Engine Assembly Removal

Disconnect the cable from the negative (-) battery terminal.

CAUTION:

Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.

Remove the front driver side scuff plate.

1. Using a screwdriver, detach the 7 claws.
   

   HINT:

   Tape the screwdriver tip before use.

2. Using a clip remover, detach the 3 clips and remove the scuff plate.
   

Fold back the floor carpet and disconnect the joining connector, as shown in the illustration.

HINT:

This connector has the lines of the fuel pump and rear speed sensor.

Connect the cable to the negative (-) battery terminal.

Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

HINT:

DTC C0210/33 and DTC C0215/34 (rear speed sensor circuit) and DTC P0171/25 (system too lean) may be set.

Crank the engine again, and then check that the engine does not start.

Loosen the fuel tank cap, and then discharge the pressure in the fuel tank completely.

Connect the fuel pump connector.

Install the front driver side scuff plate.

Clear the DTCs (Toyota Fortuner RM000000ZPW007X.html).

Remove the 4 bolts and under cover.

Remove the 3 clips, 3 bolts and side cover LH.

Remove the 3 clips, 3 bolts and side cover RH.

Remove the radiator cap.

Loosen the cylinder block drain cock plug and radiator drain cock plug, and then drain the coolant.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Remove the oil filler cap.

Remove the oil drain plug and drain the oil into a container.

Disconnect the vacuum hose.

Disconnect the No. 2 ventilation hose.

Disconnect the MAF meter connector and wire harness clamps.

Loosen the hose clamp and remove the 4 bolts, air cleaner and intake air connector assembly.

Remove the 2 screws.

Using a clip remover, remove the 2 clips.

Pull the radiator grille in the direction indicated by the arrow in the illustration to detach the 6 claws and remove the radiator grille.

Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the drive belt. Then remove the drive belt.

NOTICE:

When removing the drive belt, do not use the idle pulley's bolt.

HINT:

After removing the drive belt, move the tensioner upward to the maximum position.

Disconnect the reservoir hose from the radiator tank upper.

Loosen the 4 nuts holding the fluid coupling fan.

Remove the drive belt (Toyota Fortuner RM000000YMP008X.html).

Remove the 2 bolts holding the fan shroud.

Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley from the water pump.

Disconnect the 2 front airbag sensor connectors.

Using a clip remover, detach the 4 clamps shown in the illustration from the radiator side.

HINT:

Tape the clip remover tip before use.

Remove the 4 bolts and radiator.

Disconnect the vacuum hose from the intake manifold.

for Unleaded Gasoline Specification Vehicle:
Disconnect the hose from the purge VSV.

Disconnect the No. 2 fuel hose from the pressure regulator.

Disconnect the No. 1 fuel hose from the pulsation damper.

1. Detach the lock claw by lifting up the cover, as shown in the illustration.
   

2. Check for foreign matter on the pipe and around the connector before disconnecting. Clean if necessary.
   





3. Disconnect the pipe from he connector.
   If the connector and the pipe are stuck together, pinch the connector, and push and pull the pipe to disconnect them.
   

   NOTICE:

   Do not use any tools in this procedure.

4. Check for foreign matter on the seal surface of the disconnected pipe. Clean if necessary.
   





5. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
   

Disconnect the ECM connectors.

1. Remove the glove compartment door.
   

2. Disconnect the 4 ECM connectors.
   

Remove the bolt and clamp, and disconnect the ground wire.

Remove the bolt and disconnect the ground wire from the frame.

Pull out the engine wire from the cabin.

Remove the engine room relay block cover (upper).

Remove the engine room relay block cover (side).

1. Using a screwdriver, detach the 4 claws and remove the relay block cover.
   

   HINT:

   Tape the screwdriver tip before use.

Remove the nut and disconnect the cable from the engine room junction block.

Disconnect the 2 engine room junction block connectors and disconnect the wire clamp.

Remove the bolt and disconnect the wire clamp from the front engine mounting bracket LH.

Remove the bolt and disconnect the sensor clamp.

Disconnect the oil pressure switch connector.

Remove the 2 bolts and disconnect the vane pump from the engine.

Support the vane pump securely.

Remove the bolt, dipstick guide and O-ring.

HINT:

Cover the dipstick guide hole to prevent foreign matter from entering it.

Disconnect the compressor connector.

Remove the 2 bolts and disconnect the suction hose from the engine.

Remove the 4 bolts and disconnect the compressor from the engine.

Support the cooler compressor securely.

Disconnect the washer nozzle hose.

Remove the 4 bolts and hood.

NOTICE:

Be careful not to damage the vehicle.

