ДВИГАТЕЛЬ В СБОРЕ СНЯТИЕ

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed or replaced during the engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Replacement of ECM Vehicle Identification Number (VIN) registration DTC P0630 is output

Click here

Code registration

(Immobiliser system)

 Engine start function See the Service Bulletin for the registration method.
Replacement of engine assembly Inspection after repair Poor idle, engine start, etc.

Click here


  • Replacement of throttle body with motor assembly

  • Cleaning the deposits from the throttle body with motor assembly

  • Replacement of cylinder head sub-assembly

  • Replacement of cylinder head LH

  • Replacement of camshaft

  • Replacement of No. 2 camshaft

  • Replacement of No. 3 camshaft sub-assembly

  • Replacement of No. 4 camshaft sub-assembly

  • Replacement of camshaft timing gear assembly

  • Replacement of piston sub-assembly

  • Replacement of piston ring

  • Replacement of intake mass air flow meter sub-assembly

  • Replacement of fuel injector assembly

  • Replacement of fuel pump

  • Replacement of air fuel ratio sensor

  • Replacement of engine coolant temperature sensor

  • Replacement of spark plug

  • Replacement of ignition coil assembly

  • Air leaks from intake system

  • Gas leaks from exhaust system

  • Replacement of knock sensor

 Inspection after repair Poor idle, engine start, etc.

Click here


    for AC60E:

  • Automatic transmission assembly

  • Transmission valve body assembly

  • Any of the shift solenoid valves

 Reset memory

  • Large shift shock

  • Engine overruns

Click here


    for AC60E:

  • Automatic transmission fluid

 ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

Click here


    for AC60F:

  • Automatic transmission assembly

  • Transmission valve body assembly

  • Any of the shift solenoid valves

 Reset memory

  • Large shift shock

  • Engine overruns

Click here


    for AC60F:

  • Automatic transmission fluid

 ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

Click here

CAUTION:


  • B0027QTC01
    *a An Object Exceeding Weight Limit of Engine Lifter

    The engine assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly may fall off the engine lifter.

  • B002664

    To prevent injury due to contact with an operating fan and generator V-belt or cooling fan, keep your hands and clothing away from the fan and generator V-belt and cooling fans when working in the engine compartment with the engine running.

  • B0024EA

    Do not remove the radiator cap sub-assembly,cylinder block drain cock plugs or radiator drain cock plug while the engine and radiator assembly are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

  • B00263K

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

  • B00253Y

    To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. 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

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  4. DRAIN ENGINE COOLANT

    Click here

  5. DRAIN ENGINE OIL

    Click here

  6. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. Remove the 4 bolts and hood sub-assembly.

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

  8. REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

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

  10. DRAIN DIFFERENTIAL OIL (for 4WD)

    Click here

  11. REMOVE FRONT UPPER FENDER APRON SEAL LH


    1. Remove the 6 clips and front upper fender apron seal LH.

  12. REMOVE FRONT UPPER FENDER APRON SEAL RH


    1. Remove the 6 clips and front upper fender apron seal RH.

  13. REMOVE FRONT FENDER SEAL LH


    1. for 2WD:

      Remove the 5 clips and front fender seal LH.

    2. for 4WD and Pre-Runner:

      Remove the 6 clips and front fender seal LH.

  14. REMOVE FRONT FENDER SEAL RH


    1. for 2WD:

      Remove the 5 clips and front fender seal RH.

    2. for 4WD and Pre-Runner:

      Remove the 6 clips and front fender seal RH.

  15. REMOVE RADIATOR SIDE DEFLECTOR LH

    Click here

  16. REMOVE RADIATOR SIDE DEFLECTOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE

    Click here

  18. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B0027BJ

      Disconnect the 3 clamps from the air cleaner case sub-assembly.

    2. Remove the 3 bolts and air cleaner case sub-assembly.

  20. REMOVE NO. 1 RADIATOR AIR GUIDE

    Click here

  21. REMOVE RADIATOR HOSE INLET

    Click here

  22. REMOVE RADIATOR HOSE OUTLET

    Click here

  23. REMOVE RADIATOR RESERVOIR

    Click here

  24. REMOVE FAN SHROUD

    Click here

  25. DISCONNECT NO. 1 OIL COOLER INLET HOSE

    Click here

  26. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE

    Click here

  27. REMOVE RADIATOR ASSEMBLY

    Click here

  28. DISCONNECT VANE PUMP ASSEMBLY


    1. B0025JC

      Disconnect the connector.

