DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)
REMOVE NO. 1, NO. 2 AND NO. 3 INJECTION PIPE (w/o EGR System)
REMOVE INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)
REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles)
REMOVE NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)
REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)
REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)
DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
Water Pump -- Removal |
| 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. REMOVE UPPER RADIATOR SUPPORT SEAL |
Remove the 13 clips and upper radiator support seal.
| 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. REMOVE ENGINE REAR UNDER COVER ASSEMBLY |
Remove the 4 bolts and rear engine under cover.
| 6. 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
| 7. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System) |
Remove the electric EGR control valve assembly (LandCruiser RM000002RK903VX.html).
| 8. DISCONNECT INLET HEATER WATER HOSE (w/o EGR System) |
Remove the bolt and disconnect the inlet heater water hose.
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| 9. DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System) |
Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.
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| 10. REMOVE NO. 1 INTAKE PIPE (w/o EGR System) |
Disconnect the 3 connectors from the intake air temperature sensor, throttle control motor and manifold absolute pressure sensor.
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Detach the 2 clamps.
Disconnect the vacuum hose from the manifold absolute pressure sensor.
Loosen the 2 hose clamps of the No. 1 air hose.
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Loosen the hose clamp of the intercooler air hose.
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Remove the 2 bolts and No. 1 intake pipe.
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| 11. 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.
| 12. REMOVE NO. 1, NO. 2 AND NO. 3 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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| 13. REMOVE AIR CONNECTOR STAY (w/o EGR System) |
Remove the 3 bolts and air connector stay.
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| 14. DISCONNECT ENGINE WIRE (w/o EGR System) |
for LHD:
Remove the 2 bolts and disconnect the clamp and engine wire.
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for RHD:
Remove the bolt and disconnect the engine wire.
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| 15. 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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| 16. 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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| 17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY |
Remove the bolt and detach the injection pipe clamp.
- NOTICE:
- If an injection pipe clamp is removed from the No. 4 injection pipe, replace the injection clamp with a new one.
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Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
Text in Illustration *a Injector Side *b Common Rail Side
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| 18. REMOVE NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY |
Disconnect the 4 injector connectors.
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Detach the 2 wire harness clamps and disconnect the wire harness from the No. 2 cylinder head cover.
Remove the 4 bolts and No. 2 cylinder head cover.
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| 19. REMOVE FRONT HEATER BRACKET (for Cold Area Specification Vehicles) |
Remove the 2 bolts and front heater bracket.
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| 20. REMOVE NO. 1 RADIATOR HOSE |
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| 21. REMOVE NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles) |
Remove the 2 nuts from the battery terminal.
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Detach the 3 wire harness clamps.
Remove the No. 3 engine wire from the fan shroud.
| 22. REMOVE NO. 1 AIR HOSE |
Loosen the 2 clamps.
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Remove the No. 1 air hose from the inlet pipe and intercooler.
| 23. REMOVE INTERCOOLER AIR HOSE |
Disconnect the No. 2 vacuum transmitting hose from the intercooler.
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Loosen the 2 clamps.
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Remove the intercooler hose from the intake pipe and intercooler.
| 24. REMOVE FAN SHROUD |
Disconnect the No. 1 water by-pass hose and detach the 2 clamps from the fan shroud.
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Disconnect the No. 2 water by-pass hose from the radiator reservoir.
Remove the 3 bolts and radiator reservoir.
for Automatic Transmission:
Remove the inlet and outlet oil cooler hoses and detach the clamp from the fan shroud.
Disconnect the 2 oil cooler hoses from the radiator.
Loosen the 4 nuts holding the fluid coupling and fan.
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Remove the fan and generator V belt (LandCruiser RM00000147701OX_01_0001.html).
Remove the 2 bolts holding the fan shroud.
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Remove the 4 nuts for the fan with fluid coupling fan, and then remove the shroud together with the coupling fan.
- NOTICE:
- Be careful not to damage the radiator core.
Detach the No. 2 water by-pass hose from the hose clamp on the fan shroud.
