COMMON RAIL (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 (for Double Cab)

  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 REAR DOOR SCUFF PLATE LH (for Double Cab)

    A01KF1Z

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

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

    A01KINS

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

  15. REMOVE REAR FLOOR MAT (for Double Cab)

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

    A01KGPT

    1. Remove the 6 screws and mat set plate.

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

    A01KIQM

    1. Remove the 12 bolts and service hole cover.

  18. 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 }

  19. 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.

  20. DISCONNECT NO. 3 AIR HOSE


    1. A01KGQ4

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

  21. REMOVE INJECTION PIPE SUB-ASSEMBLY


    1. A01KG0R

      Separate the fuel injector connector and harness clamp.

    2. Remove the 3 bolts and separate the wire harness.

    3. A01KG8U

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

    4. A01KH8X

      Using union nut wrench 17 mm, loosen the union nuts and remove the 4 injection pipe sub-assemblies.

  22. 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.

  23. 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.

  24. REMOVE COMMON RAIL


    1. A01KHC7

      Disconnect the 2 connectors from the common rail.

    2. Disconnect the fuel hose.

    3. A01KI1X

      Remove the 2 bolts and remove the common rail.