    2. Remove the 2 bolts and disconnect the vane pump assembly.

      Note

      Do not hit other parts with the pulley when disconnecting the vane pump assembly.

      Tech Tips

      Be sure to suspend the vane pump assembly securely.

  29. REMOVE INTAKE AIR SURGE TANK

    Click here

  30. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  31. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  32. REMOVE MANIFOLD STAY

    Click here

  33. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  34. REMOVE NO. 2 MANIFOLD STAY

    Click here

  35. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  36. REMOVE STARTER ASSEMBLY

    Click here

  37. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  38. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (w/ Cover)

    Click here

  39. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  40. REMOVE ECM

    Click here

  41. DISCONNECT ENGINE WIRE


    1. B0027DV

      Detach the 2 clamps and disconnect the 3 connectors from the instrument panel wire.

    2. B0027FO

      Disconnect the connector.

    3. B0024QL

      Remove the bolt and disconnect the engine wire.

    4. B00296T

      Detach the clamp and disconnect the engine wire from the bracket.

    5. Detach the grommet and pull out the engine wire from the cabin.

    6. B00266M

      Remove the nut and disconnect the engine room main wire from the battery positive cable.

    7. B002654

      Loosen the nut and remove the positive (+) battery terminal.

    8. B00286G

      Loosen the 2 nuts and remove the battery hold down clamp.

    9. Remove the battery.

    10. Remove the battery tray.

    11. B0026EA

      Detach the 2 clamps and remove the 2 bolts and disconnect the No. 2 engine wire.

    12. B0024NH

      Detach the 3 claws and remove the No. 1 relay block cover upper from the engine room relay block.

    13. B0026G9

      Detach the 2 claws and remove the No. 1 relay block cover side from the engine room relay block.

    14. B0024MY

      Remove the nut and disconnect the engine wire from the engine room relay block.

    15. Disconnect the 2 connectors from the engine room relay block.

  42. REMOVE GENERATOR ASSEMBLY


  43. DISCONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  44. REMOVE WATER HOSE SUB-ASSEMBLY


    1. B0026MY

      Remove the bolt.

    2. Slide the 4 clamps and remove the water hose sub-assembly.

  45. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  46. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

    B002600

    1. Slide the clamp and disconnect the No. 2 fuel pipe sub-assembly.

  47. REMOVE PROPELLER SHAFT GUARD (for 4WD)

    Click here

  48. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

    Click here

  49. REMOVE FRONT AXLE HUB GREASE CAP (for 4WD)

    Click here

  50. REMOVE FRONT AXLE SHAFT NUT (for 4WD)

    Click here

  51. DISCONNECT FRONT SPEED SENSOR LH (for 4WD)

    Click here

  52. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (for 4WD)

    Click here

  53. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (for 4WD)

    Click here

  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)

    Click here

  55. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING (for 4WD)

    Click here

  56. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

    Tech Tips

    Use the same procedure described for the LH side.

  57. DISCONNECT STEERING SLIDING YOKE (for 4WD)

    Click here

  58. REMOVE POWER STEERING LINK ASSEMBLY (for 4WD)

    Click here

  59. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

    Click here

  60. REMOVE PROPELLER SHAFT GUARD

    Click here

  61. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 2WD and Pre-Runner)

    Click here

  62. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for 4WD)

    Click here

  63. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  64. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY


  65. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  66. INSTALL ENGINE HANGER


    1. B0025IBC01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-31060
      No. 2 Engine Hanger 12282-31040
      Bolt 90119-08A87

  67. REMOVE ENGINE ASSEMBLY


    1. Attach an engine sling device and hang the engine with a chain block.

    2. B0024P5

      Remove the 4 bolts and 4 nuts from the body.

    3. Remove the engine assembly by operating the engine sling device and chain block.

      Note


      • Make sure that the engine is clear of all wiring and hoses.

      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.

  68. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine to an engine stand with bolts.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    2. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.