Oil Pump -- Removal |
- NOTICE:
- 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.
| 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL |
- NOTICE:
- 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 (LandCruiser RM000003YMD00TX.html).
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (LandCruiser RM000003YMF011X.html).
| 2. DRAIN ENGINE OIL |
Remove the oil filler cap.
Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
Wipe the oil pan and drain plug.
Install a new gasket and the oil pan drain plug.
- Torque:
- 34 N*m{347 kgf*cm, 25 ft.*lbf}
| 3. REMOVE FRONT BUMPER LOWER COVER |
Remove the clip, 5 bolts and front bumper lower cover.
| 4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 engine under cover.
| 5. DRAIN ENGINE COOLANT |
- CAUTION:
- Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Loosen the radiator drain cock plug.
- HINT:
- Collect the coolant in a container and dispose of it according to the regulations in your area.
Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
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Loosen the cylinder block drain cock plug.
Text in Illustration *1 Radiator Reservoir *2 Vent Plug *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug
| 6. REMOVE ENGINE ASSEMBLY |
Remove the engine (LandCruiser RM0000045F8014X.html).
| 7. INSTALL ENGINE TO ENGINE STAND |
| 8. REMOVE GENERATOR ASSEMBLY |
Remove the 2 bolts and generator.
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| 9. REMOVE GENERATOR BRACKET |
Remove the bolt and generator bracket.
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| 10. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET |
Remove the 5 bolts and No. 1 compressor mounting bracket.
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| 11. REMOVE VENTILATION PIPE |
Type A
Slide the 2 clamps and disconnect the No. 3 turbo water hose and No. 4 turbo water hose from the ventilation pipe.
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Remove the bolt and disconnect the 2 ventilation hoses and ventilation pipe from the cylinder head sub-assembly.
Text in Illustration *A Type A *B Type B
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| 12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE |
Remove the engine oil level dipstick.
Remove the 2 bolts and engine oil level dipstick guide from the cylinder block sub-assembly.
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Remove the O-ring from the engine oil level dipstick guide.
| 13. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 2 cylinder head cover.
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| 14. REMOVE TIMING GEAR COVER INSULATOR |
Remove the bolt and gear cover insulator.
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| 15. REMOVE VACUUM PUMP ASSEMBLY |
Remove the 2 nuts, vacuum pump and 2 O-rings.
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| 16. REMOVE VANE PUMP ASSEMBLY |
Remove the 2 nuts, vane pump and O-ring.
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| 17. REMOVE CAMSHAFT POSITION SENSOR |
Remove the bolt and camshaft position sensor.
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| 18. REMOVE CRANKSHAFT POSITION SENSOR |
Detach the clamp and remove the bolt and crankshaft position sensor.
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| 19. REMOVE TIMING BELT |
Remove the timing belt (LandCruiser RM00000147C027X.html).
| 20. REMOVE NO. 1 TIMING BELT IDLER SUB-ASSEMBLY |
- NOTICE:
- When inspecting the No. 1 timing belt idler, do not remove it unless absolutely necessary.
Using a 10 mm hexagon wrench, remove the bolt, No. 1 timing belt idler and washer.
| 21. REMOVE CRANKSHAFT PULLEY |
Using SST, hold the crankshaft pulley and loosen the pulley bolt.
- SST
- 09213-58014
09330-00021
 |
Using SST, remove the pulley bolt and crankshaft pulley.
- SST
- 09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
 |
| 22. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System) |
Remove the electric EGR control valve (LandCruiser RM000002RK903VX.html).
| 23. REMOVE THROTTLE BODY BRACKET (w/o EGR System) |
Disconnect the vacuum hose.
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Remove the bolt and gas filter with gas filter bracket.
Remove the 2 bolts and throttle body bracket.
| 24. REMOVE INJECTION PIPE (w/o EGR System) |
- NOTICE:
- After removing the injection pipe, cover the outlets on the common rail with tape to keep out foreign matter.
- After removing the injection pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
Remove the 2 nuts and No. 3 injection pipe clamp.
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Remove the 2 bolts and 2 No. 2 injection pipe clamps.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.
Text in Illustration *a Injector Side *b Common Rail Side
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| 25. REMOVE AIR CONNECTOR STAY (w/o EGR System) |
Remove the 3 bolts and air connector stay.
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| 26. REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System) |
Disconnect the throttle position sensor connector.
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Remove the 3 bolts, intake air connector with diesel throttle and gasket.
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| 27. REMOVE MANIFOLD STAY WITH VACUUM SWITCHING VALVE |
Disconnect the vacuum switching valve connector.
w/o EGR System:
Disconnect the connector.w/ EGR System without EGR Cooler:
Disconnect the 2 connectors.w/ EGR System with EGR Cooler:
Disconnect the 3 connectors.
Disconnect the No. 1 vacuum transmitting hose.
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w/ EGR System:
Disconnect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose.
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w/ EGR Cooler:
Disconnect the No. 3 vacuum transmitting hose.
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Disconnect the No. 3 vacuum transmitting hose and No. 4 vacuum transmitting hose.
Text in Illustration *A w/o EGR System *B w/ EGR System
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Remove the 2 bolts and manifold stay with vacuum switching valve.
