Removal

2TR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. REMOVE HOOD SUB-ASSEMBLY

2. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

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.

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 Removal

24. REMOVE EXHAUST PIPE ASSEMBLY FRONT Removal

25. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)





26. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)





27. REMOVE ENGINE ASSEMBLY





(a) Install the engine hanger with the bolt.

Torque : 42 Nm (420 kgf-cm, 30 ft-lbf)

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) 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 Removal

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