ENGINE ASSEMBLY REMOVAL

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 with motor body assembly

  • Cleaning the deposits from the throttle with motor body assembly

  • Replacement of cylinder head sub-assembly

  • Replacement of camshaft (for intake or exhaust camshaft)

  • Replacement of camshaft timing gear assembly

  • Replacement of camshaft timing exhaust gear assembly

  • Replacement of piston or piston ring

  • Replacement of 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:

  • Replacement of automatic transmission assembly

 Reset memory

  • Large shift shock

  • Engine overruns

Click here


    for AC60E:

  • Replacement of 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:

  • Replacement of automatic transmission assembly

 Reset memory

  • Large shift shock

  • Engine overruns

Click here


    for AC60F:

  • Replacement of 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:


  • B003PKE

    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.

  • B003Q6I

    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.

  • B003QNZ

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

  • B003QLO

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

PROCEDURE


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD (for 4WD)

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. 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

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  5. DRAIN ENGINE COOLANT

    Click here

  6. DRAIN ENGINE OIL

    Click here

  7. DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)


  8. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


  9. DRAIN DIFFERENTIAL OIL (for 4WD)

    Click here

  10. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose from the hood sub-assembly.

    2. Remove the 4 bolts and hood sub-assembly from the 2 hood hinge assemblies.

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


    1. B003Q8P

      Disconnect the intake mass air flow meter connector and detach the 2 wire harness clamps.

    2. B003KGS

      Detach the 4 clamps.

    3. Loosen the hose clamp and remove the air cleaner cap sub-assembly with No. 1 air cleaner hose.

  12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B003N3S

      Detach the 3 wire harness clamps.

    2. B003MLM

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

  14. REMOVE INTAKE AIR CONNECTOR

    Click here

  15. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

  16. REMOVE NO. 2 ENGINE UNDER COVER

  17. REMOVE NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY (w/ Cover)

  18. REMOVE FRONT UPPER FENDER APRON SEAL LH


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

  19. REMOVE FRONT UPPER FENDER APRON SEAL RH


    1. w/ Secondary Air Injection System:


      1. Remove the 5 clips and front upper fender apron seal RH.

    2. w/o Secondary Air Injection System:


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

  20. REMOVE FRONT FENDER SEAL LH


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

  21. REMOVE FRONT FENDER SEAL RH


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

  22. REMOVE RADIATOR SIDE DEFLECTOR LH

    Click here

  23. REMOVE RADIATOR SIDE DEFLECTOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  24. REMOVE NO. 1 RADIATOR AIR GUIDE

    Click here

  25. REMOVE RADIATOR HOSE INLET

    Click here

  26. REMOVE RADIATOR HOSE OUTLET

    Click here

  27. DISCONNECT AIR PUMP INLET (w/ Secondary Air Injection System)

    Click here

  28. REMOVE RADIATOR RESERVOIR

    Click here

  29. REMOVE FAN SHROUD

    Click here

  30. DISCONNECT NO. 1 OIL COOLER INLET HOSE (for Automatic Transmission)

    Click here

  31. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

    Click here

  32. REMOVE RADIATOR ASSEMBLY

    Click here

  33. DISCONNECT HEATER HOSE (w/ Heater)


    1. B003PEGC01
      *A for LHD
      *B for RHD
      *1 Heater Water Outlet Hose
      *2 Heater Water Inlet Hose

      Slide the clamp and disconnect the heater water outlet hose from the heater radiator unit sub-assembly.

    2. Slide the clamp and disconnect the heater water inlet hose from the heater radiator unit sub-assembly.

  34. DISCONNECT VANE PUMP ASSEMBLY


    1. Disconnect the power steering oil pressure switch connector.

    2. B003NVJ

      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.

  35. REMOVE ENGINE OIL LEVEL DIPSTICK

  36. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the bolt, engine oil level dipstick guide and O-ring.

      Note

      Cover the engine oil level dipstick guide hole to prevent foreign matter from entering it.

