ENGINE ASSEMBLY REMOVAL

Note

When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.
After removing the injection pipes, clean them with a brush and compressed air.

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE HOOD SUB-ASSEMBLY
1. Disconnect the washer nozzle hose.
2. Remove the 4 bolts and hood.
REMOVE NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)
REMOVE NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)
DRAIN ENGINE OIL
1. Remove the oil filter cap.
2. Remove the oil drain plug, and drain the engine oil from the oil pan.
  
  Note
  
  Collect the oil in an oil disposal container.
DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)
DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)
DRAIN POWER STEERING FLUID
DRAIN ENGINE COOLANT
Note

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.
2. Loosen the cylinder block drain cock plug and the radiator drain cock plug.
  
  Tech Tips
  
  Collect the coolant in a container and dispose of it according to the regulations in your area.
REMOVE BATTERY BRACKET
REMOVE BATTERY AND BATTERY TRAY
REMOVE AIR CLEANER ASSEMBLY
1. Disconnect the mass air flow meter connector.
2. Loosen the hose clamp.
3. Remove the 2 bolts and air cleaner.
REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ EGR Cooler)
1. Remove the 3 bolts, 2 nuts and engine cover.
REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (w/o EGR Cooler)
1. Remove the 3 bolts, 2 nuts and engine cover.
REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/ EGR Cooler)
1. Detach the 2 clamps.
2. Disconnect the vacuum hose from the manifold absolute pressure sensor.
3. Disconnect the IAT sensor connector and manifold absolute diesel pressure sensor connector.
4. Loosen the 2 hose clamps of the No. 1 air hose.
5. Loosen the 2 hose clamps of the No. 2 air hose.
6. Remove the 4 bolts and intercooler.
REMOVE INTERCOOLER ASSEMBLY WITH INTAKE AIR CONNECTOR (w/o EGR Cooler)
1. Disconnect the vacuum hose from the manifold absolute pressure sensor.
2. Disconnect the IAT sensor connector and manifold absolute diesel pressure sensor connector.
3. Loosen the 2 hose clamps of the No. 1 air hose.
4. Loosen the 2 hose clamps of the No. 2 air hose.
5. Remove the 4 bolts and CAC.
REMOVE STARTER ASSEMBLY
- for 2.2 kW Type Bosch Made: Click here
- for 2.2 kW Type Denso Made: Click here
- for 2.7 kW Type : Click here
REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click here
REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
1. Place matchmarks on the propeller shaft flange and differential flange.
2. Remove the 4 nuts, 4 bolts and 4 washers, and disconnect the propeller shaft.
3. Place matchmarks on the propeller shaft flange and transfer flange.
4. Remove the 4 nuts, 4 washers and front propeller shaft.
REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here
REMOVE RADIATOR ASSEMBLY

Click here
DISCONNECT HEATER HOSE
1. Disconnect the 2 heater hoses.
DISCONNECT PRESSURE FEED TUBE ASSEMBLY
1. Disconnect the oil reservoir to pump hose.
2. Disconnect the pressure feed tube.
DISCONNECT FUEL HOSE
1. Disconnect the 2 fuel hoses.
DISCONNECT UNION TO CONNECTOR TUBE HOSE
1. Disconnect the union to connector tube hose.
REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
Text in Illustration

*1 Stopper
1. Slightly bend the upper part of the glove compartment door to release the 2 stoppers and open the glove compartment door until it is horizontal.
2. Text in Illustration
  
  *1 Hinge
  
  Pull the glove compartment door toward the rear of the vehicle to detach the 2 hinges and remove the glove compartment door.
DISCONNECT WIRE HARNESS
1. Remove the upper relay block cover.
2. Remove the side relay block cover.
3. Remove the nut and disconnect the engine room junction block wire.
4. Disconnect the 2 engine room junction block connectors.
5. Remove the bolt and disconnect the ground cable.
6. Remove the 2 nuts, detach the clamp and disconnect the wire harness.
7. Text in Illustration
  
  *A for LHD:
  
  *B for RHD:
  
  Disconnect the 3 EDU connectors.
8. Disconnect the 4 ECM connectors.
9. Text in Illustration
  
  *A for LHD:
  
  *B for RHD:
  
  Disconnect the turbo motor driver connector.
10. w/ A.D.D.
  
