Engine Assembly Removal

Disconnect the washer nozzle hose.

Remove the 4 bolts and hood.

Remove the 4 bolts and under cover.

Remove the 2 bolts and under cover.

Remove the oil filler cap.

Remove the oil drain plug, and drain the engine oil from the oil pan.

NOTICE:

Collect the oil in an oil disposal container.

Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

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

HINT:

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

R151:
Drain transmission oil (Toyota Fortuner RM0000011AV003X.html).

R151F:
Drain transmission oil (Toyota Fortuner RM0000011AF003X.html).

A340E:
Drain transmission fluid (Toyota Fortuner RM0000010NV00IX_01_0011.html).

Disconnect the MAF meter connector.

Loosen the hose clamp.

Remove the 2 bolts and air cleaner.

Remove the radiator assembly (Toyota Fortuner RM00000144G007X.html).

Remove the 3 bolts, 2 nuts and engine cover.

Disconnect the IAT sensor connector.

Disconnect the manifold absolute diesel pressure sensor connector.

Disconnect the vacuum hose from the manifold absolute pressure sensor.

Loosen the 2 clamps.

Remove the 4 bolts and CAC.

Remove the starter (Toyota Fortuner RM0000013XL00CX_01_0003.html).

Remove the 2 bolts and 2 compression springs.

Disconnect the front pipe from the outlet pipe and remove the gasket.

Remove the front pipe from the pipe support.

Front side:
Remove the propeller shaft (Toyota Fortuner RM0000010QG009X_01_0001.html).

Rear side:
Remove the propeller shaft (Toyota Fortuner RM000000ZZ3008X_01_0002.html).

R151:
Remove the transmission (Toyota Fortuner RM0000011B2004X_01_0019.html).

R151F:
Remove the transmission (Toyota Fortuner RM0000011AL003X_01_0024.html).

A340E:
Remove the transmission (Toyota Fortuner RM0000010NV00IX.html).

Remove the engine room relay block cover (upper).

Remove the No. 1 engine room relay block cover (side).

Remove the nut and disconnect the engine room J/B wire.

Disconnect the 2 engine room junction block connectors.

Remove the bolt and disconnect the ground cable.

for LHD:
Disconnect the 2 injector driver connectors.

for RHD:
Disconnect the 2 injector driver connectors.

for LHD:
Disconnect the connectors.

1. Disconnect the turbo motor driver connector.
   

2. Disconnect the 3 TCM connector.
   

3. Disconnect the 4 ECM connector.
   

for RHD:
Disconnect the connectors.

1. Disconnect the turbo motor driver connector.
   

2. Disconnect the 3 TCM connector.
   

3. Disconnect the 4 ECM connector.
   

Disconnect the 2 fuel hoses.

Disconnect the vacuum pump hose.

Disconnect the oil reservoir to pump hose.

Using 17 mm union nut wrench, disconnect the pressure feed tube.

Remove the 4 bolts and disconnect the cooler compressor.

HINT:

It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

Using SST, hold the crankshaft.

SST

09213-58013
09330-00021

Remove the 8 bolts, drive plate spacer, and drive plate ring gear.

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

09213-58013
09330-00021

Remove the 8 bolts and flywheel.

Remove the bolt and end plate.

Set the No. 1 engine hanger and No. 2 engine hanger to the locations shown in the illustration.

Engine hanger part No.:

Part Name	Part No.
No. 1 engine hanger	12284-30020
Bolt for No. 1 engine hanger	90105-T0164 or 91512-61014
No. 2 engine hanger	12282-67030
Bolt for No. 2 engine hanger	90119-T0065 or 91642-81030

Torque:

25 N*m{255 kgf*cm, 18 ft.*lbf} for No. 1 engine hanger bolt

60 N*m{612 kgf*cm, 44 ft.*lbf} for No. 2 engine hanger bolt

NOTICE:

Install the engine hangers with new bolts.

Hold the engine with the engine sling device and chain block.

Remove the 4 bolts and 4 nuts.

Remove the engine by operating the engine sling device and chain block.

Disconnect the engine wire from the engine.

Remove the bolt and water hose clamp.

Remove the wire harness clamp.

Remove the 6 bolts and timing belt cover.

Turn the crankshaft clockwise and align the timing marks as shown in the illustration.

Uniformly loosen the 2 bolts and remove the timing belt tensioner.

Remove the timing belt.

Using a 10 mm hexagon wrench, remove the bolt, timing belt idler and washer.

