FUEL SUPPLY PUMP (w/o DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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


    1. Disconnect the connector.

    2. Remove the 4 bolts and front seat LH.

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

    A01KG08

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

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

    A01KHZT

    1. Remove the screw and parking brake hole cover.

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

  6. 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.

  7. REMOVE NO. 1 FRONT FLOOR MAT REAR

  8. 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.

  9. 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.

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

    A01KGMH

    1. Remove the 4 bolts and transmission floor shift.

  11. 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.

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

    A01KEH0

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

  13. 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.

  14. 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 }

  15. REMOVE INLET RADIATOR HOSE

    A01KI7K

    1. Disconnect the 2 hose clamps and remove the inlet radiator hose.

  16. REMOVE FLUID COUPLING ASSEMBLY

    A01KEB0

    1. Loosen the 4 nuts from the fan pulley.

    2. Remove the fan and generator V belt Click here.

    3. Remove the 4 nuts.

  17. REMOVE FAN SHROUD

    A01KH8R

    1. Disconnect the reserve tank hose from the fan shroud.

    2. A01KF3H

      Disconnect the outlet radiator hose from the fan shroud.

    3. A01KEBHE02

      Remove the 2 bolts and separate the the fan shroud.

    4. Remove the fan with fluid coupling and fan shroud.

  18. REMOVE FAN PULLEY


    1. Remove the fan pulley from the water pump.

  19. 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.

  20. 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.

  21. REMOVE NO. 3 AIR HOSE


    1. A01KGB1

      Loosen the hose clamp shown in the illustration and separate the No. 3 air hose.

  22. REMOVE DIESEL THROTTLE BODY


    1. A01KGJM

      Disconnect the 2 connectors.

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

  23. REMOVE EGR COOLER ASSEMBLY


    1. A01KENY

      Loosen the clamp and disconnect the oil return hose.

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

    3. Loosen the clamp and disconnect water by-pass hose No. 2.

    4. A01KGQB

      Remove the 3 bolts and 2 nuts and remove the EGR cooler assembly.

  24. REMOVE OIL LEVEL GAGE GUIDE (for RHD)


    1. A01KHS1

      Remove the oil level gage sub-assembly.

    2. Remove the bolt and remove the oil level gage guide.

  25. REMOVE FUEL INLET PIPE SUB-ASSEMBLY


    1. A01KGTAE02
      Text in Illustration
      *1 No. 1 Clamp
      *2 No. 2 Clamp

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

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

    3. A01KIQC

      Using union nut wrench 17 mm, loosen the union nuts and remove the fuel inlet pipe sub-assembly.

  26. REMOVE MANIFOLD STAY


    1. A01KG2P

      Remove the wire harness and 2 bolts and remove the manifold stay.

  27. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY

  28. SEPARATE VANE PUMP


    1. Remove the 2 nuts, and then remove the vane pump and O-ring.

      Tech Tips

      Remove the vane pump together with hoses.

  29. REMOVE PUMP DRIVE SHAFT PULLEY


    1. A01KHRQ

      Remove the 4 bolts and remove camshaft timing pulley flange No. 2 and pump drive shaft pulley.

  30. REMOVE FUEL SUPPLY PUMP


    1. A01KEAJ

      Using SST, secure the crankshaft pulley and remove the supply pump gear set nut and O-ring.

      SST
      09213-58013
      09330-00021

    2. Disconnect the 2 connectors from the fuel supply pump.

    3. Disconnect the 3 fuel hoses from the fuel supply pump.

    4. A01KIHV

      Loosen the 2 nuts.

      Note

      Do not remove the nuts.

    5. A01KF9YE01

      Using SST, disengage the fuel supply pump from the supply pump gear.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
    6. A01KIHV

      Remove the 2 nuts and remove the fuel supply pump.

    7. Remove the O-ring and pulley key from the fuel supply pump.