WATER PUMP (w/ DPF) REMOVAL

Note

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.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. 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 }

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


    1. Disconnect the connector.

    2. Remove the 4 bolts and front seat LH.

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

    A01KG08

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

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

    A01KHZT

    1. Remove the screw and parking brake hole cover.

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

  7. 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.

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

  9. 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.

  10. 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.

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

    A01KGMH

    1. Remove the 4 bolts and transmission floor shift.

  12. 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.

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

    A01KEH0

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

  14. 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.

  15. 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.

  16. REMOVE INLET RADIATOR HOSE

    A01KI7K

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

  17. 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.

  18. 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.

  19. REMOVE FAN PULLEY


    1. Remove the fan pulley from the water pump.

  20. 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.

  21. 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.

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


    1. Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

  23. REMOVE NO. 1 AIR HOSE


    1. A01KHI5

      Loosen the hose clamp shown in the illustration and remove the No. 1 air hose.

  24. REMOVE GENERATOR ASSEMBLY


    1. A01KEBI

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

    2. Remove the oil level gage sub-assembly (for LHD).

    3. Remove the bolt and remove the oil level gage guide (for LHD).

    4. A01KFOZ

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

    5. A01KGMT

      Disconnect the generator connector.

    6. Remove the terminal cap.

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

    8. A01KFRT

      Remove the 2 bolts and remove the generator bracket.

    9. A01KFAR

      Remove the bolt and remove the generator.

  25. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (w/ Air Conditioning System)

  26. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    A01KEG8

    1. Remove the 4 bolts and belt tensioner.

  27. 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.

  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01KGG4

      Insert a screwdriver into the cutout of the cylinder head cover sub-assembly and remove the 4 nozzle holder seals.

    2. A01KHKA

      Disconnect the ventilation hose.

    3. A01KHJF

      Remove the 10 bolts, 2 nuts, cylinder head cover sub-assembly and the cylinder head cover gasket.

    4. A01KGGW

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover sub-assembly.

  29. REMOVE CAMSHAFT TIMING PULLEY

    A01KGL6

    1. Remove the bolt from the camshaft timing pulley while holding the camshaft with a wrench.

    2. A01KIA4E06
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the camshaft timing pulley and set key.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
    3. A01KGB9E02

      Rotate the crankshaft approximately 90° counterclockwise from the TDC position to lower the piston.

  30. REMOVE NO. 2 TIMING BELT COVER

    A01KGVI

    1. Remove the nut, 4 bolts and timing belt No. 2 cover.

  31. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01KH9K

      Remove the 2 nuts, 5 bolts, engine water pump assembly and the gasket from the cylinder block sub-assembly.

    2. A01KFUI

      Remove the bolt, water pump assembly without cover and the gasket from the water pump cover.

  32. REPLACE STUD BOLT

    Tech Tips

    Perform this procedure only when replacement of the stud bolts is necessary.


    1. A01KGC3

      Remove the 4 stud bolts from the water pump assembly without cover.

    2. Install the 4 stud bolts to the water pump assembly without cover.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  33. REPLACE WATER PUMP SET RING PIN

    Tech Tips

    Perform this procedure only when replacement of the water pump set ring pin is necessary.


    1. A01KHQ0

      Remove the water pump set ring pin from the water pump cover.

    2. Using a plastic-faced hammer, tap in the water pump set ring pin to the water pump cover.