REMOVAL (To 8/2009): Removal

REMOVE ENGINE ROOM SIDE COVER . Refer to REMOVAL - Step 1
REMOVE ENGINE ROOM SIDE COVER LH . Refer to REMOVAL - Step 2
REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 3
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION
REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to REMOVAL - Step 32
REMOVE NO. 1 ENGINE UNDER COVER
REMOVE NO. 2 ENGINE UNDER COVER
DRAIN ENGINE COOLANT See step 7
REMOVE NO. 2 ENGINE MOUNTING STAY RH . Refer to REMOVAL - Step 53
REMOVE ENGINE MOVING CONTROL ROD BRACKET . Refer to REMOVAL - Step 54
REMOVE ENGINE MOVING CONTROL ROD . Refer to REMOVAL - Step 55
REMOVE V-RIBBED BELT
Refer to REMOVAL
DISCONNECT FRONT ENGINE MOUNTING INSULATOR
1. Remove the 2 hole plugs.
  
  Fig 1: Identifying Front Engine Mounting Insulator, Hole Plugs & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts.
DISCONNECT ENGINE MOUNTING INSULATOR RH
1. Remove the 2 hole plugs.
  
  Fig 2: Identifying Engine Mounting Insulator RH, Hole Plugs & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts.
DISCONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY
1. Remove the 2 hole plugs.
  
  Fig 3: Identifying Rear Engine Mounting Insulator Assembly, Hole Plugs & Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 nuts.
REMOVE NO. 2 ENGINE MOUNTING STAY RH . Refer to REMOVAL - Step 7
DISCONNECT NO. 2 RADIATOR HOSE . Refer to REMOVAL - Step 45
REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH
1. Remove the 4 bolts
  
  Fig 4: 4 Bolts & SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, loosen the bolt (A).
  - SST: 09249-37010
3. Using SST, loosen the bolt (B).
  - SST: 09961-00950
4. Place a wooden block between a jack and the engine.
  
  Fig 5: Set A Jack As Shown
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Make sure to set a jack as shown in the illustration. Do not place the jack on the oil pan.
5. Jack up the engine slightly, and remove the 2 bolts and No. 1 front engine mounting bracket LH.
  
  Fig 6: 2 Bolts And No. 1 Front Engine Mounting Bracket LH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not jack up the engine excessively.
  
  HINT:
  
  Lift the engine so that bolt A passes above the No. 1 cooler refrigerant suction pipe.
6. Lower the engine, and remove the jack.
  NOTE:
  When lowering the jack, align the stud bolts of the engine mounting insulators with the bolt holes of the front frame assembly.
REMOVE WATER INLET HOUSING
1. Disconnect the water hose.
  
  Fig 7: Water Hose, 2 Bolts, Nut And Water Inlet Housing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 bolts, nut and water inlet housing.
3. Remove the water inlet housing gasket and water outlet pipe O-ring.
  
  Fig 8: Identifying O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE V-RIBBED BELT TENSIONER PULLEY
1. Remove the 5 mm bi-hexagon wrench.
2. Using SST, remove the bolt, dust shield and Vribbed belt tensioner pulley.
  
  Fig 9: Bolt, Dust Shield And Vribbed Belt Tensioner Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09961-00950
  NOTE:
  - Do not turn the bolt labeled "L" counterclockwise.
  - Store the V-ribbed belt tensioner pulley so that the bearing does not get damaged.
REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Remove the bolt, No. 2 idler pulley cover plate, No. 2 idler pulley sub-assembly and idler pulley cover plate.
  
  Fig 10: Identifying Bolt, Idler Pulley Cover Plate, No. 2 Idler Pulley Cover Plate And No. 2 Idler Pulley Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Plate diameter:
  
  Idler pulley cover plate: 33.6 mm (1.32 in.)
  
  No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
SEPARATE WATER PUMP PULLEY
1. Using SST, hold the water pump pulley.
  
  Fig 11: Identifying Water Pump Pulley And SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09960-10010
    - 09962-01000
    - 09963-00700
2. Using SST and a union nut wrench, remove the 4 bolts and separate the water pump pulley from the water pump.
  - SST: 09961-00950
  HINT:
  
  There is not enough clearance to completely remove the water pump pulley from the water pump shaft. Remove the water pump pulley together with the water pump.
REMOVE WATER PUMP ASSEMBLY
1. Remove the 16 bolts, water pump assembly, water pump pulley and water pump gasket.
  
  Fig 12: Identifying Engine Water Pump Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002