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Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (See FUEL SYSTEM ).
  2. REMOVE FRONT WHEELS 
  3. REMOVE ENGINE UNDER COVER ASSEMBLY 
    1. w/ engine under cover assembly
  4. REMOVE ENGINE UNDER COVER NO. 1 
  5. REMOVE ENGINE UNDER COVER NO. 2 
    1. w/ engine under cover No. 2
  6. REMOVE FRONT FENDER SPLASH SHIELD SUBASSEMBLY LH 
  7. REMOVE FRONT FENDER SPLASH SHIELD SUBASSEMBLY RH 
  8. REMOVE FRONT FENDER APRON SEAL LH 
  9. REMOVE FRONT FENDER APRON SEAL RH 
  10. DRAIN ENGINE COOLANT 
    1. Drain engine coolant (See COOLANT ).
  11. DRAIN ENGINE OIL 
    1. Drain engine oil (See REPLACEMENT ).
  12. DRAIN AUTOMATIC TRANSAXLE FLUID 
    1. Drain automatic transaxle fluid (See AUTOMATIC TRANSAXLE ASSEMBLY ).
  13. DRAIN TRANSFER OIL (for 4WD) 
  14. REMOVE FR WIPER ARM RH 
    1. Remove the FR wiper arm RH (See FRONT WIPER MOTOR ).
  15. REMOVE FR WIPER ARM LH 
    1. Remove the FR wiper arm LH (See FRONT WIPER MOTOR ).
  16. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY 
    1. Remove the cowl top ventilator louver sub-assembly (See FRONT WIPER MOTOR ).
  17. REMOVE WINDSHIELD WIPER LINK ASSEMBLY 
    1. Remove the windshield wiper link assembly (See FRONT WIPER MOTOR ).
  18. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER 
    1. Remove the cowl top panel sub-assembly outer (See REMOVAL ).
  19. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Remove the V-bank cover sub-assembly (See ADJUSTMENT  ).
  20. REMOVE BATTERY 
  21. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 
    1. Remove the air cleaner cap sub-assembly (See REMOVAL ).
  22. REMOVE AIR CLEANER FILTER ELEMENT SUBASSEMBLY 
  23. REMOVE AIR CLEANER INLET NO. 2 
    1. Remove the air cleaner inlet No. 2 (See REMOVAL ).
  24. REMOVE AIR CLEANER CASE 
    1. Remove the air cleaner case (See REMOVAL ).
  25. REMOVE AIR CLEANER BRACKET 
    1. Remove the air cleaner bracket (See REMOVAL ).
  26. REMOVE AIR CLEANER INLET NO. 1 
    1. Remove the air cleaner inlet No. 1 (See REMOVAL ).
  27. REMOVE V-(COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 
    1. Remove the V-(cooler compressor to crankshaft pulley) belt No. 1 (See REMOVAL  ).
  28. REMOVE GENERATOR ASSEMBLY 
    1. Remove the generator assembly (See REMOVAL ).
  29. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the engine moving control rod (See REMOVAL  ).
  30. REMOVE ENGINE MOUNTING STAY NO. 2 RH 
    1. Remove the engine mounting stay No. 2 RH (See REMOVAL  ).
  31. REMOVE GENERATOR BRACKET NO. 2 
    1. Remove the generator bracket No. 2 (See REMOVAL  ).
  32. REMOVE GENERATOR BELT ADJUSTING BAR 
    1. Remove the generator belt adjusting bar (See REMOVAL ).
  33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Separate compressor and magnetic clutch (See REMOVAL ).
  34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Separate transmission control cable assembly (See TRANSMISSION CONTROL CABLE ASSEMBLY ).
  35. DISCONNECT UNION TO CHECK VALVE HOSE 
  36. DISCONNECT FUEL VAPOR FEED HOSE 
  37. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO. 1 
    1. Disconnect the fuel pipe sub-assembly No. 1 (See FUEL SYSTEM ).
  38. DISCONNECT HEATER INLET WATER HOSE 
  39. DISCONNECT HEATER OUTLET WATER HOSE 
  40. DISCONNECT RADIATOR HOSE INLET 
  41. DISCONNECT RADIATOR HOSE OUTLET 
  42. DISCONNECT OIL COOLER INLET TUBE NO. 1 
  43. DISCONNECT OIL COOLER OUTLET TUBE NO. 1 
  44. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO. 1 
    1. Remove the clamp and disconnect the oil reservoir to pump hose No. 1.
    Fig 1: Disconnecting Oil Reservoir To Pump Hose No. 1
    G04087760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. DISCONNECT STEERING GEAR OUTLET RETURN TUBE 
    1. Remove the clamp and disconnect the steering gear outlet return tube.
  46. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY 
  47. SEPARATE ENGINE WIRE 
    1. Disconnect the engine wire harness from the ECM and the junction block.
      Fig 2: Disconnecting Steering Gear Outlet Return Tube
      G04087761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine wire harness from the engine room junction block.
      1. Remove the nut and separate the wire harness.
      2. Using a screwdriver, release the engine room junction block. Separate the engine wire by pulling it up-ward.
    3. Remove the 2 nuts and pull out the engine wire harness.
    4. Remove the body ground.
    Fig 3: Disconnecting Engine Wire Harness From Engine Room Junction Block
    G04087762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE PROPELLER SHAFT (for 4WD) SST 09325-20010 
    1. Remove the propeller shaft (See REMOVAL ).
  49. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3 
    1. Remove the exhaust pipe sub-assembly front No. 3 (See REMOVAL ).
  50. REMOVE EXHAUST PIPE ASSEMBLY FRONT 
    1. Remove the exhaust pipe assembly front (See REMOVAL ).
  51. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1 
  52. REMOVE FRONT STABILIZER LINK ASSEMBLY LH 
    1. Remove the front stabilizer link assembly LH (See REMOVAL ).
  53. REMOVE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side

