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 and seat belt pretensioner activation.

Disconnect the fuel pump connector.

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 P0171/25 (system too lean) may be set.

Crank the engine again, and 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.

Remove the radiator cap.

Loosen the 2 cylinder block drain cock plugs 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 engine under cover.

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

Disconnect the washer nozzle hose.

Remove the 4 bolts and hood.

Remove the 2 nuts and V-bank cover.

Disconnect the vacuum hose.

Disconnect the MAF meter connector.

Remove the 2 wire harness clamps.

Loosen the 2 hose clamps.

Remove the 2 bolts and air cleaner.

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.

Using a clip remover, remove the 2 clips.

Detach the claw and remove the deflector.

Using a clip remover, remove the 2 clips.

Detach the claw and remove the deflector.

Remove the 3 bolts and oil reservoir.

Disconnect the reservoir hose from the radiator tank upper.

Loosen the 4 nuts holding the fluid coupling fan.

Remove the drive belt (Toyota Fortuner RM000000YN4003X_01_0001.html).

Remove the 2 bolts holding the fan shroud.

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

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley from the water pump.

While releasing the belt tension by turning the belt tensioner counterclockwise, remove the V-ribbed belt from the belt tensioner.

Remove the 4 nuts and fan with fluid coupling.

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 oil pressure switch connector.

Remove the 2 bolts, and disconnect the vane pump.

NOTICE:

Do not hit other parts with the pulley when disconnecting the vane pump.

HINT:

Make sure to suspend the vane pump securely.

Disconnect the terminal cap.

Remove the nut and generator wire.

Disconnect the generator connector.

Remove the 2 bolts, adjusting bar and generator.

Disconnect the connector.

Detach the clamp from the cooler bracket.

Remove the 4 bolts, cooler bracket and compressor.

Remove the fuel pipe clamp.

Pinch the tube connector and then pull out the fuel pipe.

NOTICE:

1. 
   
2. Check if there is any dirt or mud around the connector before performing this procedure. Clean if necessary. Foreign matter can affect the quick connector O-ring's seal between the fuel pipe and fuel delivery pipe.
   
3. Do not use any tools in this procedure.
   
4. Do not bend or twist the nylon tube.
   
5. Keep the plug free from foreign objects.
   
6. To protect the fuel pipe, cover it with a plastic bag after checking it.
   
7. When the fuel pipe and fuel delivery pipe are stuck, pinch the nylon tube with your fingers, turn it carefully to free it and then disconnect the fuel pipe.
   

Remove the fuel pipe clamp.

Pinch the tube connector and then pull out the fuel pipe.

NOTICE:

1. 
   
2. Check if there is any dirt or mud around the connector before this procedure. Clean if necessary. Foreign matter can affect the quick connector O-ring's seal between the fuel pipe and fuel delivery pipe.
   
3. Do not use any tools in this procedure.
   
4. Do not bend or twist the nylon tube.
   
5. Keep the plug free from foreign objects.
   
6. To protect the fuel pipe, cover it with a plastic bag after checking it.
   
7. When the fuel pipe and fuel pressure regulator are stuck, pinch the nylon tube with your fingers, turn it carefully to free it and then disconnect the fuel pipe.
   

Disconnect the heater water inlet hose.

Disconnect the heater water outlet hose.

Disconnect the 2 water by-pass hoses.

Disconnect the purge line hose.

Disconnect the ventilation hose.

Disconnect the 2 VSV connectors.

Disconnect the throttle body with motor connector.

Separate the 3 wire harness clamps and hose clamp.

Remove the 2 bolts and throttle body bracket.

Remove the bolt and oil baffle plate.

Remove the 4 bolts and 2 surge tank stays.

Remove the 2 nuts.

Using an 8 mm hexagon socket wrench, remove the 4 bolts, intake air surge tank and gasket.

Disconnect the ECM connectors from the cabin:

1. Remove the glove compartment door.
   

2. Disconnect the 5 ECM connectors.
   

3. Disconnect the 4WD control ECU connector.
   

Remove the nut, and disconnect the ground wire.

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

Pull the end of the engine wire into the engine compartment.

Remove the upper relay block cover.

Remove the side relay block cover.

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 detach the wire clamp.

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

Disconnect the 2 A/F sensor connectors.

Disconnect the A.D.D. connector.

Disconnect the No. 2 engine wire from the cylinder block.

Remove the 2 nuts, gasket, pipe support and exhaust pipe.

Remove the front tires.

Remove the 10 clips and RH and LH fender seals.

Remove the 10 clips and RH and LH fender apron seals.

Remove the 6 nuts, exhaust manifold and gasket.

Remove the 6 nuts, exhaust manifold and gasket.

Disconnect the starter connector.

Remove the nut and disconnect the starter wire.

Remove the 2 bolts and starter.

Remove the automatic transmission from the vehicle (Toyota Fortuner RM0000013F6003X.html).

Manual transmission for 4WD:
Remove the manual transmission from the vehicle (Toyota Fortuner RM0000011B2004X.html).

Manual transmission for Pre runner:
Remove the manual transmission from the vehicle (Toyota Fortuner RM0000011AL003X.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 SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 8 bolts, rear spacer, drive plate and front spacer.

NOTICE:

Do not reuse the bolts.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 8 bolts and flywheel.

NOTICE:

Do not reuse the bolts.

Install the 2 engine hangers with 4 bolts as shown in the illustration.

Engine hanger part No. :

Item	Part No
No. 1 engine hanger	12281-31060
No. 2 engine hanger	12282-31040
Bolt	90119-08A87

Torque:

33 N*m{336 kgf*cm, 24 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 brackets to the frame.

Lift the engine out of the vehicle carefully.

NOTICE:

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

Install the engine assembly to a stand.

Remove the 4 bolts and engine mounting bracket with engine mounting insulator.

Remove the 3 bolts and engine mounting bracket with engine mounting insulator.

Remove the 3 bolts and idler pulley.

Remove the 5 bolts and V-ribbed belt tensioner.

Remove the 3 nuts, water inlet housing with thermostat and gasket.

Remove the 3 bolts, 2 nuts, oil filter bracket and gasket.

Disconnect the 6 fuel injector connectors.

Remove the 10 bolts, intake manifold and 2 gaskets.

Remove the 2 bolts and 2 camshaft timing oil control valves.

Disconnect the engine coolant temperature sensor connector.

Remove the 2 bolts, 4 nuts, water by-pass joint and 2 gaskets.

Remove the O-ring from the water outlet pipe.

Remove the 2 nuts, oil filler cap housing and gasket.

Remove the 6 bolts and 6 ignition coils.

Remove the oil dipstick gauge.

Remove the bolt and pull out the oil dipstick gauge guide.

Remove the O-ring from the oil dipstick gauge guide.

w/ Idler Pulley Cover Plate:

1. Remove the bolt, No. 2 idler pulley cover plate, idler pulley and idler pulley cover plate.
   

w/o Idler Pulley Cover Plate:

1. Remove the bolt, No. 2 idler pulley cover plate and idler pulley.
   

for Integrated Type:
Remove the 2 bolts and 2 No. 2 idler pulleys.

Remove the bolt and idler pulley.