Removal

1UR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PRECAUTION

NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Service Precautions.

2. DISCHARGE FUEL SYSTEM PRESSURE Removal

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

4. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

(a) Remove the front wiper motor and link Removal.

5. REMOVE NO. 1 ENGINE UNDER COVER Replacement

6. DRAIN ENGINE OIL Replacement

7. DRAIN ENGINE COOLANT Service and Repair

8. REMOVE HOOD SUB-ASSEMBLY

(a) Using a screwdriver, release the 2 clips and remove the 2 hood supports assembly.





HINT
Tape the screwdriver tip before use.

CAUTION:
Remove the hood support assembly while supporting the hood by hand.

(b) Remove the 4 bolts and hood.

9. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Raise the front of the V-bank cover to detach the 2 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.





10. REMOVE AIR CLEANER HOSE ASSEMBLY

(a) Disconnect the vacuum sensing hose and ventilation hose.





(b) Loosen the 2 clamps.

(c) Remove the air cleaner hose.

11. REMOVE AIR CLEANER ASSEMBLY

(a) Remove the air cleaner cap.





(1) Disconnect the MAF meter connector.

(2) Using a clip remover, detach the wire harness clamp.

(3) Unfasten the 4 hook clamps and then remove the air cleaner cap.

(b) Remove the air cleaner element.

(c) Remove the 2 bolts and air cleaner case.





12. REMOVE COWL TOP OUTER PANEL SUB-ASSEMBLY Removal

13. REMOVE FRONT FENDER APRON SEAL RH Removal

14. REMOVE FRONT FENDER APRON SEAL REAR RH Removal

15. REMOVE FRONT FENDER APRON SEAL LH Removal

16. REMOVE FRONT FENDER APRON SEAL REAR LH Removal

17. REMOVE INLET RADIATOR HOSE Removal

18. DISCONNECT OUTLET RADIATOR HOSE Removal

19. REMOVE RADIATOR SIDE DEFLECTOR RH Removal

20. REMOVE RADIATOR SIDE DEFLECTOR LH Removal

21. REMOVE FAN AND GENERATOR V BELT Removal

22. REMOVE FAN SHROUD Removal

23. REMOVE RADIATOR ASSEMBLY Removal

24. DISCONNECT NO. 12 WATER BY-PASS HOSE Removal

25. DISCONNECT NO. 13 WATER BY-PASS HOSE Removal

26. REMOVE EGR VALVE ASSEMBLY Removal

27. REMOVE EGR VALVE BRACKET Removal

28. REMOVE VENTILATION HOSE ASSEMBLY Removal

29. REMOVE AIR TUBE SUB-ASSEMBLY LH Removal

30. REMOVE INTAKE MANIFOLD Removal

31. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp.





(b) Disconnect the No. 1 fuel pipe Service Precautions.

32. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY





(a) Disconnect the No. 2 fuel tube Service Precautions.

33. DISCONNECT WIRE HARNESS AND HOSE





(a) Disconnect the clamp and ECM connector.

HINT
Refer to the following procedures to disconnect the ECM connector Removal.





(b) Disconnect the No. 4 water by-pass hose.

(c) Disconnect the 2 heater hoses.









(d) Disconnect the 4 connectors from the connector holder block.





(e) Remove the bolt and disconnect the clamp and ground wire.

(f) Disconnect the air pump connector and 2 clamps.

(g) Remove the nut and connector bracket.

(h) Disconnect the air injection system hose.

(i) Remove the nut and disconnect the wire from the positive (+) battery cable.





(j) Disconnect the cable from the positive (+) battery terminal.

(k) Remove the bolt and disconnect the ground wire.

(l) Disconnect the 4 air injection control driver connectors.

(m) Remove the nut and disconnect the wire and 2 clips from the engine room junction block.

(n) Disconnect the 2 connectors and 2 clips from the engine room junction block.

34. DISCONNECT COOLER COMPRESSOR ASSEMBLY Removal

35. DISCONNECT VANE PUMP ASSEMBLY Removal

36. DISCONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ Trailer Towing System)





(a) Remove the 2 bolts and disconnect the oil cooler tube.

37. REMOVE GENERATOR ASSEMBLY Removal (from 08/2011)

38. REMOVE PROPELLER SHAFT ASSEMBLY

(a) for 2WD:

Refer to the following procedures Removal (from 08/2011).

(b) for 4WD:

Refer to the following procedures Removal (from 08/2011).

39. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

(a) Remove the front propeller shaft .

40. REMOVE EXHAUST PIPE ASSEMBLY

(a) for Regular Cab Standard Deck:

Refer to the following procedures Removal.

(b) except Regular Cab Standard Deck:

Refer to the following procedures Removal.

41. DISCONNECT NO. 1 WATER BY-PASS PIPE

(a) Remove the 3 bolts and disconnect the No. 1 water by-pass pipe.





42. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE Removal

43. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY Removal

44. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Removal

45. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Removal

46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal

47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal

48. REMOVE STARTER COVER Removal (from 08/2011)

49. REMOVE STARTER ASSEMBLY Removal (from 08/2011)

50. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

(a) for 2WD:

Refer to the following procedures Removal.

(b) for 4WD:

Refer to the following procedures .

51. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for 2WD) Removal

52. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for 4WD)

53. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.





SST : 09213-70011

SST : 09330-00021

(b) Remove the 10 bolts, rear drive plate spacer, drive plate and crankshaft angle sensor rotor.





54. REMOVE ENGINE ASSEMBLY

(a) Install 2 engine hangers with 2 bolts as shown in the illustration.





Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

HINT






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

(c) Remove the 4 engine mounting insulator bolts.





(d) Lift the engine out from the vehicle slowly and carefully.

NOTICE:
Make sure the engine is clear of all wiring, hoses and cables.

55. INSTALL ENGINE TO ENGINE STAND

(a) Install the engine to an engine stand with the bolts.

(b) Remove the 2 bolts and 2 engine hangers.