  Disconnect the 4WD control ECU connector.
11. for Automatic Transmission:
  
  Disconnect the 3 TCM connectors.
12. Disconnect the 4 ECU connectors.
DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Remove the 4 bolts and disconnect the cooler compressor.
  
  Tech Tips
  
  It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.
REMOVE TRANSMISSION ASSEMBLY
- for R151: Click here
- for R151F: Click here
- for A340E: Click here
- for A340F: Click here
- for A750F: Click here
REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)
1. Place matchmarks on the clutch cover and flywheel.
2. Loosen each set bolt one turn at a time until spring tension is released.
3. Remove the 6 set bolts and pull off the clutch cover.
  
  Note
  
  Do not drop the clutch disc.
REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

Note

Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.
REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-58014
  
  09330-00021
2. Remove the 8 bolts and flywheel.
REMOVE PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)
1. Using SST, hold the crankshaft pulley.
  
  SST
  
  09213-58014
  
  09330-00021
2. Remove the 8 bolts, the rear drive plate spacer, the pump impeller drive plate, and the flywheel and ring gear.
REMOVE REAR END PLATE
1. Remove the bolt and end plate.

Text in Illustration
*1	Stopper

Text in Illustration
*1	Hinge

Text in Illustration
*A	for LHD:
*B	for RHD:

Text in Illustration
*A	for LHD:
*B	for RHD:

INSTALL ENGINE HANGERS

Text in Illustration
*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger

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

Torque:: for No. 1 engine hanger; 25 N*m { 255 kgf*cm, 18 ft.*lbf }; for No. 2 engine hanger; 60 N*m { 612 kgf*cm, 44 ft.*lbf }

Tech Tips

Part No.

No. 1 engine hanger	w/ EGR Cooler	12284-30060
	w/o EGR Cooler	12284-30020
No. 2 engine hanger		12282-67030
Bolt		90105-T0164 or 91552-81014 and 90119-T0065 or 91642-81030

Note

Install the engine hangers with new bolts.

REMOVE ENGINE ASSEMBLY
1. Attach an engine sling device and hang the engine with a chain block.
2. w/ EGR Cooler:
  
  Remove the bolt and No. 2 cylinder block insulator.
3. Remove the 4 bolts and 4 nuts.
4. Remove the engine by operating the engine sling device and chain block.
FIX ENGINE ON ENGINE STAND
1. Attach an engine sling device and hang the engine with a chain block.
2. Remove the engine from the engine stand.
REMOVE ENGINE WIRE
1. Remove the engine wire.
REMOVE NO. 1 TIMING BELT COVER
1. Remove the bolt and water hose clamp.
2. Remove the wire harness clamp.
3. Remove the 6 bolts and timing belt cover.
REMOVE TIMING BELT

Click here
REMOVE CRANKSHAFT PULLEY
1. Using SST, remove the pulley bolt.
  
  SST
  
  09213-58014
  
  09330-00021
2. Using SST, remove the pulley.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
  
  Note
  
  Apply oil or grease to the threads and tip of SST (center bolt) before using it.
REMOVE TURBOCHARGER SUB-ASSEMBLY (w/ EGR Cooler)

Click here
REMOVE TURBOCHARGER SUB-ASSEMBLY (w/o EGR Cooler)

Click here
REMOVE EXHAUST MANIFOLD
1. Remove the 8 nuts and exhaust manifold.
INSPECT EXHAUST MANIFOLD
1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  
  Maximum warpage
  
  0.40 mm (0.0157 in.)
  
