Engine Assembly Removal

Start the engine.

Turn the A/C switch on.

Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

Stop the engine.

Recover the refrigerant from the A/C system using a refrigerant recovery unit.

Remove the 2 nuts and No. 1 engine cover.

Remove the 7 clips and upper radiator support seal.

Remove the 2 hood stay bolts. Then disconnect the 2 hood supports.

NOTICE:

1. Avoid touching the stroke portions of the rod as much as possible to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing.
   
2. Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks.
   
3. Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed.
   
4. Remove the hood support while supporting the hood by hand.
   

Remove the 4 bolts and hood.

Remove the 3 bolts and screw.

Loosen the clip and remove the front fender splash shield LH.

Remove the 3 bolts and 2 screws.

Loosen the clip and remove the front fender splash shield RH.

Remove the 10 bolts and No. 1 engine under cover.

Remove the 2 bolts and No. 2 engine under cover.

Remove the 4 bolts and oil pan protector assembly.

Remove the 6 bolts and oil pan protector assembly LH.

Remove the 4 bolts and oil pan protector assembly RH.

Loosen the radiator drain cock plug.

Remove the radiator reservoir cap to drain the coolant in the radiator.

Loosen the oil filter bracket drain cock plug to drain the coolant in the engine.

Tighten the radiator drain cock plug by hand.

Tighten the oil filter bracket drain cock plug.

Torque:

13 N*m{133 kgf*cm, 10 ft.*lbf}

Remove the oil filler cap.

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

Install a new gasket and the oil pan drain plug.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Disconnect the 4 wire harness clamps.

Remove the 2 nuts and No. 3 engine room wire.

Loosen the hose clamp.

Disconnect the mass air flow meter connector and using a clip remover, detach the wire harness clamp from the air cleaner cap.

Detach the 4 clamps and remove the air cleaner cap.

Using a clip remover, detach the wire harness clamp.

Remove the 3 bolts and air cleaner case.

Loosen the hose clamp and remove the No. 1 air cleaner hose.

w/ Viscous Heater:
Disconnect the 2 connectors from the viscous with magnet clutch heater and water temperature sensor.

w/o Viscous Heater:
Disconnect the connector from the water temperature sensor.

Using a clip remover, detach the 3 wire harness clamps.

Loosen the 2 hose clamps and remove the 2 bolts and intake air connector.

Insert a screwdriver between the reservoir and oil reservoir bracket, push the claw, and then disconnect the reservoir by pulling it upwards.

Remove the 2 bolts and bracket.

Disconnect the 2 hoses.

Remove the 3 bolts and radiator reservoir.

Loosen the lock nut and turn the bolt counterclockwise.

Remove the V-ribbed belt.

Remove the bolt, cover, No. 1 idler pulley and collar.

Remove the nut and No. 3 idler pulley.

Using a wrench to the V-ribbed belt tensioner bracket, turn the wrench clockwise and remove the V-ribbed belt.

Remove the 3 clips and front fender apron seal front RH.

Remove the 4 clips and front fender apron seal rear RH.

w/o KDSS:
Remove the 4 clips and front fender apron seal front LH.

w/ KDSS:
Remove the 3 clips and front fender apron seal front LH.

Remove the 4 clips and front fender apron seal rear LH.

Disconnect the inlet and outlet No. 1 oil cooler hose.

Disconnect the inlet No. 2 and No. 3 oil cooler hoses.

Disconnect the inlet No. 4 oil cooler hose.

Remove the 2 bolts and transmission oil cooler tube.

Loosen the 4 nuts holding the fluid coupling fan.

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 fluid coupling fan.

Put protective tape around the front bumper winch cover sub-assembly.

Using moulding remover A, detach the 2 claws.

Detach the 2 guides and remove the front bumper winch cover sub-assembly as shown in the illustration.

Detach the 10 claws, and remove the radiator grille assembly.

Using a T30 "TORX" socket, remove the 3 screws.

