Removal

ENGINE ASSEMBLY

COMPONENTS (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):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

COMPONENTS (Part 15):

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
^ After the ignition switch is turned OFF, the navigation system requires approximately 90 seconds to record various types of memory and setting. As a result, after turning the ignition switch OFF, wait 90 seconds or more before disconnecting the cable from the negative (-) battery terminal.
^ Some systems need to be initialized after the cable is reconnected.

3. REMOVE NO. 1 ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL





6. REMOVE HOOD SUB-ASSEMBLY
(a) Using a screwdriver, remove the hood support assembly while releasing the 2 clips.

HINT: Tape the screwdriver tip before use.

CAUTION: Remove the hood support assembly while supporting the hood by hand.

(b) Remove the 4 bolts and hood.
7. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY
(a) Remove the windshield wiper motor.
8. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY
9. REMOVE THROTTLE BODY COVER SUB-ASSEMBLY
10. REMOVE AIR CLEANER HOSE ASSEMBLY
11. REMOVE AIR CLEANER ASSEMBLY
12. REMOVE RADIATOR SIDE DEFLECTOR RH
13. REMOVE RADIATOR SIDE DEFLECTOR LH
14. REMOVE RADIATOR HOSE INLET
15. REMOVE RADIATOR HOSE OUTLET
16. REMOVE FAN AND GENERATOR V BELT
17. REMOVE FLUID COUPLING ASSEMBLY
18. REMOVE OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Remove the oil cooler.
19. REMOVE RADIATOR ASSEMBLY





20. DISCONNECT FUEL MAIN AND RETURN HOSE
(a) Remove the fuel pipe clamp.
(b) Disconnect the fuel main and return hoses.





21. DISCONNECT WIRE HARNESS AND HOSE
(a) Disconnect the vacuum hose assembly.





(b) Disconnect the heater hoses.
(c) Disconnect the clamp and ECM connector.

HINT: Refer to the following procedures to disconnect the ECM connector.





(d) Disconnect the 4 connectors from the connector holder block.





(e) Remove the bolt and connector bracket and disconnect the air pump connector.
(f) Remove the bolt and disconnect the ground wire.
(g) Disconnect the air injection system hose.





(h) Remove the nut and disconnect the wire from the positive (+) battery terminal.
(i) Disconnect the positive (+) battery terminal.
(j) Remove the bolt and disconnect the ground wire.
(k) Disconnect the 4 air injection control driver connectors.
(l) Remove the nut and disconnect the wire from the engine room junction block.
(m) Disconnect the 3 connectors from the engine room junction block.
22. DISCONNECT COOLER COMPRESSOR ASSEMBLY
23. DISCONNECT VANE PUMP ASSEMBLY
24. REMOVE GENERATOR ASSEMBLY





25. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the 2 bolts and water by-pass pipe.
26. REMOVE EXHAUST PIPE ASSEMBLY
(a) for Regular cab standard deck, refer to the following procedures.
(b) except Regular cab standard deck, refer to the following procedures.
27. REMOVE PROPELLER SHAFT ASSEMBLY
(a) for 2 Joint type, refer to the following procedures.
(b) for 3 Joint type, refer to the following procedures.
28. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD, refer to the following procedures.
(b) for 4WD, refer to the following procedures.





29. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021





(b) Remove the 8 bolts, front drive plate spacer, drive plate and rear drive plate spacer.





30. REMOVE ENGINE ASSEMBLY
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Remove the 4 engine mounting insulator's bolts.
(c) Lift the engine out from the vehicle slowly and carefully.

NOTICE: Make sure the engine is clear of all wiring, hoses and cables.

31. REMOVE NO. 3 AIR TUBE
32. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
33. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
34. REMOVE NO. 2 AIR TUBE
35. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
36. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
37. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
38. INSTALL ENGINE ON ENGINE STAND
(a) Install the engine onto an engine stand with the bolts.