY


    1. A01KFUY

      Loosen the 2 hose clamps and remove the water by-pass hose assembly.

  85. REMOVE NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01KHNH

      Loosen the hose clamp and disconnect the No. 7 water by-pass hose.

    2. Remove the bolt.

    3. Loosen the hose clamp and remove the No. 4 water by-pass pipe sub-assembly from the No. 2 water by-pass hose.

  86. REMOVE NO. 3 VACUUM SWITCHING VALVE ASSEMBLY

    A01KF08

    1. Disconnect the No. 3 vacuum switching valve assembly connector.

    2. Disconnect the 2 vacuum hoses.

    3. Remove the bolt and No. 3 vacuum switching valve assembly.

  87. REMOVE NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01KGPX

      Disconnect the 2 vacuum hoses from the No. 3 vacuum transmitting pipe sub-assembly.

    2. Remove the 2 bolts and No. 3 vacuum transmitting pipe sub-assembly.

  88. REMOVE OIL LEVEL DIPSTICK GUIDE (for RHD)


    1. A01KHJY

      Detach the clamp and remove the bolt and engine oil level dipstick guide.

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

  89. REMOVE NO. 1 GAS FILTER


    1. A01KG1Z

      Disconnect the 2 vacuum hose and No. 1 gas filter from the gas filter bracket.

  90. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Remove the 2 bolts and manifold absolute pressure sensor.

  91. REMOVE GAS FILTER BRACKET


    1. A01KF13

      Remove the bolt and gas filter bracket.

  92. REMOVE MANIFOLD STAY


    1. A01KF8T

      Remove the 2 bolts and manifold stay.

  93. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01KF7C

      Loosen the clamp and disconnect the No. 3 water by-pass hose.

  94. REMOVE INTAKE AIR CONNECTOR ASSEMBLY


    1. A01KFDU

      Remove the 2 bolts, 2 nuts and intake air connector assembly.

    2. Remove the gasket.

  95. REMOVE INTAKE AIR CONNECTOR


    1. A01KG0S

      Remove the 3 bolts and intake air connector.

    2. Remove the gasket.

  96. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01KFQN

      Using a 17 mm union nut wrench, loosen the union nut.

    2. Remove the 2 bolts and inlet fuel pipe sub-assembly.

  97. REMOVE EGR COOLER ASSEMBLY


    1. Remove the 2 nuts, 3 bolts and EGR cooler assembly with No. 2 EGR valve assembly.

      A01KGSX

  98. REMOVE FUEL INJECTION PIPE


    1. A01KFWX

      Remove the 3 bolts and 3 No. 2 injection pipe clamps.

    2. A01KF34

      Using a union nut wrench 17 mm, remove the No. 1 to No. 4 injection pipe sub-assembly.

  99. REMOVE COMMON RAIL ASSEMBLY


    1. A01KI78

      Remove the 2 bolts and common rail assembly.

  100. REMOVE INTAKE MANIFOLD STAY


    1. A01KHHD

      Remove the 2 bolts and intake manifold stay.

  101. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR


    1. A01KI8G

      Remove the No. 1 intake manifold insulator from the intake manifold.

  102. REMOVE NO. 1 GLOW PLUG CONNECTOR


    1. A01KG8Z

      Remove the 4 screw grommets and nut and separate the wire harness from the No. 1 glow plug connector.

    2. A01KG5Z

      Remove the 4 nuts and the No. 1 glow plug connector.

  103. REMOVE GLOW PLUG ASSEMBLY


    1. A01KFNO

      Remove the 4 glow plugs.

  104. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01KHEI

      Disconnect the 3 fuel hoses.

    2. Remove the fuel check valve and gasket from the No. 3 nozzle leakage pipe.

      Text in Illustration
      A01KGZT Fuel Check Valve

    3. Remove the bolt and No. 2 injection pipe clamp from the No. 3 nozzle leakage pipe and No. 3 fuel pipe.

    4. Remove the bolt and No. 3 nozzle leakage pipe.

  105. REMOVE NO. 3 FUEL PIPE

    A01KHV0
    Text in Illustration
    A01KGZT Union Bolt A01KF96 Fuel Check Valve
    A01KFFI Bolt - -

    1. Remove the 2 union bolts and gasket from the No. 3 fuel pipe.

    2. Remove the fuel check valve and gasket from the No. 3 fuel pipe.

    3. Remove the 3 bolts and No. 3 fuel pipe.

  106. REMOVE PUMP DRIVE SHAFT PULLEY


    1. A01KHRQJ01

      Remove the 4 bolts indicated by the arrows in the illustration.

