Removal
ENGINE ASSEMBLYCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
COMPONENTS (Part 12):
REMOVAL
1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type)
(a) Remove the 4 bolts, then remove the engine under cover No.1.
4. REMOVE NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type, Regular Cab)
(a) Remove the 4 bolts, then remove engine cover No.2.
5. DRAIN ENGINE COOLANT
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH
9. REMOVE FAN SHROUD
10. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
11. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
12. REMOVE AIR CLEANER CASE
(a) Remove the 3 bolts, then remove the air cleaner case.
13. SEPARATE VANE PUMP
14. REMOVE NO. 2 RADIATOR HOSE
15. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
16. REMOVE RADIATOR HOSE INLET
17. SEPARATE WATER HOSE SUB-ASSEMBLY
(a) Separate the water hoses.
18. DISCONNECT FUEL HOSE
19. DISCONNECT NO. 2 FUEL HOSE
20. SEPARATE FUEL VAPOR FEED HOSE ASSEMBLY
(a) Disconnect the fuel vapor feed hose.
21. DISCONNECT NO. 1 AIR INJECTION HOSE
(a) Disconnect the No.1 air injection hose.
22. DISCONNECT ENGINE WIRE
(a) Disconnect the connector from the ECM, then pull the engine wire harness to the compartment side.
NOTICE: Do not forcibly pull the wire harness to the engine compartment side.
(b) Disconnect all wire harnesses and connectors in the engine room.
23. REMOVE EXHAUST PIPE ASSEMBLY TAIL
24. REMOVE EXHAUST PIPE ASSEMBLY FRONT
25. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
26. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
27. REMOVE ENGINE ASSEMBLY
(a) Install the engine hanger with the bolt.
Torque: 42 Nm (420 kgf-cm, 30 ft. lbs.)
Part No:
NOTICE: Be sure to use the bolts when installing the engine hanger.
(b) Attach the engine sling device and chain block to the engine hangers.
(c) Remove the 4 bolts and 4 nuts.
(d) Lift the engine out of the vehicle slowly and carefully by operating the engine sling device and chain block.
NOTICE: Make sure that no wires, hoses or cables are connected to the engine.
28. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)
29. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)
30. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)
31. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)
32. REMOVE REAR END PLATE
33. REMOVE INTAKE AIR CONNECTOR
34. REMOVE FUEL HOSE
35. REMOVE NO. 2 FUEL HOSE
36. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY
37. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET
38. REMOVE IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)
39. REMOVE ENGINE WIRE
40. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
41. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolts, then remove the oil level gage guide.
42. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET
(a) Remove the 4 bolts, then remove the engine mounting bracket front No. 1 LH with engine mounting insulator front.
43. REMOVE THERMOSTAT
44. REMOVE FUEL INJECTOR ASSEMBLY
45. REMOVE KNOCK SENSOR
46. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.
47. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the 2 nuts, then remove the water by-pass pipe No. 1.
48. REMOVE VENTILATION PIPE
(a) Remove the bolts, then remove the ventilation pipe.
49. REMOVE IGNITION COIL ASSEMBLY
50. REMOVE SPARK PLUG
51. REMOVE GENERATOR ASSEMBLY
52. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
53. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
54. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
55. REMOVE AIR SWITCHING VALVE ASSEMBLY
56. REMOVE EXHAUST MANIFOLD
57. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Remove the 4 bolts, then remove the engine mounting bracket front No. 1 together with the engine mounting insulator front.
58. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY