Engine removal (4JJ3 without DPD)

1. Preliminary and post procedures

1. Preliminary procedures

1) Open the engine hood.

2) Disconnect the battery cable from the battery negative terminal.

Caution

  • After turning OFF the ignition switch (power mode for models with passive entry and start system), do not disconnect the battery cable within 3 minutes.
  • If the battery cable is disconnected within 3 minutes, the vehicle electronic control system may malfunction.
  • If the battery cable is disconnected, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function after connecting the battery negative terminal.

3) Raise the vehicle.

2. Underguard removal

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard removal".

3. Coolant drain

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

1) Remove the radiator cap from the radiator.

2) Loosen the radiator drain plug, and drain the coolant into a pan.

3) Loosen the drain plug on the cylinder block, and drain the coolant to a pan.

Legend

  1. Drain plug

4) Apply LOCTITE 262 or equivalent to the threaded portion of the cylinder block side drain plug.

5) Tighten the drain plug on the cylinder block.

Tightening torque: 21.6 N・m { 2.2 kgf・m / 16 lb・ft }

6) Tighten the radiator drain plug.

4. Exhaust pipe removal

Refer to "1.Engine 1G.Exhaust(4JJ3 without DPD) exhaust pipe removal".

5. Air duct removal

1) Remove the intake air duct from the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the PCV hose from the cylinder head cover and air duct.

Legend

  1. PCV hose
  2. Clamp

3) Remove the air duct from the air cleaner and turbocharger.

Legend

  1. Air duct

6. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Remove the air cleaner from the vehicle.

Legend

  1. Air cleaner
  2. MAF and IAT sensor

7. Intake hose removal

1) Remove the intake hose from the intercooler and turbocharger.

Legend

  1. Clamp
  2. Intake hose

8. Air intake hose removal

1) Remove the air intake hose from the intake throttle valve and intercooler.

Legend

  1. Air intake hose
  2. Clamp

9. Transmission removal

Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission removal".

10. Clutch removal

Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch removal".

11. Battery removal

1) Disconnect the battery ground cable from the frame.

2) Disconnect the battery cable from the battery.

3) Remove the battery bracket from the frame.

4) Remove the battery from vehicle.

Legend

  1. Battery cable
  2. Battery bracket
  3. Battery ground cable

12. Oil level gauge guide tube removal

1) Remove the oil level gauge from the oil level gauge guide tube.

2) Remove the oil level gauge guide tube from the crankcase.

Caution

  • Do not reuse the O-ring.

13. Fuse box disconnect

1) Remove the fuse box cover from the fuse box.

2) Disconnect the engine harness from the fuse box.

3) Disconnect the battery harness from the fuse box.

14. Radiator upper hose removal

1) Remove the radiator upper hose from the thermostat and radiator.

Legend

  1. Radiator upper hose

15. Radiator reserve tank removal

1) Disconnect the radiator reserve tank hose from the radiator.

2) Remove the radiator reserve tank from the fan guide.

16. A/C compressor drive belt removal

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the A/C compressor drive belt from the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. A/C compressor drive belt

17. A/C compressor disconnect

1) Disconnect the A/C compressor from the A/C compressor bracket.

Legend

  1. A/C compressor bracket
  2. A/C compressor

18. Fan guide removal

1) Remove the fan shroud from the fan guide.

2) Remove the fan guide from the radiator.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

19. Cooling fan belt removal

1) Loosen the tension pulley lock nut.

2) Loosen the tension pulley adjust bolt.

3) Remove the cooling fan belt from the following parts.

  • Fan pulley
  • Generator
  • Crankshaft pulley

Legend

  1. Adjust bolt
  2. Cooling fan belt
  3. Lock nut

20. Cooling fan removal

1) Remove the cooling fan and cooling fan clutch as a set from the water pump.

2) Remove the fan pulley from the water pump.

21. Glove box removal

1) Remove the glove box from the instrument panel.

RHD

Legend

  1. Glove box

LHD

Legend

  1. Glove box

22. Instrument panel passenger-side lower cover removal

1) Remove the instrument panel passenger-side lower cover from the instrument panel.

RHD

Legend

  1. Instrument panel passenger-side lower cover
  2. Clip

LHD

Legend

  1. Instrument panel passenger-side lower cover
  2. Clip

2) Disconnect the connector from the instrument panel passenger-side lower cover.

23. ECM disconnect

1) Disconnect the connector from the ECM.

2) Pull out the harness to the engine room side.

3) Disconnect the harness from the frame.

24. Vacuum hose disconnect

1) Disconnect the vacuum hose from the vacuum pipe.

25. Fuel hose disconnect

1) Disconnect the fuel feed hose from the fuel supply pump.

2) Disconnect the fuel return hose from the fuel leak-off pipe.

Legend

  1. Fuel feed hose
  2. Fuel return hose

26. Power steering oil pump disconnect

1) Disconnect the power steering oil pump and power steering oil hose as a set from the timing gear case.

Legend

  1. Power steering oil pump
  2. Nut

2) Remove the power steering oil hose from the bracket.

Legend

  1. Bracket

27. Radiator lower hose disconnect

1) Disconnect the radiator lower hose from the water intake pipe.

Legend

  1. Radiator lower hose

28. Engine removal

1) Install special tool to the cylinder head.


SST: 5-8840-2886-0 - rear engine hanger

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the wire to the engine hanger and hoist.

3) Hold up the engine as high as not to be lifted up.

4) Disconnect the engine mounting from the engine foot.

Note

  • Loosen the engine mounting fixing bolts from above the engine using an extension bar that is 600 mm {23.6 in} or longer.

Engine left side

Engine right side

5) Remove the engine from vehicle.

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