Remove the No. 2 water by-pass hose from the water inlet.
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Remove the fan pulley from the water pump.
| 25. REMOVE NO. 1 AIR CLEANER HOSE |
Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.
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| 26. REMOVE AIR CLEANER CAP SUB-ASSEMBLY |
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except Cold Area Specification Vehicles:
Detach the 2 clamps and disconnect the mass air flow meter connector.Text in Illustration *A except Cold Area Specification Vehicles *B for Cold Area Specification Vehicles
for Cold Area Specification Vehicles:
Detach the 3 clamps and disconnect the mass air flow meter connector.
Detach the 4 clamps and remove the air cleaner cap sub-assembly.
| 27. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY |
| 28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY |
Remove the 3 bolts and air cleaner case sub-assembly.
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| 29. REMOVE COMPRESSOR OUTLET ELBOW |
Detach the 3 wire harness clamps.
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Remove the bolt and wire harness bracket.
Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.
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| 30. REMOVE VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles) |
Disconnect the viscous heater connector.
Disconnect the water by-pass hose and water hose.
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Remove the 2 bolts and viscous heater with magnet clutch.
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| 31. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles) |
Remove the 4 bolts and No. 1 viscous heater bracket.
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| 32. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System) |
Disconnect the compressor connector.
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Remove the 4 bolts and disconnect the cooler compressor.
| 33. REMOVE GENERATOR BRACKET |
Remove the bolt and generator bracket.
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| 34. REMOVE GENERATOR ASSEMBLY |
Disconnect the generator connector.
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Remove the terminal cap.
Remove the nut and disconnect the generator wire.
Remove the 2 bolts and generator.
| 35. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET |
Remove the 5 bolts and No. 1 compressor mounting bracket.
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| 36. 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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| 37. 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.
Using a small screwdriver, remove the nozzle holder seal by prying the portion between the nozzle holder seal and the cutout part of the cylinder head cover.
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Remove the 10 bolts, 2 nuts, cylinder head cover and cylinder head cover gasket.
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Remove the 4 No. 3 cylinder head cover gaskets from the cylinder head cover.
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| 38. REMOVE NO. 1 TIMING BELT COVER |
Remove the 6 bolts, 6 washers and timing belt cover.
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| 39. REMOVE TIMING BELT |
Turn the crankshaft clockwise and align the timing marks as shown in the illustration.
Text in Illustration *1 Timing Mark - HINT:
- If reusing the timing belt, place matchmarks on the timing belt so that it can be installed exactly as before.
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Uniformly loosen and remove the 2 bolts and No. 1 timing belt tensioner.
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Remove the timing belt.
- HINT:
- If turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
- When installing the timing belt, turn the camshaft to align the timing marks and then turn the crankshaft clockwise to align the timing marks.
| 40. 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.
| 41. 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.
| 42. REMOVE NO. 2 TIMING BELT COVER |
Remove the 4 bolts, nuts and No. 2 timing belt cover.
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| 43. REMOVE CYLINDER BLOCK INSULATOR |
Remove the cylinder block insulator from the cylinder head.
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| 44. REMOVE ENGINE WATER PUMP ASSEMBLY |
Remove the 2 nuts, 5 bolts, engine water pump assembly and the gasket from the cylinder block sub-assembly.
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Remove the bolt, water pump assembly without cover and the gasket from the water pump cover.
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| 45. REPLACE STUD BOLT |
- HINT:
- Perform this procedure only when replacement of the stud bolts is necessary.
Remove the 4 stud bolts from the water pump assembly without cover.
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Install the 4 stud bolts to the water pump assembly without cover.
- Torque:
- 7.8 N*m{80 kgf*cm, 69 in.*lbf}
| 46. REPLACE WATER PUMP SET RING PIN |
- HINT:
- Perform this procedure only when replacement of the water pump set ring pin is necessary.
Remove the water pump set ring pin from the water pump cover.
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Using a plastic-faced hammer, tap in the water pump set ring pin to the water pump cover.