HINT:

1. 
   
2. When turning the camshaft while the timing belt is removed, turn the crankshaft 90° counterclockwise as shown in the illustration.
   
3. When installing the timing belt, return the camshaft to the timing marks and then turn the crankshaft clockwise until it aligns with the timing marks.
   

Using SST, remove the pulley bolt.

SST

09213-58013
09330-00021

Using SST, remove the pulley.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)

NOTICE:

Apply oil or grease to the threads and tip of SST (center bolt) before using it.

Remove the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

NOTICE:

Make sure to remove the bolt of the camshaft timing pulley with the timing belt not installed.

Remove the camshaft timing pulley.

Remove the bolt and insulator.

Move the 2 clamps and disconnect the 2 hoses.

Remove the 3 nuts, outlet elbow and gasket.

Remove the 2 bolts, 2 nuts, union bolt, inlet pipe and 3 gaskets.

NOTICE:

Do not loosen the nut labeled A.

Remove the 3 bolts and stay.

Remove the 8 nuts and exhaust manifold w/turbocharger.

Disconnect the terminal cap.

Remove the nut and generator wire.

Disconnect the generator connector.

Remove the 2 bolts and generator.

Remove the 4 bolts and belt tensioner.

Remove the 2 bolts and support bracket.

Remove the 2 bolts and support bracket.

Remove the 4 bolts and mounting bracket.

Remove the 2 bolts, water outlet and gasket.

Using a 12 mm deep socket wrench, remove the 4 glow plugs.

Remove the 2 bolts and stay.

Disconnect the 2 connectors.

Disconnect the vacuum hose from the 3 points shown in the illustration.

Remove the 2 bolts and bracket.

Disconnect the 2 connectors.

Remove the 2 bolts, 2 nuts, throttle body and gasket.

Remove the 3 bolts and bracket.

Remove the 2 nuts, bolt, gasket and air connector.

Remove the 2 bolts, 2 nuts, pipe and 2 gaskets.

Remove the EGR valve and gasket.

Using SST, remove the oil filter.

SST

09228-07501

HINT:

Insert the drain hose in the oil filter. Put the disposal container beneath the drain hose to collect the oil from the oil filter.

Remove the 2 nuts and No. 3 injection pipe clamp.

Remove the bolt and No. 2 injection pipe clamp.

Using union nut wrench, loosen the union nuts and remove the No. 1, No. 2 and No. 3 injection pipes.

1. Remove the 2 bolts and disconnect the 2 injection pipe clamps.
   





2. Using union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.
   

Disconnect the 2 fuel hoses.

Remove the check valve, 3 bolts, leakage pipe and gasket.

Remove the bolt and clamp.

Remove the bolt and oil dipstick guide.

Using union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

Disconnect the fuel pressure sensor connector.

Remove the 2 bolts and common rail.

NOTICE:

Do not remove the pressure limiter and pressure sensor.

Remove the bolt and clamp.

Remove the bolt and oil dipstick guide.

Using union nut wrench, loosen the union nuts and remove the fuel inlet pipe.

Disconnect the 2 fuel hoses.

Disconnect the 2 connectors.

Remove the 4 bolts indicated by the arrows in the illustration.

Remove the No. 2 camshaft timing pulley flange and pump drive shaft pulley.

Remove the set nut and O-ring while holding the crankshaft pulley using SST.

SST

09213-58013
09330-00021

Loosen the 2 nuts.

Using SST, disconnect the pump from the injection gear.

SST

09950-50013(09951-05010,09952-05010,09953-05020,09954-05021)

NOTICE:

Apply lubricant to the threads and tip of SST (center bolt) before using it.

Remove the 2 nuts and pump.

NOTICE:

1. Do not hold or carry the pump by holding the pipe.
   
2. The pump must be kept horizontal.
   

Remove the O-ring.

Remove the bolt, oil dipstick guide and O-ring.

Remove the O-ring from the oil dipstick guide.

Remove the 4 bolts, 2 nuts, manifold and gasket.

Disconnect the oil pressure switch connector and wire harness.

Remove the 13 bolts, 2 nuts and oil cooler cover.

Remove the 2 nuts, vacuum pump and 2 O-rings.

Remove the 2 nuts, vane pump and O-ring.

Remove the bolt, sensor and O-ring.

Remove the bolt, sensor and O-ring.

Using a 17 mm deep socket wrench, remove the sensor.

Remove the 4 bolts and mounting bracket.

Remove the 4 bolts and mounting bracket.