HINT:

Use the same procedure for the other side.

Remove the 2 screws and 4 bolts.

Remove the 3 screws.

Remove the 3 clips.

Put protective tape around the front bumper cover.

HINT:

Use the same procedure for the other side.

Detach the 3 claws.

HINT:

Use the same procedure for the other side.

Remove the front bumper cover.

w/ TOYOTA Parking Assist-sensor System or w/ Fog Light:
Disconnect the No. 4 engine room wire connector.

w/ Headlight Cleaner System:
Disconnect the headlight cleaner hose.

w/ Multi-terrain Monitor:
Disconnect the connector.

w/ Dynamic Radar Cruise Control System:
Disconnect the connector.

Remove the 4 bolts and transmission oil cooler air duct.

Using a clip remover, remove the 4 clips, and remove the radiator side deflector RH.

Using a clip remover, remove the 4 clips, and remove the radiator side deflector LH.

Remove the 4 bolts and radiator.

w/ DPF:
Disconnect the 2 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

w/o DPF:
Disconnect the 3 fuel tubes from the No. 1 and No. 3 fuel tube clamps.

Loosen the No. 1 air hose clamp.

Disconnect the turbo pressure sensor connector, intake air temperature sensor connector and vacuum hose.

Remove the 3 nuts, bolt and No. 1 cool air inlet.

Remove the gasket from the air tube RH.

Loosen the No. 2 air hose clamp.

Remove the 3 nuts, bolt and No. 2 cool air inlet.

Remove the gasket from the air tube LH.

Disconnect the wire harness clamp from the No. 2 engine oil level dipstick guide.

Disconnect the ventilation hose from the cylinder head cover RH.

Remove the 2 bolts and No. 2 engine oil level dipstick guide.

Remove the O-ring from the No. 2 engine oil level dipstick guide.

Loosen the hose clamp.

Remove the air tube from the throttle body.

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket from the intake pipe.

Disconnect the 2 flexible hose tubes from the clutch hose with a 10 mm union nut wrench while holding the flexible hose with a wrench.

NOTICE:

1. Do not bend or damage the flexible hose tubes.
   
2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tubes from the connecting point.
   

Remove the 2 clips.

Remove the bolt and clutch hose.

Loosen the hose clamp.

Remove the air tube from the throttle body.

Using a 10 mm union nut wrench, disconnect the tube connector to flexible hose tube from the clutch tube to release cylinder 2 way.

NOTICE:

1. Do not bend or damage the flexible hose tube.
   
2. Do not allow any foreign matter such as dirt and dust to enter the flexible hose tube from the connecting point.
   

Remove the 2 bolts and tube connector to flexible hose tube.

Disconnect the hose from the intake pipe.

Remove the No. 1 gas filter.

for Manual Transmission:

1. Remove the bolt and disconnect the clutch tube to release cylinder 2 way from the No. 3 intercooler support bracket.
   

Remove the 2 bolts and No. 3 intercooler support bracket.

Disconnect the throttle position sensor connector.

Disconnect the throttle motor connector.

Remove the 2 bolts, 2 nuts and throttle body.

Remove the gasket from the intake pipe.

Loosen the hose clamp and remove the No. 1 air hose.

Disconnect the wire harness from the clamp.

Remove the nut and ground wire.

Remove the bolt and disconnect the wire harness bracket.

Loosen the hose clamp and remove the bolt and No. 3 air tube.

Remove the bolt and No. 1 air tube.

Remove the O-ring.

Loosen the hose clamp and remove the No. 2 air hose.

Remove the bolt and disconnect the suction hose.

Loosen the hose clamp and remove the bolt and No. 4 air tube.

Remove the bolt and No. 2 air tube.

Remove the O-ring.

Disconnect the ventilation hose from the oil separator.

Loosen the hose clamp.

Remove the bolt and No. 2 air cleaner pipe.

Remove the bolt and disconnect the discharge hose from the cooler compressor.

