Removal
1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
3. REMOVE HOOD SUB-ASSEMBLY
(a) Remove the 4 bolts, 2 clips and hood.
4. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY
Removal
5. REMOVE FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY Removal
6. REMOVE NO. 1 ENGINE UNDER COVER Replacement
7. REMOVE FRONT FENDER APRON SEAL LH
(a) Remove the 6 clips and front fender apron seal.
8. REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the 6 clips and front fender apron seal.
9. REMOVE FRONT FENDER APRON SEAL REAR LH
(a) Remove the 5 clips and fender apron seal.
10. REMOVE FRONT FENDER APRON SEAL REAR RH
(a) Remove the 5 clips and fender apron seal.
11. DRAIN ENGINE OIL Replacement
12. DRAIN ENGINE COOLANT Service and Repair
13. REMOVE AIR CLEANER CAP AND HOSE Removal
14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal
15. REMOVE RADIATOR HOSE INLET Removal
16. REMOVE RADIATOR HOSE OUTLET Removal
17. REMOVE FAN SHROUD Removal
18. REMOVE RADIATOR ASSEMBLY Removal
19. REMOVE AIR TUBE ASSEMBLY Removal
20. REMOVE INTAKE AIR SURGE TANK Removal
21. REMOVE FAN AND GENERATOR V BELT Removal
22. DISCONNECT VANE PUMP ASSEMBLY Removal
23. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for Regular Cab Standard Deck)
(a) Remove the 2 bolts and 2 nuts.
(b) Disconnect the exhaust pipe from the exhaust pipe support and remove the 2 gaskets.
24. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck)
(a) Disconnect the air fuel ratio sensor connector.
(b) Disconnect the heated oxygen sensor connector.
(c) Remove the 3 nuts, exhaust pipe and gasket.
25. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)
(a) Disconnect the air fuel ratio sensor connector.
(b) Disconnect the heated oxygen sensor connector.
(c) Remove the 3 nuts, 2 bolts, exhaust pipe and gasket.
26. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the air fuel ratio sensor connector.
(b) Disconnect the heated oxygen sensor connector and detach the 2 clamps.
(c) Remove the 2 bolts.
(d) Remove the 3 nuts, exhaust pipe and 2 gaskets.
27. REMOVE MANIFOLD STAY Removal
28. REMOVE AIR TUBE Removal
29. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal
30. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal
31. REMOVE NO. 2 MANIFOLD STAY Removal
32. REMOVE NO. 2 AIR TUBE Removal
33. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Removal
34. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Removal
35. REMOVE GENERATOR ASSEMBLY Removal
36. REMOVE STARTER COVER (for 1.4 kW Type) Removal
37. REMOVE STARTER ASSEMBLY (for 1.4 kW Type) Removal
38. REMOVE STARTER ASSEMBLY (for 1.6 kW Type) Removal
39. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT Removal
40. DISCONNECT ENGINE WIRE
Disconnect the 2 air injection control driver connectors.
Detach the 2 wire harness clamps.
(a) Remove the junction block cover.
Disconnect the 7 connectors, detach the 2 clamps and disconnect the junction block connector from the junction block.
Detach the clamp and disconnect the ECM connector Removal.
Remove the 2 bolts and ground cable.
Disconnect the air pump connector and detach the clamp.
Remove the bolt, detach the claw and disconnect the engine wire harness.
Disconnect the 2 connectors, detach the 2 claws and disconnect the engine room junction block connector from the engine room junction block.
41. DISCONNECT COOLER COMPRESSOR ASSEMBLY
(a) Disconnect the cooler compressor connector.
(b) Remove the 2 bolts, 2 nuts and 2 stud bolts and disconnect the cooler compressor.
HINT
It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.
42. DISCONNECT HEATER WATER HOSE ASSEMBLY
(a) Disconnect the heater water inlet and outlet hoses.
43. DISCONNECT NO. 1 AND NO. 2 FUEL PIPES
(a) Remove the No. 2 fuel pipe clamp from the fuel tube connector.
Disconnect the No. 1 and No. 2 fuel pipes Service Precautions.
44. REMOVE PROPELLER SHAFT ASSEMBLY
Removal
45. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
Removal
46. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.
(a) Remove the 4 bolts and rear engine mounting insulator from the transmission.
47. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft.
SST : 09213-54015
91651-60855
SST : 09330-00021
(a) Remove the 8 bolts, rear spacer, drive plate and front spacer.
48. REMOVE ENGINE ASSEMBLY
(a) Install 2 engine hangers with 4 bolts as shown in the illustration.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
Text in Illustration
HINT
(b) Attach an engine sling device and hang the engine with a chain block.
(c) Remove the 2 nuts, 4 bolts and front engine mounting insulator LH and RH.
(d) Lift the engine out of the vehicle carefully.
Text in Illustration
NOTICE:
* Make sure the engine is clear of all wiring and hoses.
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
* Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
49. INSTALL ENGINE TO ENGINE STAND
(a) Install the engine to an engine stand with bolts.
(b) Remove the 2 engine hangers and 4 bolts.
50. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH
(a) Remove the bolt and front No. 2 engine mounting bracket LH.