THERMOSTAT (w/o EGR Cooler) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

  2. REMOVE INTERCOOLER ASSEMBLY (w/ Intercooler)

    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 VENTILATION HOSE HEAT INSULATOR (w/o Intercooler)


    1. Remove the 2 bolts and insulator.

  6. REMOVE AIR CLEANER ASSEMBLY


    1. w/ Mass Air Flow Meter:


      1. Disconnect the mass air flow meter connector and detach the wire harness clamp.

        A01E03XE01
        Text in Illustration
        *A w/ Intercooler *B w/o Intercooler

      2. Loosen the hose clamp, and then remove the air cleaner hose from the turbocharger.

      3. w/o Intercooler:

        Disconnect the ventilation hose and remove the 2 bolts and air cleaner.

    2. w/o Mass Air Flow Meter:


      1. A01DV6E

        Remove the clamp and disconnect the intake air temperature sensor connector.

      2. Loosen the clamp of the turbocharger.

      3. Slide the clamp and disconnect the ventilation hose.

      4. Remove the 2 bolts and air cleaner.

  7. REMOVE VENTILATION PIPE (w/ Intercooler)


    1. A01DV0H

      for Waste Gate Type Turbocharger:

      Remove the bolt and ventilation pipe.

    2. for Variable Nozzle Vane Turbocharger:


      1. A01DXEZ

        Disconnect the No. 12 water by-pass hose and No. 13 water by-pass hose.

      2. A01DXFZ

        Remove the bolt and ventilation pipe.

  8. REMOVE COMPRESSOR INLET ELBOW (w/ Intercooler)


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

    2. A01DX8N

      Disconnect the No. 1 turbo water hose.

    3. A01E0Z9E01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 13 Water By-pass Hose

      Disconnect the No. 2 water by-pass hose.

    4. Remove the No. 12 water by-pass hose and No. 13 water by-pass hose.

    5. Remove the 2 nuts, compressor inlet elbow and gasket.

    6. A01DXHHE01
      Text in Illustration
      *1 No. 7 Water By-pass Hose
      *2 No. 12 Water By-pass Hose

      Remove the No. 7 water by-pass hose and No. 12 water by-pass hose.

  9. DISCONNECT NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)

    A01DX6PE01

    1. Remove the bolt and disconnect the No. 1 automatic transmission oil cooler tube clamp.

  10. DISCONNECT RADIATOR HOSE OUTLET


    1. Disconnect the radiator hose outlet from the water inlet.

  11. REMOVE WATER INLET

    A01DZUQE01

    1. Remove the 3 bolts and water inlet.

  12. REMOVE THERMOSTAT


    1. Remove the thermostat from the cylinder block.

    2. Remove the gasket from the thermostat.