DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
REMOVE FRONT WHEEL
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 | Radiator Cap |
| *2 | Engine Drain Plug |
| *3 | Radiator Drain Plug |
Loosen the radiator drain plug (on the radiator).
Remove the radiator cap.
Loosen the engine drain plug (on the oil cooler cover), and drain the coolant.
Drain the coolant from the reservoir tank.
Tighten the engine drain plug.
DRAIN ENGINE OIL
Remove the oil filler cap.
Remove the drain plug from the oil pan and drain the engine oil into a container.
Clean the drain plug.
Install the drain plug with a new gasket.
REMOVE ENGINE SIDE COVER SUB-ASSEMBLY LH
for Single Cab:
Remove the 4 bolts and engine side cover LH.
for Double Cab:
Remove the 3 bolts and engine side cover LH.
REMOVE ENGINE SIDE COVER SUB-ASSEMBLY RH
for Single Cab:
Remove the 4 bolts and engine side cover RH.
for Double Cab:
Remove the 3 bolts and engine side cover RH.
REMOVE FRONT SEAT ASSEMBLY LH (for Double Cab)
Disconnect the connector.
Remove the 4 bolts and front seat LH.
REMOVE FRONT DOOR SCUFF PLATE LH (for Double Cab)
Remove the 4 screws and front door scuff plate LH.
REMOVE PARKING BRAKE HOLE COVER (for Double Cab)
Remove the screw and parking brake hole cover.
REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Double Cab)
REMOVE FRONT FLOOR PANEL BRACE (for Double Cab)
Remove the 3 clips, then remove the floor panel brace with the shifting hole cover.
REMOVE NO. 1 FRONT FLOOR MAT REAR (for Double Cab)
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (for Double Cab)
Remove the clip.
Remove the nut and washer, and separate the floor shift cable transmission control shift.
SEPARATE FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (for Double Cab)
Remove the clip.
Remove the clip and washer, and separate the floor shift cable transmission control select.
REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (for Double Cab)
Remove the 4 bolts and transmission floor shift.
SEPARATE PARKING BRAKE LEVER ASSEMBLY (for Double Cab)
Disconnect the connector.
Remove the 4 bolts, and separate the parking brake lever with parking brake cable.
REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)
Remove the 7 bolts and engine service hole sub cover.
REMOVE REAR DOOR SCUFF PLATE LH (for Double Cab)
Remove the 3 screws and rear door scuff plate.
REMOVE REAR DOOR SCUFF PLATE RH (for Double Cab)
Remove the 3 screws and rear door scuff plate.
REMOVE REAR FLOOR MAT (for Double Cab)
REMOVE NO. 4 MAT SET PLATE (for Double Cab)
Remove the 6 screws and mat set plate.
REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)
Remove the 12 bolts and service hole cover.
REMOVE INTERCOOLER ASSEMBLY
Refer to the procedures up to "REMOVE INTERCOOLER ASSEMBLY" Click here.
DISCONNECT HEATER WATER HOSE OUTLET B (w/ Heater)
Disconnect the heater water outlet hose.
DISCONNECT HEATER WATER HOSE INLET A (w/ Heater)
Disconnect the heater water inlet hose.
REMOVE INLET RADIATOR HOSE
Disconnect the 2 hose clamps and remove the inlet radiator hose.
REMOVE FLUID COUPLING ASSEMBLY
Loosen the 4 nuts from the fan pulley.
Remove the fan and generator V belt Click here.
Remove the 4 nuts.
REMOVE FAN SHROUD
Disconnect the reserve tank hose from the fan shroud.
Disconnect the outlet radiator hose from the fan shroud.
Remove the 2 bolts and separate the the fan shroud.
Remove the fan with fluid coupling and fan shroud.
REMOVE FAN PULLEY
Remove the fan pulley from the water pump.
DISCONNECT OUTLET RADIATOR HOSE
Disconnect the hose clamp and outlet radiator hose.
DISCONNECT RADIATOR RESERVE TANK HOSE
Disconnect the reserve tank hose from the radiator.
REMOVE RADIATOR ASSEMBLY
Remove the 2 bolts and separate the outlet heater water pipe (w/ Heater).
Remove the bolt and separate the inlet heater water pipe (w/ Heater).
Remove the bolt and nut and separate the wire harness.