  If the warpage is more than the maximum, replace the exhaust manifold.
REMOVE GENERATOR ASSEMBLY
1. Remove the nut and generator wire.
2. Disconnect the generator connector.
3. Remove the 2 bolts and generator.
REMOVE GENERATOR BRACKET
1. Remove the bolt and generator bracket.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
1. Remove the 4 bolts and V-ribbed belt tensioner.
REMOVE INTERCOOLER SUPPORT BRACKET
1. Remove the 2 bolts and intercooler support bracket.
REMOVE NO. 2 INTERCOOLER SUPPORT BRACKET
1. Remove the 2 bolts and No. 2 intercooler support bracket.
REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)
1. Remove the 4 bolts and No. 1 compressor mounting bracket.
REMOVE WATER INLET
1. Remove the 3 bolts and water inlet.
REMOVE THERMOSTAT
REMOVE WATER OUTLET
1. Text in Illustration
  
  *A w/ EGR Cooler
  
  *B w/o EGR Cooler
  
  Remove the 2 bolts and water outlet.
REMOVE GLOW PLUG ASSEMBLY
- w/ EGR Cooler: Click here
- w/o EGR Cooler: Click here
REMOVE OIL FILTER SUB-ASSEMBLY
1. Using SST, remove the oil filter.
  
  SST
  
  09228-07501
  
  Tech Tips
  
  Insert the drain hose in the oil filter. Put the drain oil container beneath the drain hose to collect the oil from the oil filter.
REMOVE INTAKE MANIFOLD
- w/ EGR Cooler: Click here
- w/ EGR system without EGR Cooler: Click here
- w/o EGR System: Click here
INSPECT INTAKE MANIFOLD
1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
  
  Maximum warpage
  
  0.40 mm (0.0157 in.)
  
  If the warpage is more than the maximum, replace the intake manifold.
REMOVE FUEL SUPPLY PUMP ASSEMBLY
1. Remove the bolt and clamp.
2. Remove the 2 bolts and oil level gauge guide.
3. Using a 17 mm union nut wrench, loosen the union nuts and remove the fuel inlet pipe.
4. Disconnect the 2 fuel hoses.
5. Disconnect the 2 connectors.
6. Remove the 4 bolts indicated by the arrows in the illustration.
7. Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.
8. Remove the set nut and O-ring while holding the crankshaft pulley by using SST.
  
  SST
  
  09213-58013
  
  09330-00021
9. Loosen the 2 nuts.
10. Using SST, disconnect the pump from the injection gear.
  
  SST
  
  09950-50013 ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )
  
  Note
  
  Apply lubricant to the threads and tip of SST (center bolt) before using it.
11. Remove the 2 nuts and pump.
  Note
  - Do not hold the pump or carry it holding the pipe.
  - The pump must be kept horizontal.
12. Remove the O-ring.
REMOVE COMMON RAIL ASSEMBLY
1. Disconnect the 2 connectors.
2. Remove the 2 bolts, common rail and No. 2 intake manifold insulator.
  
  Note
  
  Do not remove the pressure discharge valve and fuel pressure sensor.
REMOVE OIL COOLER COVER SUB-ASSEMBLY
1. Disconnect the oil pressure switch connector.
2. Remove the 2 nuts and disconnect the No. 2 vacuum transmitting pipe from the oil cooler cover.
3. Remove the 13 bolts, oil cooler cover and gasket.
REMOVE TIMING GEAR COVER INSULATOR (w/ EGR Cooler)
1. Remove the bolt and timing gear cover insulator.
REMOVE VACUUM PUMP ASSEMBLY
1. Remove the 2 nuts, vacuum pump and 2 O-rings.
REMOVE VANE PUMP ASSEMBLY
1. Remove the 2 nuts, vane pump and O-ring.
REMOVE CRANKSHAFT POSITION SENSOR
1. Remove the bolt and crankshaft position sensor.
REMOVE CAMSHAFT POSITION SENSOR
1. Remove the bolt and camshaft position sensor.
REMOVE ENGINE COOLANT TEMPERATURE SENSOR
1. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.
REMOVE FRONT ENGINE MOUNTING INSULATOR
1. Text in Illustration
  
  *a RH Side
  
  *b LH Side
  
  Remove the 2 nuts and 2 front engine mounting insulators.
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET RH
1. Text in Illustration
  
  *a RH Side
  
  *b LH Side
  
  Remove the 4 bolts and No. 1 front engine mounting bracket.
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Remove the 4 bolts and No. 1 front engine mounting bracket.

Text in Illustration
*a	RH Side
*b	LH Side

Text in Illustration
*a	RH Side
*b	LH Side