Engine Assembly Removal

Remove the radiator cap.

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Loosen the cylinder block drain cock plug and radiator drain cock plug to 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.

Clean and install the oil drain plug with a new gasket.

Torque:

38 N*m{382 kgf*cm, 28 ft.*lbf}

Remove the filler plug and gasket.

Remove the drain plug and gasket to drain the manual transmission oil.

Install a new gasket and the drain plug.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Disconnect the vacuum hose.

Disconnect the No. 2 PCV hose.

Disconnect the mass air flow meter connector and detach the wire harness clamps.

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

Put protective tape around the radiator grille.

Remove the 2 clips and 2 screws.

Detach the 6 claws and remove the radiator grille.

Disconnect the radiator hose inlet from the radiator.

Disconnect the radiator hose outlet from the radiator.

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

NOTICE:

When removing the fan and generator V belt, do not use the idle pulley's bolt.

HINT:

After removing the fan and generator V belt, move the tensioner upward as far as possible.

Disconnect the reservoir hose from the radiator.

Loosen the 4 nuts holding the fluid coupling fan.

Remove the fan and generator V belt (HILUX_TGN26 RM000000YMP01PX_01_0001.html).

Remove the 2 bolts holding the fan shroud.

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

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley from the engine water pump.

Disconnect the oil cooler inlet hose from the radiator.

Disconnect the oil cooler outlet hose from the radiator.

w/ Airbag System:

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

   HINT:

   Tape the clip remover tip before use.

Remove the 4 bolts and radiator.

Disconnect the heater water inlet hose and heater water outlet hose from the heater pipe.

Disconnect the vacuum hose (for the brake master cylinder).

Disconnect the purge line hose.

Loosen the clamp and disconnect the No. 4 air injection system hose.

Disconnect the No. 2 fuel hose.

Disconnect the No. 1 fuel hose (HILUX_TGN26 RM000000YL401AX.html).

Disconnect the fuel hose.

Disconnect the ECM connectors from the cabin.

1. Remove the glove compartment door.
   

2. Disconnect the 4 ECM connectors.
   

Disconnect the air injection driver connector.

Pull out the engine wire from the cabin.

Disconnect the air fuel ratio sensor connector.

Remove the bolt and disconnect the sensor bracket from the right side of the frame.

Remove the bolt and disconnect the ground wire from the left side of the frame.

Remove the nut and disconnect the ground wire from the body.

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.
   

   Text in Illustration

   *a

   Pull

   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 wire clamp.

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

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, engine oil level dipstick guide and O-ring.

NOTICE:

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

Remove the bolt and disconnect the suction hose from the engine.

Disconnect the cooler compressor connector.

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.

Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

Disconnect the heated oxygen sensor connector and detach the wire harness clamp.

Remove the 4 bolts, 2 nuts and 2 compression springs.

Remove the front exhaust pipe from the exhaust pipe support.

Place matchmarks on the propeller shaft flange and differential flange.

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

Place matchmarks on the propeller shaft flange and transfer flange.

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

Place matchmarks on the propeller shaft flange and differential flange.

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

Remove the 2 set bolts and 2 plates of the center support bearing from the frame crossmember.

Pull out the propeller shaft.

Install SST to the extension housing to prevent oil leakage.

SST

09325-40010

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 2 set bolts and 2 plates of the center support bearing from the frame crossmember.

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 disconnect the release cylinder assembly.

Remove the 4 bolts and rear No. 1 engine mounting insulator.

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 SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 10 bolts and flywheel.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 10 bolts, rear drive plate spacer, drive plate and front drive plate spacer.

Remove the bolt and disconnect the No. 1 water by-pass pipe from the rear end plate.

Remove the bolt and rear end plate.

Install 2 engine hangers with 2 bolts.

Torque:

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

HINT:

Attach an engine sling device to the engine hangers.

Remove the 4 bolts and 4 nuts holding the engine mounting brackets to the frame.

Lift the engine out of the vehicle slowly and carefully.

Text in Illustration

Lift

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.

Install the engine to an engine stand with bolts.

NOTICE:

1. 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.
   
2. 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.
   

Remove the 2 bolts and 2 engine hangers.