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

  • Learning values save

  • Learning values write

 Engine starting

Click here

Code registration (Immobiliser system) Engine start function See the Service Bulletin for the registration method.
Replacement of engine assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

Click here

Clear Crank Time Compensation Data Engine starting

Click here

Replacement of crankshaft position sensor plate Clear Crank Time Compensation Data Crank time compensation data compensation amount is same as before replacement, affecting crank time compensation data

Click here

Replacement of injector assembly

  • Injector compensation code registration

  • Pilot quantity learning

 Engine starting

Click here


  • Replacement of diesel throttle body assembly

  • Replacement of electric EGR control valve assembly

  • Replacement of turbocharger sub-assembly

  • Replacement of turbocharger sub-assembly or turbocharger variable nozzle motor

 Perform initialization -

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

    w/ Automatic Headlight Beam Level Control System:

  • The vehicle height changes due to replacement of suspension components or after performing such operations as removal and reinstallation

 Headlight leveling ECU assembly initialization Headlight leveling function

Click here


    for 4WD:

  • Front wheel alignment adjustment

  • Clearing zero point calibration data

  • Yaw rate and acceleration sensor zero point calibration

 VSC malfunctioning

Click here

CAUTION:

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

B0068EY

PROCEDURE


  1. 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

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

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

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

  5. DRAIN ENGINE OIL

    Click here

  6. DRAIN ENGINE COOLANT

    Click here

  7. DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)


  8. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

    Click here

  9. 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.

  10. REMOVE RADIATOR ASSEMBLY

    Click here

  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  12. DISCONNECT ENGINE WIRE


    1. Remove the ECM.

      Click here

    2. B0068R0C01
      *A for LHD
      *B for RHD

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

    3. B0069EHC01
      *A for LHD
      *B for RHD

      Disconnect the connector from the engine room main wire.

    4. B0068V6C01
      *A for LHD
      *B for RHD

      Detach the clamp and disconnect the 4 connectors from the glow plug controller.

    5. B0068WXC01
      *A for LHD
      *B for RHD

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

    6. B0068B2C01
      *A for LHD
      *B for RHD

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

  13. REMOVE AIR CLEANER CAP AND HOSE


    1. B00691M

      Detach the 2 clamps and disconnect the connector from the mass air flow meter.

    2. B00691E

      Loosen the hose clamp.

    3. Detach the 4 clips and remove the air cleaner cap and hose.

  14. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  15. REMOVE NO. 1 AIR HOSE


    1. B0069F8

      Slide the 2 clamps and remove the No. 1 air hose from the compressor outlet elbow and air tube.

  16. REMOVE NO. 4 AIR HOSE


    1. B00693H

      Slide the clamp and disconnect the oil return hose from the engine oil level dipstick guide assembly.

    2. B00698R

      Slide the 2 clamps and remove the No. 4 air hose from the No. 2 air tube and intercooler air tube.

  17. REMOVE INTERCOOLER AIR TUBE


    1. B0068CD

      Disconnect the connector from the intake air temperature sensor.

    2. B00697W

      Slide the clamp and remove intercooler air tube from the diesel throttle body assembly.

  18. REMOVE FUEL FILTER ASSEMBLY

    Click here

  19. REMOVE NO. 1 FUEL HOSE


    1. B0068IY

      Detach the clamp from the No. 1 fuel hose.

    2. Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.

  20. REMOVE NO. 2 FUEL HOSE


    1. B0069B0

      Detach the clamp from the No. 2 fuel hose.

    2. Slide the clamp and disconnect the No. 2 fuel hose from the No. 3 nozzle leakage pipe assembly.

  21. DISCONNECT WIRE HARNESS


    1. B0068KI

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

    2. B0068AI

      Detach the 2 clips and remove the No. 1 relay block cover side from the engine room relay block sub-assembly.

    3. B00699X

      Remove the nut and disconnect the wire to wire from the engine room relay block sub-assembly.

    4. B00692Q

      Disconnect the 2 connectors from the engine room relay block sub-assembly.

    5. B0068FN

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

    6. B00697P

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

  22. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. Loosen the 2 nuts and remove the battery clamp sub-assembly from the battery.

  23. REMOVE BATTERY

  24. REMOVE BATTERY TRAY

  25. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. B0069EY

      Slide the 2 clamps and disconnect the water hose sub-assembly from the air conditioning unit assembly.

  26. DISCONNECT VANE PUMP ASSEMBLY


    1. B0068BO

      Disconnect the connector from the power steering oil pressure switch.

    2. B00689U

      Remove the 2 bolt and disconnect the vane pump assembly from the generator bracket.

  27. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. B00692F

      Slide the clamp and disconnect the union to connector tube hose from the No. 1 hose to hose tube.

  28. REMOVE GENERATOR ASSEMBLY

    Click here

  29. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. B0068DM

      Remove the 2 bolts and disconnect the suction hose sub-assembly from the water inlet and timing chain cover.

    2. B0068QA

      Disconnect the connector from the cooler compressor assembly.

    3. Remove the 2 bolt and 2 nuts.

    4. B0069BI

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts and disconnect the cooler compressor assembly from the compressor mounting bracket.

  30. REMOVE WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)


    1. B006991

      Remove the bolt and disconnect the water hose from the water inlet.

    2. B00699M

      Slide the 4 clamps and remove the water hose sub-assembly from the viscous heater with magnet clutch assembly, No. 2 water pipe and water outlet sub-assembly.

  31. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)


    1. Disconnect the connector from the viscous heater with magnet clutch assembly.

    2. B0068SO

      Remove the 2 bolts, nut and viscous heater with magnet clutch assembly from the No. 1 viscous heater bracket.

  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

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

    Click here

  34. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

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


  36. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

    Click here

  37. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  38. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


  39. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)


  40. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. B006930

      w/ Viscous Heater:

      Remove the 4 bolts, viscous heater crankshaft pulley and crankshaft pulley cover from the crankshaft pulley.

    2. B0068UU

      w/o Viscous Heater:

      Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.

    3. B0068XCN01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    4. B0068OV

      for Manual Transmission:

      Remove the 8 bolts and flywheel sub-assembly from the crankshaft.

    5. B0069AY

      for Automatic Transmission:

      Remove the 8 bolts, rear drive plate spacer, pump impeller drive plate and flywheel sub-assembly from the crankshaft.

  41. REMOVE REAR END PLATE


    1. B0068RU

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

  42. INSTALL ENGINE HANGER


    1. B0068YFC01
      *1 No. 1 Engine Hanger Upper
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger upper and No. 2 engine hanger with the 3 bolts as shown in the illustration.

      Torque:
      for No. 1 engine hanger upper
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for No. 2 engine hanger
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger Upper 12284-11010 or 12284-11020
      No. 2 Engine Hanger 12282-11080 or 12282-11090
      Bolt 90119-T0073 or 91552-81025 and 90119-T0219 or, 91672-80835

  43. REMOVE ENGINE ASSEMBLY


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

    2. B00693J

      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 assembly is clear of all wiring and hoses.

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

  44. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

    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 assembly while it is suspended, as doing so is dangerous.


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

    2. Remove the 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.

  45. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  46. REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. B00690G

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

  47. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B0068QY

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