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| 28. REMOVE FUEL INLET PIPE SUB-ASSEMBLY |
Loosen the union nuts and remove the fuel inlet pipe.
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| 29. REMOVE SUPPLY PUMP ASSEMBLY |
Remove the 4 bolts indicated by the arrows in the illustration.
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Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.
Remove the set nut and O-ring while holding the crankshaft pulley using SST.
- SST
- 09213-58014
09330-00021
 |
Loosen the 2 nuts.
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Using SST, disconnect the supply pump from the injection gear.
- SST
- 09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)
- NOTICE:
- Apply lubricant to the threads and tip of SST (center bolt) before using it.
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Remove the 2 nuts and supply pump.
- NOTICE:
- Do not hold or carry the fuel supply pump by holding the pipe.
- The fuel supply pump must be kept horizontal.
Remove the O-ring.
| 30. REMOVE NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY |
Remove the bolt, nut and No. 1 vacuum transmitting pipe.
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| 31. REMOVE NO. 1 OIL PAN COVER SUB-ASSEMBLY |
Remove the 4 bolts and No. 1 oil pan cover.
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| 32. REMOVE NOZZLE HOLDER SEAL |
Using a small screwdriver, remove the 4 holder seals by prying between each holder seal and the cutout part of the cylinder head cover.
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| 33. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY |
- NOTICE:
- If the cylinder head cover is removed, replace the 4 No. 3 cylinder head cover gaskets with new ones.
Remove the 10 bolts, 2 nuts, cylinder head cover and gasket.
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Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
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| 34. REMOVE INJECTOR ASSEMBLY |
Remove the union bolt, 4 injector hollow screws, 5 gaskets and nozzle leakage pipe.
Text in Illustration *1 Union Bolt - NOTICE:
- When removing the nozzle leakage pipe, place a cushion under the pipe.
- Be careful not to deform or scratch the union seal surface.
- After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
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Remove the 4 bolts, 4 washers, 4 No. 1 nozzle holder clamps and 4 injectors.
- HINT:
- Arrange the injectors, No. 1 nozzle holder clamps, washers and bolts in the correct order.
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Remove the O-ring from each injector.
Remove the 4 injection nozzle seats from the cylinder head.
| 35. REMOVE CAMSHAFT TIMING PULLEY |
Remove the bolt of the camshaft timing pulley while holding the camshaft with a wrench.
- NOTICE:
- Make sure the timing belt is not installed when removing the bolt of camshaft timing pulley.
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Remove the camshaft timing pulley.
| 36. REMOVE NO. 2 TIMING BELT COVER |
Remove the 4 bolts, nuts and No. 2 timing belt cover.
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| 37. REMOVE WATER PUMP ASSEMBLY |
Remove the 5 bolts, 2 nuts, water pump and gasket.
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| 38. REMOVE TIMING GEAR COVER |
- NOTICE:
- As the fuel supply pump is not installed, the injection gear is loose inside the timing gear case. Do not allow the injection gear to fall.
- HINT:
- To prevent the injection gear from falling, temporarily install the fuel supply pump.
Remove the 14 bolts and 2 nuts.
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Pry the gear cover at the locations shown in the illustration, and remove the gear cover together with the injection gear.
- NOTICE:
- Be careful not to drop the injection gear.
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Remove the O-ring from the timing gear case.
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| 39. REMOVE INJECTION GEAR |
Secure the No. 2 idle sub gear to the No. 1 idle gear with a service bolt.
- Torque:
- 8.0 N*m{82 kgf*cm, 71 in.*lbf}
- NOTICE:
- If the bolt hole of the No. 2 idle sub gear is not aligned with the bolt hole of the No. 1 idle gear, rotate the crankshaft counterclockwise to align the bolt holes. Then install the service bolt.
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Remove the injection gear.
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| 40. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE |
Remove the No. 1 crankshaft position sensor plate.
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| 41. REMOVE CRANKSHAFT TIMING GEAR |
Using SST, remove the crankshaft timing gear.
- SST
- 09950-50013(09951-05010,09952-05010,09953-05010,09954-05021)
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| 42. REMOVE IDLE GEAR THRUST PLATE |
Remove the 2 bolts and thrust plate.
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| 43. REMOVE NO. 1 IDLE GEAR |
Remove the No. 1 idle gear together with No. 2 idle sub gear.
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| 44. REMOVE NO. 1 IDLE GEAR SHAFT |
Remove the idle gear shaft.
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| 45. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY |
Remove the 11 bolts and 2 nuts.
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Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan.
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| 46. REMOVE OIL STRAINER SUB-ASSEMBLY |
Remove the 2 nuts, oil strainer and gasket.
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| 47. REMOVE OIL PAN SUB-ASSEMBLY |
Remove the 22 bolts and 2 nuts.
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Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.
Text in Illustration *A LH Side *B RH Side *1 Pry - HINT:
- Tape the screwdriver tip before use.
- NOTICE:
- Be careful not to damage the contact surfaces of the cylinder block and oil pan.
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Remove the gasket.
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| 48. REMOVE TIMING GEAR CASE ASSEMBLY |
Remove the union bolt and 8 bolts.
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Pry the gear case at the location shown in the illustration, and remove the gear case and gasket.
Remove the 2 O-rings.