Remove the 2 bolts and radiator support.
Remove the 2 bolts, 2 radiator support cushions, 2 cushions and radiator.
REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
Refer to the procedures up to "REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY" Click here.
REMOVE CLUTCH COVER ASSEMBLY
| *a | Matchmark |
Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.
Loosen each set bolt one turn at a time until spring tension is released.
Remove the set bolts, and pull off the clutch cover assembly.
Note
Do not drop the clutch disc assembly.
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.
REMOVE FLYWHEEL SUB-ASSEMBLY
Using SST, hold the crankshaft pulley.
Remove the 8 bolts and flywheel.
REMOVE NO. 3 AIR HOSE
SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY
Remove the 3 bolts and separate the vane pump oil reservoir.
Tech Tips
Remove the vane pump oil reservoir together with the 2 hoses, then suspended them from the body with piece of rope.
REMOVE VANE PUMP ASSEMBLY
Remove the 2 nuts, and then remove the vane pump and O-ring.
Tech Tips
Remove the vane pump together with hoses.
DISCONNECT VACUUM HOSE
Disconnect the vacuum hose from the vacuum pump as shown in the illustration.
REMOVE TIMING GEAR COVER INSULATOR
Remove the bolt and timing gear cover insulator.
REMOVE VACUUM PUMP ASSEMBLY
Remove the 2 nuts, and then remove the vacuum pump and 2 O-rings.
REMOVE GENERATOR ASSEMBLY
Remove the 2 bolts, disconnect the connector shown in the illustration and separate the engine wire harness (for LHD).
Remove the oil level gage sub-assembly (for LHD).
Remove the bolt and remove the oil level gage guide (for LHD).
Remove the 2 bolts, disconnect the connector shown in the illustration and separate the engine wire harness (for RHD).
Disconnect the generator connector.
Remove the terminal cap.
Remove the nut and disconnect the wire harness from terminal B.
Remove the 2 bolts and remove the generator bracket.
Remove the bolt and remove the generator.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
Remove the 4 bolts and V-ribbed belt tensioner.
REMOVE COMPRESSOR OUTLET ELBOW
Remove the hose clamp and bolt shown in the illustration and remove the compressor outlet elbow with No. 2 air hose.
DISCONNECT TURBOCHARGER MOTOR CONNECTOR
Disconnect the turbocharger motor connector from the turbocharger.
REMOVE NO. 2 AIR CLEANER HOSE
Loosen the hose clamp and remove the NO. 2 air cleaner hose.
DISCONNECT TURBOCHARGER STROKE SENSOR CONNECTOR
Disconnect the turbocharger stroke sensor connector from the turbocharger.
SEPARATE ENGINE WIRE HARNESS (for LHD)
Remove the 2 bolts and separate the engine wire harness with bracket.
SEPARATE ENGINE WIRE HARNESS (for RHD)
Remove the 2 bolts and separate the engine wire harness with bracket.
REMOVE VENTILATION PIPE SUB-ASSEMBLY
Remove the bolt and ventilation pipe sub-assembly.
REMOVE NO. 1 TURBO INSULATOR
Remove the 2 bolts and turbo insulator No. 1.
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Remove the 2 bolts and No. 1 exhaust manifold heat insulator.
DISCONNECT NO. 1 TURBO WATER HOSE
Loosen the 2 clamps and disconnect No. 1 turbo water hose.
REMOVE TURBINE OUTLET ELBOW
Remove the 3 nuts, turbine outlet elbow and gasket.
REMOVE TURBOCHARGER STAY
Remove the 2 bolts and nut and remove the turbocharger stay.
REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY
Remove the 2 bolts, 2 nuts and union bolt, then remove the turbo oil inlet pipe sub-assembly and gasket.
Note
Do not loosen the nut labeled A.
REMOVE EXHAUST MANIFOLD
Remove the 8 nuts, and then remove the exhaust manifold.
SEPARATE TIE ROD END SUB-ASSEMBLY LH
Remove the cotter pin and nut.
Using SST, disconnect the tie rod end from the steering knuckle arm.
SEPARATE TIE ROD END SUB-ASSEMBLY RH
Tech Tips
Remove the RH side using the same procedures as the LH side.
SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH
Remove the bolt and nut, disconnect the front shock absorber LH from the suspension lower arm.
SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH
Tech Tips
Separate the RH side using the same procedures as the LH side.
SEPARATE FRONT STABILIZER BAR
Remove the 4 bolts and separate the front stabilizer bar.
SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH
Remove the cotter pin and castle nut.
| *a | Hold |
| *b | Turn |
Using SST, disconnect the lower ball joint from suspension lower arm.
SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH
Tech Tips
Separate the RH side using the same procedures as the LH side.
REMOVE STEERING TORQUE SHAFT ASSEMBLY
Remove the 3 bolts, steering link protector UPR and steering link protector LWR.
Remove the 2 bolts.
| *a | Matchmark |
Shift the sliding yoke and place the matchmarks to the sliding yoke and steering gear.
Remove the bolt.
| *a | Matchmark |
Shift the torque shaft and place the matchmarks to the torque shaft and bevel gear.
Remove the torque shaft.
SEPARATE STEERING GEAR OUTLET RETURN TUBE
Remove the bolt (LHD steering position type only).
Remove the clip and disconnect the return hose.
Remove the return tube.
SEPARATE PRESSURE FEED TUBE ASSEMBLY
Remove the union bolt and gasket, and disconnect the feed tube.
SEPARATE ENGINE WIRE
REMOVE FRONT SUSPENSION MEMBER ASSEMBLY
| *1 | Front Suspension Damper |
Set a jack under the front suspension member.
Remove the 2 nuts and the 2 suspension dampers.
Remove the 4 bolts, and then remove the front suspension member.
REMOVE ENGINE ASSEMBLY
Using an engine lifter to hold the engine assembly.
Install the 2 engine hangers in the correct direction.
| Part No. | ||||||
|---|---|---|---|---|---|---|
|
First remove the engine mount insulator RH and LH, and then the engine assembly.
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.
REMOVE REAR END PLATE
Remove the bolt and rear end plate.
REMOVE NO. 1 TIMING BELT COVER
Remove the bolt and water hose clamp.
Remove the wire harness clamp.
Remove the 6 bolts and timing belt cover.
REMOVE TIMING BELT
Set No. 1 cylinder to TDC/compression.
Turn the crankshaft clockwise and align the timing marks as shown in the 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.
Alternately loosen the 2 bolts, and remove the timing belt tensioner.
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.
REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
Using a socket hexagon wrench 10 mm, remove the bolt and timing bolt idler.
REMOVE NO. 2 CRANKSHAFT POSITION SENSOR
Disconnect the crankshaft position sensor connector.
Detach the 3 wire harness clamps.
Remove the bolt and remove the crankshaft position sensor.
REMOVE CAMSHAFT POSITION SENSOR
Disconnect the camshaft position sensor connector.
Remove the bolt and remove the camshaft position sensor.
REMOVE EGR COOLER ASSEMBLY
Loosen the clamp and disconnect the oil return hose.
Loosen the clamp and disconnect water by-pass hose No. 4.
Loosen the clamp and disconnect water by-pass hose No. 2.
Remove the 3 bolts and 2 nuts and remove the EGR cooler assembly.
REMOVE DIESEL THROTTLE BODY ASSEMBLY
Disconnect the 2 connectors.
Remove the 2 nuts and 2 bolts and remove the diesel throttle body and gasket.
REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY
Disconnect the vacuum regulating valve connector.
Disconnect the 2 vacuum hoses from the vacuum regulating valve.
Remove the 2 bolts and remove the vacuum regulating valve with bracket.
Disconnect the electric EGR control valve connector.
Disconnect the vacuum hose from the electric EGR control valve.
Disconnect the vacuum hose from the intake air connector.
Disconnect the intake air temperature sensor connector.
Remove the bolt and separate the manifold stay.
Remove the bolt and 2 nuts, disconnect the intake air connector and remove the electric EGR control valve.
REMOVE MANIFOLD STAY
Remove the bolt and manifold stay.
REMOVE OIL LEVEL GAUGE GUIDE
Remove the oil level gauge.
Remove the bolt, and then remove the oil level gauge guide and O-ring.
REMOVE FUEL INJECTION PIPE
Separate the fuel injector connector and harness clamp.
Remove the 3 bolts and separate the wire harness.
Remove the 2 bolts and remove the 2 No. 2 injection pipe clamps.