Remove the O-ring from the discharge hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

Remove the bolt and disconnect the suction hose from the cooler compressor.

Remove the O-ring from the suction hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

Disconnect the 4 connectors.

Using a clip remover, detach the 3 wire harness clamps.

Remove the 4 bolts and cooler compressor.

w/ Intercooler:
Disconnect the vacuum hose.

Loosen the hose clamp, and remove the bolt and No. 2 intake air connector pipe.

Remove the 4 bolts and disconnect the 4 water hose ends, and then remove the heater water pipe.

Loosen the hose clamp.

Remove the bolt and No. 1 air cleaner pipe.

w/ DPF:

w/o DPF:

Remove the 2 bolts and disconnect the 2 water hose ends, and then remove the No. 3 water by-pass pipe.

w/ EGR System:

1. Remove the 2 bolts and nut.
   
   

   
   
   
   
   

   Text in Illustration

   *A

   w/ DPF

   *B

   w/o DPF

2. w/ DPF:
   Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
   

3. w/o DPF:
   Disconnect the 4 water hose ends, and then remove the No. 4 water by-pass pipe.
   

w/o EGR System:

1. Remove the 2 bolts and nut.
   

2. Disconnect the 3 water hose ends, and then remove the No. 4 water by-pass pipe.
   

LH Side:

1. w/ DPF:
   Disconnect the 7 connectors from the injector driver.
   

   Text in Illustration

   *A	w/ DPF
   *B	w/o DPF

2. w/o DPF:
   Disconnect the 4 connectors from the injector driver.
   

3. Disconnect the 2 connectors and detach the wire harness holder from the relay block.
   

4. Remove the bolt and disconnect the ground wire.
   

5. Disconnect the wire harness from the wire harness clamp holder.
   





6. Remove the bolt and disconnect the ground wire from the body panel.
   

7. Using a clip remover, detach the ground wire clamp labeled A from the relay block side.
   

8. Disconnect the wire harness from the wire harness clamp holder labeled B.
   





9. Remove the nut and detach the generator positive (+) cable holder from the relay block.
   

10. Disconnect the generator positive (+) cable from the 2 clamps.
    





11. Disconnect the 2 connectors.
    

12. Using a clip remover, detach the 3 wire harness clamps.
    





13. for RHD:
    Disconnect the 4 connectors and detach the wire harness tab labeled A from the relay block.
    

14. for RHD:
    Disconnect the ECM connector.
    

15. for RHD:
    Disconnect the wire harness from the wire harness clamp holder.
    





16. Disconnect the 8 connectors.
    
    

    
    
    
    
    

    Text in Illustration

    *A

    w/ DPF

    *B

    w/o DPF

17. Remove the bolt and the engine wire harness bracket labeled B.
    

18. Using a clip remover, detach the wire harness clamp labeled D.
    

19. Remove the 2 bolts and disconnect the engine wire protector labeled A.
    

20. for RHD:
    Disconnect the wire harness from the wire harness clamp holder labeled C.
    

RH Side:

1. for LHD:
   Disconnect the 4 connectors, and detach the wire harness holder from the relay block labeled A.
   

2. for LHD:
   Disconnect the ECM connector.
   

3. for LHD:
   Disconnect the wire harness from the wire harness clamp holder.
   





4. Disconnect the 7 connectors.
   
   

   
   
   
   
   

   Text in Illustration

   *A

   w/ DPF

   *B

   w/o DPF

5. Using a clip remover, detach the wire harness clamp.
   

6. Remove the 3 bolts and disconnect the engine wire protector labeled A.
   

7. Remove the bolt and the wire harness bracket labeled B.
   

8. Remove the screw grommet, nut and the glow plug wire harness labeled C.
   





9. for RHD:
   Disconnect the wire harness from the wire harness clamp holder.
   

   Text in Illustration

   *A	w/ DPF
   *B	w/o DPF

10. for RHD:
    Remove the bolt and wire harness clamp holder.
    





