Tools & consumables
- Basic hand tools: socket set (8–32 mm), deep sockets, extensions, breaker bar, open/box wrenches.
- Large sockets likely needed: 27–32 mm (verify on vehicle).
- Fan clutch holding tool / water-pump pulley holder (Toyota SST or generic “fan clutch spanner” that engages pulley holes or fan clutch splines).
- Impact wrench (optional, speeds job; use with care).
- Torque wrench (up to ~200 Nm range).
- Screwdrivers, pliers, trim tool.
- Jack and stands or ramps (if needed for access).
- Marker / paint pen, clean rags, penetrating oil (PB Blaster), anti-seize.
- Replacement parts: correct fan clutch assembly for your engine (1HZ / 1PZ / 1HD‑T), replacement bolts/nuts if corroded, rubber isolators if fitted, new fan shroud fasteners if broken. Have coolant available only if you open cooling system (usually not required).
- Safety gear: gloves, eye protection.

Safety & prep
- Work on a level surface, park, engage handbrake, chock wheels.
- Engine must be completely cold. The viscous clutch and water pump can be very hot.
- Disconnect negative battery terminal to prevent accidental cranking.
- Remove radiator cap only when cold. If you must remove shroud or move hoses, expect a little coolant in some layouts — have rags ready.
- Support fan assembly when removing so it cannot drop and damage radiator or fingers.

Overview of common Toyota setups
- Two common arrangements on these diesels:
1) Fan/clutch bolted to a hub on the water‑pump flange (center nut or large nut + holding tool).
2) Fan clutch bolted with multiple studs/bolts to water pump flange (6–8 bolts).
- Identify which yours has before starting.

Step-by-step removal (general; match to your layout)

1) Access and visibility
- Remove engine cover/air intake snorkel as needed.
- Remove top half of fan shroud (usually 2–4 bolts/clips). Leave lower half in place for protection if possible.
- Remove any obstructing components (overflow bottle, intercooler pipe bracket, alternator bracket) only as needed for clearance.

2) Mark orientation
- Mark fan/clutch to water pump flange or fan to clutch with paint so you reinstall in same orientation. Also note blade tilt.

3) Loosen drive belt (if necessary)
- On some models removing the belt gives extra slack to hold pulley; if required, loosen belt tensioner and remove belt.

4) Prepare fasteners
- Apply penetrating oil to nuts/bolts and let soak 5–10 minutes.
- Position a clean rag between fan and radiator.

5A) If center nut style (single large nut)
- Use the fan clutch holding tool: engage tool into water pump pulley holes or behind pulley vanes so the pump cannot turn. The holding tool usually bolts into the pump flange or hooks over the pulley.
- Place correct socket on the large center nut (commonly 27–32 mm). Use breaker bar or impact. Turn nut counterclockwise to loosen.
- While loosening, hold fan assembly with a gloved hand or a pry strap so blades don’t spin or catch.
- Remove nut and any washer(s), then slide fan/clutch assembly forward off the shaft. Support the fan — do not let it fall.

5B) If multiple-bolt style (fan clutch bolted to flange)
- Remove the 6–8 bolts/nuts around the flange using the appropriate socket.
- Support the fan assembly; once bolts removed the fan/clutch will drop forward.
- Inspect gasket / O‑ring at flange (replace if leaking).

6) Removing fan from clutch (if swapping fan blades)
- If you’re replacing only the clutch and reusing fan blades, remove small bolts securing fan to clutch. Support fan when the last bolts are removed.

7) Inspect & clean
- Inspect fan blades for cracks, deformation, looseness.
- Inspect shroud for cracks and radiator fins for damage.
- Clean the mounting flange and check studs/threads. Replace studs or bolts if corroded/stripped.

8) Install new fan clutch
- If installing clutch only, transfer fan blades from old clutch to new (match orientation and mark earlier).
- Clean threads and apply a small amount of anti-seize to bolt threads.
- Mount fan to clutch; hand‑start bolts. Tighten evenly in a star pattern to snugness.

9A) Reinstall center‑nut style
- Slide assembly onto shaft, fit washer(s) and nut. Tighten by hand, then torque to OEM spec. If you don’t have OE spec available, tighten firmly and compare with original torque — final torque must be to Toyota spec (consult manual). Use torque wrench.

9B) Reinstall multiple‑bolt style
- Fit clutch flange to water pump, hand‑start all bolts. Torque progressively in a star pattern to OEM spec.

10) Final checks
- Ensure fan blades clear shroud and radiator (spin by hand to check).
- Reinstall shroud, belts, air intake components.
- Reconnect battery negative terminal.
- Start engine, run briefly to check for unusual vibration/noise and ensure fan engagement. Watch for leaks if any hoses were moved.

How the fan clutch holding tool is used
- The SST or generic tool either: (A) bolts into the water pump pulley holes and provides a place for a breaker bar to hold the pump stationary while you break the center nut, or (B) engages the fan clutch splines so you can apply rotational force to loosen bolts. You mount the holding tool solidly, then put the breaker bar/ratchet on the fan nut (or drive bolts) and apply steady force opposite the locking tool until the nut breaks free. Do not hammer on the tool or use quick jerks that can pop bolts/studs.

Common pitfalls / what causes failures
- Working on a hot engine — risk of burns and broken viscous coupling.
- Not supporting the fan when removing — fan drops & damages radiator or blades.
- Using wrong holding point — holding plastic shroud or fan blades can break them.
- Rounding nuts/studs by using incorrect socket size.
- Reusing rusted studs/bolts — they may fail under load. Replace corroded fasteners.
- Overtightening or undertightening bolts — can warp clutch or cause loosening.
- Not transferring blade orientation — fan efficiency and engine cooling affected.
- Reusing an old failing clutch — if the clutch shows free play, leaks, or incorrect engagement replace the assembly.

Replacement parts required
- New viscous fan clutch assembly (part number specific to vehicle/engine and year).
- Fan blade assembly if cracked/damaged.
- New mounting bolts/nuts/studs if corroded or stretched.
- Fan shroud fasteners/clips if brittle/broken.
- Small washer(s)/lock washer(s) if missing.
- Gasket or O‑ring for pump flange if the design uses one.

Final notes
- Always follow Toyota workshop manual torque specs and procedures for your exact year/model.
- If unsure of fastener sizes or configuration, inspect the assembly before disassembly and photograph orientation for reassembly.
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