    2. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

  107. REMOVE SUPPLY PUMP ASSEMBLY


    1. A01KHLVE08

      Using SST, remove the nut and O-ring while holding the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    2. Disconnect the fuel temperature sensor connector and suction control valve connector from the fuel supply pump.

    3. Disconnect the fuel hose.

    4. A01KIHV

      Loosen the 2 nuts.

    5. A01KGXIE05

      Using SST, disconnect the fuel supply pump assembly from the injection gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply lubricant to the threads and tip of SST (center bolt) before using it.

    6. A01KIHV

      Remove the 2 nuts and fuel supply pump.

      Note


      • Do not hold or carry the fuel supply pump by the pipe.

      • The fuel supply pump must be kept horizontal.

    7. Remove the O-ring from the fuel supply pump assembly.

  108. REMOVE CRANKSHAFT PULLEY SUB-ASSEMBLY


    1. A01KEV4E02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, loosen the pulley bolt.

      SST
      09213-58014
      09330-00021
    2. A01KGA8E02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the pulley bolt and pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

      Note

      Apply oil or grease to the threads and tip of SST (center bolt) before to using it.

  109. REMOVE NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts and No. 5 water by-pass pipe.

  110. DISCONNECT NO. 2 TURBO WATER HOSE


    1. Remove the bolt and separate the hose clamp.

    2. Disconnect the No. 2 turbo water hose from the water inlet.

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


    1. Remove the 2 nuts, bolt and No. 2 water by-pass pipe.

    2. Remove the gasket.

  112. REMOVE WATER INLET

    A01KG1I

    1. Remove the 3 bolts and water inlet.

  113. REMOVE THERMOSTAT


    1. Remove the thermostat from the cylinder block.

    2. Remove the gasket from the thermostat.

  114. REMOVE NO. 2 CYLINDER BLOCK INSULATOR

  115. REMOVE INTAKE MANIFOLD


    1. A01KEVY

      Remove the 7 bolts, 2 nuts and intake manifold.

    2. Remove the gasket.

  116. REMOVE VACUUM CONTROL VALVE SET

    A01KGXZ

    1. Remove the 2 connectors and 3 vacuum hoses.

    2. A01KFXZ

      Remove the 2 bolts and vacuum control valve set.

  117. REMOVE SWIRL CONTROL VALVE ASSEMBLY


    1. A01KESJ

      Remove the 4 bolts, 2 nuts and swirl control valve.

    2. Remove the gasket.

  118. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Disconnect the vacuum hose.

    2. Remove the nut, bolt and No. 1 vacuum transmitting pipe.

  119. REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Remove the 2 nuts, bolt and No. 2 vacuum transmitting pipe.

  120. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01KIIV

      Remove the union bolt and gasket from the No. 2 nozzle leakage pipe assembly.

      Text in Illustration
      A01KGZT Union Bolt

    2. Remove the 3 bolts and No. 2 nozzle leakage pipe assembly.

  121. REMOVE NO. 3 WATER BY-PASS HOSE

    A01KGDA

    1. Remove the No. 3 water by-pass hose.

  122. REMOVE NO. 2 WATER BY-PASS HOSE

    A01KH2W

    1. Remove the No. 2 water by-pass hose.

  123. REMOVE OIL FILTER SUB-ASSEMBLY


    1. Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Because the oil in the filter flows out through the vinyl tube, place the drain oil container under the vinyl tube.

  124. REMOVE OIL COOLER COVER SUB-ASSEMBLY


    1. Disconnect the engine oil pressure switch connector.

    2. Remove the drain cock plug.

    3. Disconnect the vinyl tube from the oil cooler cover.

    4. A01KI56

      Remove the 2 nuts and bolt and disconnect the No. 2 vacuum transmitting pipe from the oil cooler cover.

    5. A01KHCA

      Remove the 12 bolts and oil cooler cover and gasket.

  125. REMOVE WATER OUTLET


    1. Remove the 2 bolts, water outlet and gasket.

  126. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    A01KIFTE01

    1. Disconnect the engine coolant temperature sensor connector.

    2. Using SST, remove the engine coolant temperature sensor and gasket.

      SST
      09817-33190

  127. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH


    1. A01KI5Z

      Remove the 4 bolts and engine mounting bracket.

  128. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH


    1. A01KHWV

      Remove the 4 bolts and engine mounting bracket.