Remove the 2 bolts and 2 compression springs.

Disconnect the front pipe from the exhaust manifold and remove the gasket.

Remove the front pipe from the pipe support.

Place matchmarks on the yoke and differential flange.

Remove the 4 nuts, 4 bolts and 4 washers, and disconnect the propeller shaft.

Place matchmarks on the yoke and transfer flange.

Remove the 4 nuts, 4 washers and front propeller shaft.

Place matchmarks on the propeller shaft flange and transfer flange.

Remove the 4 nuts and 4 washers, and disconnect the propeller shaft.

Place matchmarks on the propeller shaft flange and differential flange.

Remove the 4 nuts, 4 bolts and 4 washers.

Remove the propeller shaft.

Disconnect the starter connector.

Disconnect the terminal cap.

Remove the nut and disconnect the starter wire.

Remove the 2 bolts and starter.

Remove the 2 bolts and clutch release cylinder.

Remove the manual transmission unit (Toyota Fortuner RM0000011B2004X.html).

Place matchmarks on the clutch cover and flywheel.

Loosen each set bolt one turn at a time until spring tension is released.

Remove the 6 set bolts and pull off the clutch cover.

NOTICE:

Do not drop the clutch disc.

Using a vernier caliper, measure the rivet head depth.

Minimum rivet depth:

0.3 mm (0.012 in)

Install the clutch disc to the transmission unit.

NOTICE:

Be careful not to insert the clutch disc facing the wrong direction.

Using a dial indicator, check the disc runout.

Maximum runout:

0.8 mm (0.031 in.)

Fix the crankshaft in place with SST.

SST

09213-54015(91651-60855)
09330-00021

Remove the 10 bolts and flywheel.

Remove the bolt and rear end plate.

Install the 2 engine hangers as shown in the illustration.

Torque:

42 N*m{428 kgf*cm, 31 ft.*lbf}

Attach the engine sling device and chain block to the engine hangers.

Remove the 4 bolts and 4 nuts holding the engine mounting bracket and frame.

Lift the engine out of the vehicle slowly and carefully.

NOTICE:

Make sure to disconnect all the wires, hoses and cables from the engine. Keep the disconnected wires, hoses and cables off of the engine.

Place the engine assembly onto the stand.

Disconnect the 4 ignition coil connectors and remove the 4 bolts and 4 ignition coils.

Remove the bolt and ventilation pipe.

Detach the terminal cap.

Remove the nut, bolt and generator wire.

Disconnect the generator connector.

Remove the 2 bolts and generator.

Disconnect the oil pressure sensor connector.

Disconnect the noise filter connector.

Disconnect the camshaft position sensor connector.

Disconnect the 4 injector connectors.

Disconnect the crankshaft position sensor connector.

Disconnect the oil control valve connector.

for Unleaded Specification Vehicle:
Disconnect the purge VSV connector.

Disconnect the throttle body connector.

Disconnect the engine coolant temperature sensor connector.

Disconnect the knock sensor connector.

Disconnect the wire harness from the clamps.

Remove the 2 bolts and wire harness from the engine.

Disconnect the throttle position sensor and control motor connector.

Disconnect the 2 water by-pass hoses.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket.

Disconnect the 4 clamps and wire harness from the delivery pipe.

Disconnect the vacuum hose.

Disconnect the 4 injector connectors.

Remove the 2 bolts and delivery pipe together with the 4 injectors.

Using 2 screwdrivers, pry out the 4 spacers from the cylinder head.

HINT:

Tape the screwdriver tips before use.

Pull out the 4 injectors from the delivery pipe.

Disconnect the crankshaft position sensor from the clamp.

Remove the 5 bolts, 2 nuts, intake manifold and gasket.

Remove the 5 bolts and heat insulator.

Remove the 6 nuts, exhaust manifold and gasket.

Remove the 5 bolts and compressor mounting bracket.

Remove the 3 bolts and belt tensioner.

Remove the bolt, 2 nuts, water inlet and gasket.

Remove the thermostat and gasket.

Remove the bolt, pulley plate, idler pulley and spacer.

Using a 24 mm deep socket wrench, remove the oil pressure switch.

Remove the 2 nuts, water by-pass pipe and gasket.

Remove the bolt and sensor.

Using a 19 mm deep socket wrench, remove the sensor and gasket.

Remove the bolt, sensor and O-ring.

Disconnect the sensor connector.

Disconnect the connector from the connector bracket.

Detach the harness clamp.

Remove the bolt and sensor.

Remove the bolt, oil control valve and O-ring.

Remove the 4 bolts and mounting bracket.

Remove the 4 bolts and mounting bracket.