  54. REMOVE FRONT AXLE HUB LH NUT SST 09930-00010 
    1. Remove the front axle hub LH nut (See REMOVAL ).
  55. REMOVE FRONT AXLE HUB RH NUT SST 09930-00010 

    HINT:

    Perform the same procedure as above on the opposite side.

  56. SEPARATE SPEED SENSOR FRONT LH 
    1. Separate the speed sensor front LH (See REMOVAL ).
  57. SEPARATE SPEED SENSOR FRONT RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  58. SEPARATE TIE ROD END SUB-ASSEMBLY LH SST 09628-62011 
    1. Separate the tie rod end sub-assembly LH (See REMOVAL ).
  59. SEPARATE TIE ROD END SUB-ASSEMBLY RH SST 09628-62011 

    HINT:

    Perform the same procedure as above on the opposite side.

  60. SEPARATE FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH 
    1. Separate the front suspension arm sub-assembly lower No. 1 LH (See REMOVAL ).
  61. SEPARATE FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  62. SEPARATE FRONT AXLE ASSEMBLY LH 
    1. Separate the front axle assembly LH (See REMOVAL ).
  63. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  64. SEPARATE STEERING INTERMEDIATE SHAFT SUBASSEMBLY 
    1. Separate the steering intermediate shaft subassembly (See REMOVAL ).
  65. SEPARATE HEIGHT CONTROL SENSOR LINK SUBASSEMBLY FRONT 
    1. Remove the nut and separate the height control sensor link from the front frame (w/ air suspension).
  66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      Fig 4: Removing Height Control Sensor Link From Front Frame (W/Air Suspension)
      G04087763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and 2 nuts, then remove the frame side rail plates RH and LH.
      Fig 5: Removing Frame Side Rail Plates RH And LH
      G04087764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
    4. Carefully remove the engine assembly from the vehicle.
      Fig 6: Removing Front Suspension Member Brace Rear RH And LH
      G04087765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the No. 2 engine hanger in the correct direction (shown in the illustration).

      Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) 

      HINT:

      ENGINE HANGER AND BOLT SPECIFICATION

      No.2 engine hanger 12282-20020 -
      Bolt 91621-60822 TMC made
        90080-11331 TMMWV made
    6. Attach the engine sling and hang the engine assembly with the chain block.
      7. Fig 7: Installing No 2 Engine Hanger
      G04087766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
  68. REMOVE MANIFOLD STAY 
  69. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY 
    1. Remove the exhaust manifold converter subassembly (See REMOVAL  ).
  70. REMOVE VANE PUMP V-BELT 
    1. Remove the vane pump V-belt (See REMOVAL  ).
  71. REMOVE VANE PUMP ASSEMBLY 
    1. Remove the 3 nuts and disconnect the PS pressure tube.
      Fig 8: Disconnecting PS Pressure Tube
      G04087767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and the vane pump.
  72. REMOVE STABILIZER BAR FRONT (for 4WD) 
  73. REMOVE POWER STEERING LINK ASSEMBLY (for 4WD) 
    Fig 9: Removing Vane Pump
    G04087768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the 2 nuts and separate the engine mounting insulators RH and LH.
      Fig 10: Removing Engine Mounting Insulators RH And LH
      G04087769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and separate engine mounting insulator FR.
      Fig 11: Removing Engine Mounting Insulator FR
      G04087770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and separate the engine mounting insulator RR.
  75. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH SST 09520-01010, 09520-24010 (09520-32040) 
    1. Remove the front drive shaft assembly LH (See REMOVAL ).
  76. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) 
    1. Remove the front drive shaft assembly RH (See REMOVAL ).
    Fig 12: Removing Engine Mounting Insulator RR
    G04087771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) 

    SST 09520-01010, 09520-24010 (09520-32040) 

    1. Remove the front drive shaft assembly RH (See REMOVAL ).
  78. REMOVE STARTER ASSEMBLY 
    1. Remove the starter assembly (See REMOVAL ).
  79. REMOVE ENGINE MOUNTING BRACKET FR 
    1. Remove the engine mounting bracket FR (See REMOVAL ).
  80. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) 
    1. Remove the automatic transaxle assembly (See REMOVAL ).
  81. REMOVE TRANSFER STIFFENER PLATE RH (for 4WD) 
    1. Remove the transfer stiffener plate RH (See REMOVAL ).
  82. REMOVE AUTOMATIC TRANSMISSION W/ TRANSFER (for 4WD) 
    1. Remove the automatic transmission w/ transfer (See REMOVAL ).
  83. REMOVE ENGINE MOUNTING BRACKET RR 
  84. REMOVE DRIVE PLATE & RING GEAR SUBASSEMBLY 

    SST 09213-54015 (91651-60855), 09330-00021 

    1. Remove the drive plate & ring gear sub-assembly (See REMOVAL  ).
  85. INSTALL ENGINE STAND 
  86. REMOVE ENGINE HANGER NO. 2 
  87. REMOVE EMISSION CONTROL VALVE SET 
    1. Remove the emission control valve set (See ADJUSTMENT  ).
  88. REMOVE INTAKE AIR SURGE TANK 
    1. Remove the intake air surge tank (See ADJUSTMENT  ).
  89. REMOVE INTAKE MANIFOLD 
    1. Remove the intake manifold (See REMOVAL  ).
  90. REMOVE WATER OUTLET 
    1. Remove the water outlet (See REMOVAL  ).
  91. REMOVE IGNITION COIL ASSEMBLY 
  92. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3 
  93. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2 
  94. REMOVE MANIFOLD STAY NO. 2 
  95. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY NO. 2 
    1. Remove the exhaust manifold converter subassembly No. 2 (See REMOVAL  ).
  96. REMOVE ENGINE MOUNTING BRACKET RH 
  97. REMOVE PUMP BRACKET 
  98. REMOVE GENERATOR BRACKET NO. 1 
  99. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1 
    1. Remove the compressor mounting bracket No. 1 (See INSTALLATION ).
  100. REMOVE WATER INLET PIPE 
    1. Remove the water inlet pipe (TMC made) ( See REMOVAL ).
  101. REMOVE WATER INLET 
    1. Remove the water inlet (TMC made) ( See REMOVAL ).
  102. REMOVE WATER INLET 
    1. Remove the water inlet (TMMWV made) (See REMOVAL ).
  103. REMOVE THERMOSTAT 
  104. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a deep socket wrench 24 mm, remove the oil pressure switch.
  105. REMOVE KNOCK SENSOR 
    1. Remove the knock sensor (See REMOVAL ).
  106. REPLACE PARTIAL ENGINE ASSEMBLY 
Fig 13: Removing Engine Oil Pressure Switch Assembly
G04087772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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