Using union nut wrench 17 mm, loosen the union nuts and remove the 4 injection pipe sub-assemblies.
REMOVE FUEL INLET PIPE SUB-ASSEMBLY
| *1 | No. 1 Clamp |
| *2 | No. 2 Clamp |
Remove the bolt and remove the No. 1 injection pipe clamp.
Remove the bolt and remove the No. 2 injection pipe clamp.
Using union nut wrench 17 mm, loosen the union nuts and remove the fuel inlet pipe sub-assembly.
REMOVE COMMON RAIL ASSEMBLY
Disconnect the 2 connectors from the common rail.
Disconnect the fuel hose.
Remove the 2 bolts and remove the common rail.
REMOVE NO. 2 CAMSHAFT TIMING PULLEY FLANGE
Remove the 4 bolts and the No. 2 camshaft timing pulley flange.
REMOVE PUMP DRIVE SHAFT PULLEY
REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY
Using SST, secure the crankshaft pulley and remove the supply pump gear set nut and O-ring.
Disconnect the 2 connectors from the fuel supply pump.
Disconnect the 3 fuel hoses from the fuel supply pump.
Loosen the 2 nuts.
Note
Do not remove the nuts.
Using SST, disengage the fuel supply pump from the supply pump gear.
Remove the 2 nuts and remove the fuel supply pump.
Remove the O-ring and pulley key from the fuel supply pump.
REMOVE CRANKSHAFT PULLEY SUB-ASSEMBLY
Using SST, remove the pulley bolt.
Using SST, remove the pulley.
Note
Apply oil or grease to the threads and tip of SST (center bolt) before to using it.
REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY
Disconnect the 3 fuel hoses.
Remove the 2 union bolts and 2 gaskets.
Remove the 3 bolts and No. 2 nozzle leakage pipe.
REMOVE FUEL COOLER
Disconnect the 2 water by-pass hose.
Remove the 2 bolts and fuel cooler.
SEPARATE NO. 2 TURBO WATER HOSE
Remove the bolt, and then separate the hose clamp.
Disconnect the turbo water hose from the water inlet.
REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
Remove the 2 nuts and bolt, and then remove the No. 2 water by-pass pipe.
Remove the gasket.
REMOVE WATER INLET
Remove the 3 bolts and water inlet.
REMOVE THERMOSTAT
REMOVE NO. 2 CYLINDER BLOCK INSULATOR
REMOVE NO. 1 GLOW PLUG CONNECTOR
Remove the screw grommet and nut and separate the wire harness from the No. 1 glow plug connector.
Remove the 4 screw grommets and 4 nuts and remove the No.1 glow plug connector.
REMOVE NO. 2 INTAKE MANIFOLD INSULATOR
Remove the No. 2 intake manifold Insulator.
REMOVE GLOW PLUG ASSEMBLY
Remove the 4 glow plugs.
REMOVE INTAKE MANIFOLD
Remove the 2 nuts and 4 bolts, then remove the intake manifold and gasket.
REMOVE WATER OUTLET
Remove the clamp and plug from the water outlet. (without Heater)
Remove the 2 bolts, and then remove the water outlet and gasket.
REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
Disconnect the vacuum hose from No. 2 vacuum transmitting pipe.
Remove the nut and bolt, and then remove the No. 1 vacuum transmitting pipe.
REMOVE NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
Remove the 2 nuts, bolt and No. 2 vacuum transmitting pipe.
REMOVE OIL FILTER SUB-ASSEMBLY
Using SST, remove the oil filter.
Tech Tips
Because the oil in the filter flows out through the vinyl tube, place the drain oil container under the vinyl tube.
REMOVE OIL COOLER COVER SUB-ASSEMBLY
Disconnect the engine oil pressure switch connector.
Disconnect the vinyl tube from the oil cooler cover.
Remove the 13 bolts, 2 nuts and separate the No. 2 vacuum transmitting pipe.
Remove the oil cooler cover and gasket from the cylinder block.
REMOVE DIESEL ENGINE ENGINE COOLANT TEMPERATURE SENSOR
Using a deep socket wrench 19 mm, remove the engine coolant temperature sensor.
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH
Remove the 4 bolts and engine mounting bracket.
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH
Remove the 4 bolts and engine mounting bracket.