Removal
2TR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:
REMOVAL
1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE (Technician Safety Information)
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type)
(a) Remove the 4bolts, 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 (Service and Repair)
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH (Removal)
9. REMOVE FAN SHROUD (Removal)
10. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (Removal)
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 (Removal)
14. REMOVE NO. 2 RADIATOR HOSE
15. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) (Removal)
16. REMOVE RADIATOR HOSE INLET
17. SEPARATE WATER HOSE SUB-ASSEMBLY
(a) Separate the water hoses.
18. DISCONNECT FUEL HOSE (Removal)
19. DISCONNECT NO. 2 FUEL HOSE (Removal)
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.
NOTE: 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 (Removal)
24. REMOVE EXHAUST PIPE ASSEMBLY FRONT (Removal)
25. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY
26. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (Service and Repair)
27. REMOVE ENGINE ASSEMBLY
(a) Install the engine hanger with the bolt.
Torque: 42 Nm (420 kgf-cm, 30 ft-lbf)
Part No:
NOTE: 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.
NOTE: 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) (Removal)
31. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) (Removal)
32. REMOVE REAR END PLATE (Removal)
33. REMOVE INTAKE AIR CONNECTOR (Removal)
34. REMOVE FUEL HOSE (Removal)
35. REMOVE NO. 2 FUEL HOSE (Removal)
36. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY (Removal)
37. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET (Removal)
38. REMOVE IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System) (Removal)
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 (Removal)
44. REMOVE FUEL INJECTOR ASSEMBLY (Removal)
45. REMOVE KNOCK SENSOR (Removal)
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 (Removal)
50. REMOVE SPARK PLUG
51. REMOVE GENERATOR ASSEMBLY (Service and Repair)
52. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (Removal)
53. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (Removal)
54. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (Removal)
55. REMOVE AIR SWITCHING VALVE ASSEMBLY (Removal)
56. REMOVE EXHAUST MANIFOLD (Removal)
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 (Testing and Inspection)