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):
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 OIL
5. DRAIN ENGINE COOLANT
6. REMOVE HOOD SUB-ASSEMBLY
(a) Using a screwdriver, release the 2 clips and remove the hood support assembly.
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 V-BANK COVER SUB-ASSEMBLY
10. REMOVE AIR CLEANER HOSE ASSEMBLY
11. REMOVE AIR CLEANER ASSEMBLY
12. REMOVE INLET RADIATOR HOSE
13. REMOVE OUTLET RADIATOR HOSE
14. REMOVE RADIATOR SIDE DEFLECTOR RH (w/o Trailer Towing System)
15. REMOVE RADIATOR SIDE DEFLECTOR LH
16. REMOVE OIL COOLER ASSEMBLY (w/ Trailer Towing System)
(a) Remove the oil cooler.
17. REMOVE FAN AND GENERATOR V BELT
18. REMOVE FAN SHROUD
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 union to check valve hose.
(b) Disconnect the purge line hose.
(c) Disconnect the heater hoses.
(d) Disconnect the clamp and ECM connector.
HINT: Refer to the following procedures to disconnect the ECM connector.
(e) Disconnect the 4 connectors from the connector holder block.
(f) Remove the nut and connector bracket and disconnect the 2 air pump connectors.
(g) Remove the bolt and disconnect the ground wire.
(h) Disconnect the 2 air injection system hoses.
(i) Remove the nut and disconnect the wire from the positive (+) battery cable.
(j) Disconnect the cable from the positive (+) battery terminal.
(k) Remove the bolt and disconnect the ground wire.
(l) Disconnect the 4 air injection control driver connectors.
(m) Remove the nut and disconnect the wire and 2 clips from the engine room junction block.
(n) Disconnect the 2 connectors and 2 clips from the engine room junction block.
22. DISCONNECT COOLER COMPRESSOR ASSEMBLY
23. DISCONNECT VANE PUMP ASSEMBLY
24. REMOVE GENERATOR ASSEMBLY
25. 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.
26. REMOVE PROPELLER SHAFT ASSEMBLY
(a) for 2WD: Refer to the following procedures.
(b) for 4WD: Refer to the following procedures.
27. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
(a) Remove the front propeller shaft.
28. REMOVE FRONT FENDER APRON SEAL RH
29. REMOVE FRONT FENDER APRON SEAL REAR RH
30. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
31. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
32. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
33. REMOVE STARTER COVER
34. REMOVE STARTER ASSEMBLY
35. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD: Refer to the following procedures.
(b) for 4WD: Refer to the following procedures.
36. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (90119-08216), 09330-00021
(b) Remove the 10 bolts, rear drive plate spacer, drive plate and crankshaft angle sensor rotor.
37. REMOVE NO. 1 WATER BY-PASS PIPE
(a) Remove the 2 bolts and disconnect the hose. Then remove the water by-pass pipe.
38. REMOVE ENGINE ASSEMBLY
(a) Install the 2 engine hangers with the 2 bolts as shown in the illustration.
Engine hanger part No.:
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
(b) Attach an engine sling device and hang the engine with a chain block.
(c) Remove the 4 engine mounting insulator's bolts.
(d) Lift the engine out from the vehicle slowly and carefully.
NOTICE: Make sure the engine is clear of all wiring, hoses and cables.
39. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
40. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
41. INSTALL ENGINE ON ENGINE STAND
(a) Install the engine onto an engine stand with the bolts.
(b) Remove the 2 bolts and 2 engine hangers.