11. w/ Winch:
    Remove the bolt and disconnect the ground wire.
    

Rear Side:

1. Using a clip remover, detach the wire harness clamp.
   

   Text in Illustration

   *A	w/ DPF
   *B	w/o DPF

2. Remove the 2 bolts and 2 ground wires labeled C.
   

3. Remove the 2 bolts and disconnect the engine wire harness protector labeled B.
   

4. w/ DPF:
   Disconnect the 3 connectors.
   

5. w/o DPF:
   Disconnect the connector.
   

6. Remove the screw grommet, nut and disconnect the glow plug wire harness labeled A.
   

Disconnect the fuel hose from the No. 5 nozzle leakage pipe.

Remove the bolt and No. 2 injection pipe clamp.

Remove the union bolt and gasket.

Remove the bolt, nut and No. 2 fuel pipe.

w/ EGR System:

1. Using a union nut wrench, loosen the No. 6 injection pipe ends.
   

2. Remove the 2 nuts and 2 No. 2 injection pipe clamps.
   

3. Remove the No. 6 injection pipe.
   

w/o EGR System:

1. Using a union nut wrench, loosen the No. 6 injection pipe ends.
   

2. Remove the nut and No. 2 injection pipe clamp.
   

3. Remove the bolt and No. 6 injection pipe.
   

Disconnect the 2 vacuum hoses.

Remove the bolt and vacuum switching valve.

Disconnect the 2 vacuum hoses.

Remove the 3 bolts and vacuum transmitting pipe.

Remove the 4 bolts and cylinder head cover silencer.

Disconnect the fuel hose.

Remove the fuel check valve, No. 4 nozzle leakage pipe and gasket.

w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.

Using a union nut wrench, remove the 4 injection pipes.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

Remove the No. 4 fuel hose.

Remove the union bolt, gasket, bolt, and No. 2 fuel pipe.

w/ DPF:

1. Disconnect the fuel hose.
   





2. Remove the union bolt, gasket and No. 5 nozzle leakage pipe.
   

w/o DPF:
Remove the union bolt, gasket and No. 5 nozzle leakage pipe.

Remove the 2 bolts and common rail.

NOTICE:

1. Do not remove the fuel pressure limiter from the common rail. If it is removed, replace the common rail.
   
2. w/ DPF:
   Do not remove the pressure discharge valve from the common rail. If it is removed, replace the common rail.
   

w/ DPF:

1. Remove the bolt and No. 2 injection pipe clamp.
   

2. Disconnect the fuel hose.
   

3. Remove the union bolt, nut, bolt, fuel filter to injection pump fuel pipe and gasket.
   

w/o DPF:

1. Disconnect the 2 hoses from the fuel pipe.
   

2. Remove the bolt and fuel filter to injection pump fuel pipe.
   

Remove the bolt and disconnect the connector from the fuel supply pump.

Using a union nut wrench, remove the No. 5 injection pipe.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail hole or injection pump hole, cover the holes with protective tape.

Remove the 4 bolts and cylinder head cover silencer.

w/ Intercooler:
Remove the 2 nuts and 4 injection pipe clamps.

Using a union nut wrench, remove the 4 injection pipes.

NOTICE:

After removing an injection pipe, to prevent dirt or foreign objects from entering the common rail holes or injector holes, cover the holes with protective tape.

Remove the 2 bolts and common rail.

NOTICE:

Do not remove the fuel pressure sensor from the common rail. If it is removed, replace the common rail.

Detach the 2 clamps and remove the connecting wire.

Remove the 2 injector hollow screws, 3 bolts, No. 3 nozzle leakage pipe and 2 gaskets.

w/ EGR System:
Remove the 2 nuts, 6 bolts, intake pipe and 2 gaskets.

w/o EGR System:
Remove the 2 nuts, 4 bolts, intake pipe and gasket.

Remove the 3 bolts and using a clip remover, detach the 2 wire harness clamps, and then disconnect the No. 2 engine wire.

