WATER PUMP (w/o EGR Cooler) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes, clean them with a brush and compressed air.


  1. PRECAUTION

    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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

  4. DRAIN ENGINE COOLANT

    Note

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    2. Loosen the cylinder block drain cock plug and the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

      A01DY14E01

  5. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  6. REMOVE NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o Intercooler)


    1. w/ No. 1 Engine Cover


      1. A01DYA3E03
        Text in Illustration
        *1 No. 1 Engine Cover Sub-assembly
        *2 Claw
        *3 Pin

        Detach the 4 claws from the pins of the engine cover bracket and remove the No. 1 engine cover sub-assembly.

      2. Remove the 2 bolts and engine cover bracket.

    2. A01E0K7

      Disconnect the manifold absolute pressure sensor connector.

    3. Disconnect the vacuum hose from the gas filter.

    4. Loosen the 2 clamps.

    5. Remove the bolt and disconnect the No. 2 air cleaner pipe sub-assembly together with the 2 air hoses.

  7. REMOVE RADIATOR HOSE INLET

  8. REMOVE FAN SHROUD


    1. A01DZXC

      Remove the 3 bolts and oil reservoir.

    2. A01DXSK

      Disconnect the No. 1 and No. 2 water by-pass hoses from the radiator.

    3. Remove the 2 bolts and radiator reservoir.

    4. Loosen the 4 nuts holding the fluid coupling with fan.

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

    6. Remove the 2 bolts holding the fan shroud.

    7. Remove the 4 nuts of the fluid coupling with fan, and then remove the fan shroud together with the fluid coupling with fan.

      Note

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the engine water pump.

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


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

      Tech Tips

      It is not necessary to completely remove the compressor assembly. With the hoses connected to the compressor assembly, hang the compressor assembly on the vehicle body with a rope.

  10. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)


    1. A01DZH8E02

      Disconnect the connector.

    2. Remove the 2 bolts and viscous with magnet clutch heater assembly.

  11. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. Remove the 4 bolts and No. 1 viscous heater bracket sub-assembly.

  12. REMOVE GENERATOR ASSEMBLY

    A01DXLF

    1. Remove the nut and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  13. REMOVE GENERATOR BRACKET


    1. Remove the bolt and generator bracket.

  14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DVWSE01

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

  15. REMOVE DIESEL THROTTLE BODY ASSEMBLY (w/ Intercooler)


    1. A01DZU2

      Disconnect the 2 connectors.

    2. A01E2KU

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

  16. REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Note


    • After removing the fuel pipe, cover the outlets on the common rail with tape to keep out foreign matter.

    • After removing the fuel pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.


    1. w/ Intercooler:


      1. A01DWWA

        Remove the 2 nuts and No. 3 injection pipe clamp.

      2. A01E1SS

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

      3. A01DXC6E01
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

        Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

    2. w/o Intercooler:


      1. A01DXPXE02
        Text in Illustration
        *1 No. 2 Injection Pipe Clamp
        *2 No. 3 Injection Pipe Clamp
        *a Injector Side
        *b Common Rail Side

        Remove the bolt and No. 2 injection pipe clamp.

      2. Remove the 2 nuts and No. 3 injection pipe clamp.

      3. Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

  17. REMOVE NO. 2 INTAKE AIR CONNECTOR BRACKET (w/ Intercooler)


    1. A01DVDTE01
      Text in Illustration
      *A w/ Intercooler
      *B w/o Intercooler
      *1 No. 2 Intake Air Connector Bracket
      *2 Intake Air Connector

      Remove the 3 bolts and No. 2 intake air connector bracket.

  18. DISCONNECT NO. 3 WATER BY-PASS PIPE (w/ Intercooler)


    1. A01DZCR

      Remove the 2 bolts and disconnect the No. 3 water by-pass pipe with the wire harness.

  19. REMOVE ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ Intercooler)


    1. w/ Intercooler:


      1. A01DZHP

        Disconnect the 2 connectors.

      2. A01E31V

        Disconnect the 6 vacuum hoses.

      3. Remove the bolt and No. 1 gas filter with gas filter bracket.

      4. A01DY7U

        Remove the 2 bolts and electric vacuum regulating valve.

    2. w/o Intercooler:


      1. A01DWIO

        Disconnect the connector.

      2. Disconnect the 2 vacuum hoses.

      3. Remove the 2 bolts and electric vacuum regulating valve together with the bracket.

        Note

        Do not remove the electric vacuum regulating valve from the bracket.

  20. REMOVE NO. 2 INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DZS6

      Remove the 3 nuts, No. 2 intake air connector and gasket.

  21. REMOVE INTAKE AIR CONNECTOR (w/ Intercooler)


    1. A01DW3T

      Remove the 3 bolts, intake air connector and 2 gaskets.

  22. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 1 EGR PIPE SUB-ASSEMBLY (w/ Intercooler)


    1. A01DX9H

      Remove the 2 nuts, electric EGR control valve with No. 1 EGR pipe and gasket.

  23. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Note

    If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.


    1. w/ Intercooler:


      1. A01E10I

        Remove the bolt and disconnect the injection pipe clamp.

      2. A01DVY2E07
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

        Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

    2. w/o Intercooler:


      1. A01E0ZRE01

        Remove the 2 bolts and disconnect the 2 injection pipe clamps.

      2. A01E2XGE02
        Text in Illustration
        *a Injector Side
        *b Common Rail Side

        Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  24. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    Note

    If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.


    1. Remove the 3 bolts and disconnect the 4 injector connectors.

    2. A01DXC5E01

      Using a small screwdriver, remove the nozzle holder seal by prying between the nozzle holder seal and the cutout part of the cylinder head cover.

    3. Disconnect the ventilation hose.

    4. A01DZGHE01

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

    5. A01DV31

      Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.

  25. REMOVE NO. 1 TIMING BELT COVER


    1. Remove the bolt and water hose clamp.

    2. Remove the wire harness clamp.

    3. A01E0I5

      Remove the 6 bolts and timing belt cover.

  26. REMOVE TIMING BELT


    1. A01DWQTE02

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

    2. A01E0E0E01

      Uniformly loosen the 2 bolts and remove the timing belt tensioner.

    3. Remove the timing belt.

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

      Tech Tips

      A01DW3FE01

      • When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise.

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

  27. REMOVE CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

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

      Note

      Make sure the timing belt is not installed when removing the bolt of the camshaft timing pulley.

    2. Remove the camshaft timing pulley.

  28. REMOVE NO. 2 TIMING BELT COVER


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

  29. REMOVE ENGINE WATER PUMP ASSEMBLY


    1. A01E0AX

      Remove the 5 bolts, 2 nuts, engine water pump and gasket.

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Nut