  37. DISCONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  38. REMOVE STARTER ASSEMBLY


  39. DISCONNECT PURGE LINE HOSE

    B003N3G

    1. Slide the clamp and disconnect the purge line hose from the purge VSV.

  40. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. B003LXI

      Slide the clamp and disconnect the union to connector tube hose from the intake manifold.

  41. DISCONNECT NO. 4 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

    Click here

  42. DISCONNECT NO. 2 FUEL HOSE

    Click here

  43. DISCONNECT NO. 1 FUEL HOSE

    Click here

  44. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

    Click here

  45. REMOVE ECM

    Click here

  46. DISCONNECT ENGINE WIRE


    1. B003LR3C01
      *A for LHD
      *B for RHD

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

    2. B003QMBC01
      *A for LHD
      *B for RHD

      w/ Secondary Air Injection System:


      1. Disconnect the air injection control driver connector.

      2. Detach the clamp.

      3. Remove the bolt and disconnect the engine wire from the air injection control bracket.

    3. B003MQEC01
      *A for LHD
      *B for RHD

      w/o Secondary Air Injection System:


      1. Remove the bolt and disconnect the engine wire from the air injection control bracket.

    4. B003QO8C01
      *A for LHD
      *B for RHD

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

    5. B003Q0MC01
      *A for LHD
      *B for RHD

      Disconnect the connector from the engine room main wire.

    6. B003KIF

      Remove the nut and disconnect the engine room main wire from the positive (+) battery terminal.

    7. B003RP4

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

    8. B003PW9

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

    9. Remove the battery.

    10. Remove the battery tray.

    11. B003M9W

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

    12. B003PNE

      Detach the clamp and remove the bolt and No. 2 engine wire.

    13. B003NFT

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

    14. B003QOB

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

    15. B003LCC

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

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

    17. Detach the clamp.

    18. B003RZR

      Remove the bolt and disconnect the wire clamp from the front engine mounting bracket LH.

    19. B003RRC

      Disconnect the air fuel ratio sensor connector.

    20. Remove the bolt and disconnect the sensor bracket from the right side of the frame.

  47. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  48. REMOVE PROPELLER SHAFT GUARD (for 4WD)


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


  50. REMOVE PROPELLER SHAFT GUARD


  51. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Pre-Runner)


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


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

    Click here

  54. REMOVE FRONT AXLE SHAFT NUT LH (for 4WD)

    Click here

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

    Click here

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

    Click here

  57. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM ASSEMBLY LH (for 4WD)

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

  61. SECURE STEERING WHEEL ASSEMBLY (for 4WD)

    Click here

  62. DISCONNECT STEERING SLIDING YOKE (for 4WD)

    Click here

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

    Click here

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

    Click here

  65. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)


  66. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


  67. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  68. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  69. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

    Click here

  70. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

    Click here

  71. REMOVE REAR END PLATE


    1. B003R68

      Remove the bolt and disconnect the No. 1 water by-pass pipe from the rear end plate.

    2. Remove the bolt and rear end plate from the cylinder block sub-assembly.

  72. INSTALL ENGINE HANGER


    1. B003LT4C01
      *a Rear Side
      *b Front Side

      Install the 2 engine hangers with the 2 bolts as shown in the illustration.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger

      12281-0C010

      12281-0C030
      Bolt

      90119-T0388

      91672-81025

  73. REMOVE ENGINE ASSEMBLY


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

    2. B003L2V

      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.

  74. 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 2 bolts and 2 engine hangers.

  75. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  76. REMOVE FRONT ENGINE MOUNTING HEAT INSULATOR RH


    1. B003R9P

      Remove the bolt and front engine mounting heat insulator RH from the front engine mounting insulator.

  77. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.


    1. B003P79C01
      *a LH Side
      *b RH Side

      Remove the 2 nuts and 2 front engine mounting insulators from the 2 front engine mounting brackets.