Remove the 16 bolts, No. 3 intake manifold and 2 gaskets.

Remove the 2 bolts and EGR pipe insulator.

Remove the 10 bolts, EGR valve with EGR cooler and 2 gaskets.

Disconnect the No. 5 water by-pass hose from the water by-pass outlet.

Disconnect the No. 1 fuel hose from the fuel cooler.

Remove the union bolt, bolt, No. 3 nozzle leakage pipe and gasket.

NOTICE:

After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

Disconnect the No. 2 fuel hose from the fuel cooler.

Remove the union bolt, bolt, No. 4 nozzle leakage pipe and gasket.

NOTICE:

After removing the nozzle leakage pipe, to prevent dirt or foreign objects from entering the nozzle leakage pipe, cover the nozzle leakage pipe ends with plastic bags.

Remove the 2 bolts and fuel cooler.

Detach the hose clamp.

Remove the bolt and No. 2 fuel injector protector.

Remove the bolt and No. 1 fuel injector protector.

Disconnect the 3 fuel tube connectors (Click here).

Detach the 3 clamps and remove the fuel tube.

Remove the union bolt, bolt, No. 1 water by-pass pipe and gasket.

Remove the 4 injector hollow screws and 4 gaskets.

Text in Illustration

	Injector Hollow Screw
	Bolt

Remove the 2 bolts and No. 2 nozzle leakage pipe.

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the 4 injector hollow screws and 4 gaskets.

Text in Illustration

	Injector Hollow Screw
	No. 2 Check Valve
	Union Bolt

Remove the No. 2 check valve from the fuel tube and No. 1 nozzle leakage pipe.

Remove the union bolt and No. 1 nozzle leakage pipe.

NOTICE:

1. When removing the nozzle leakage pipe, place a cushion under the pipe.
   
2. Be careful not to deform or scratch the union seal surface.
   
3. After removing the nozzle leakage pipe, put it in a plastic bag to prevent foreign matter from contaminating its injector inlet.
   

Remove the bolt and fuel hose bracket.

Remove the 2 bolts and 2 No. 1 fuel pipe clamps.

Remove the 9 bolts, No. 1 intake manifold and gasket.

Remove the 9 bolts, No. 2 intake manifold and gasket.

Install the No. 1 and No. 2 engine hangers to the cylinder head RH and LH with the 4 bolts as shown in the illustration.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

HINT:

Remove the bolt and clutch release cylinder to flexible hose tube.

Attach an engine sling device and hang the engine with a chain block.

Remove the 4 bolts from the engine mounting RH and LH side.

Lift the engine out of the vehicle carefully.

NOTICE:

1. Make sure the engine is clear of all wiring and hoses.
   
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.
   
3. 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.
   

Place the engine onto a work bench.

Put matchmarks on the clutch cover and flywheel.

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

Remove the 8 set bolts, and pull off the clutch cover.

NOTICE:

Do not drop the clutch disc.

Using a wrench, hold the crankshaft.

NOTICE:

Do not turn the crankshaft counterclockwise.

If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt (Click here).

Torque:

108 N*m{1101 kgf*cm, 80 ft.*lbf}or more

Remove the 8 bolts.

Remove the rear drive plate spacer labeled A, drive plate and ring gear labeled B and rear crankshaft balancer weight labeled C.

Using a wrench, hold the crankshaft.

NOTICE:

Do not turn the crankshaft counterclockwise.

If it is turned counterclockwise, check that the crankshaft pulley set bolt is not loose. If loose, tighten the bolt (Click here).

Torque:

108 N*m{1101 kgf*cm, 80 ft.*lbf}or more

Remove the 8 bolts and flywheel.

Install the engine onto an engine stand with bolts.

Remove the 4 bolts and No. 1 and No. 2 engine hangers.

Disconnect the vacuum hose.

Remove the nut and mounting insulator.

Remove the nut and mounting insulator.