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Home >> Lexus >> 2006 >> IS 250 RWD, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (4GR-FSE) >> Engine Assembly >> Removal

Engine Assembly: Removal

  1. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 11 clips and intake duct seal.
    Fig 1: Identifying Clips & Intake Duct Seal
    G04044013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE ENGINE ROOM SIDE COVER LH 
    1. Remove the 5 clips and side cover.
    Fig 2: Identifying Clips & Side Cover LH
    G04044014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE ROOM SIDE COVER RH 
    1. Remove the 2 clips and side cover.
    Fig 3: Identifying Clips & Side Cover RH
    G04044015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Raise the V-bank cover to disengage the clip on the rear of the cover. Raise the cover again to disengage the 2 clips on the front of the cover and remove the cover.
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
    Fig 4: Disengaging Clips On Front Of Cover
    G04044016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See Step 5 in  REMOVAL  ) 
  6. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION .

  7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  9. REMOVE FRONT WHEEL 
  10. REMOVE ENGINE UNDER COVER 
  11. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD) 
  12. REMOVE ENGINE UNDER COVER REAR LH (for 2WD) 
    1. Remove the bolt and engine under cover LH.
  13. REMOVE ENGINE UNDER COVER REAR RH (for 2WD) 

    HINT:

    Remove the RH side following the same procedures as with the LH side.

    Fig 5: Removing Bolt & Engine Under Cover LH
    G04044017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DRAIN ENGINE OIL (See  REPLACEMENT  ) 
  15. DRAIN ENGINE COOLANT (See Step 4 in  ON-VEHICLE INSPECTION  ) 
  16. DRAIN FRONT DIFFERENTIAL OIL (for 4WD) (See  REMOVAL  ) 
  17. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See Step 5 in REMOVAL .

  18. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING 

    HINT:

    See Step 4 in REMOVAL .

  19. REMOVE NO. 1 INLET AIR CLEANER 
    1. Remove the bolt, clip and inlet air cleaner.
  20. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See Step 6 in  REMOVAL  ) 
    Fig 6: Removing Bolt, Clip & Inlet Air Cleaner
    G04044018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts, clamp and air cleaner case.
  22. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Remove the clamp and disconnect the union to check valve hose.
    Fig 7: Removing Bolts, Clamp & Air Cleaner Case
    G04044019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE 
    1. Remove the clamp and disconnect the No. 2 fuel vapor feed hose.
    Fig 8: Identifying No. 2 Fuel Vapor Feed Hose
    G04044020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT INLET RADIATOR HOSE 
    1. Remove the clamp and disconnect the inlet radiator hose.
  25. DISCONNECT OUTLET RADIATOR HOSE 
    1. Remove the clamp and disconnect the outlet radiator hose.
  26. DISCONNECT RADIATOR RESERVOIR TANK HOSE 
    1. Remove the clamp and disconnect the radiator reservoir tank hose.
    Fig 9: Identifying Clamp
    G04044021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
    Fig 10: Identifying Inlet Heater Water Hose
    G04044022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
  29. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE (See Step 8 in  REMOVAL  ) 
  30. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See Step 9 in  REMOVAL  ) 
  31. REMOVE ECM COVER (See Step 3 in  REMOVAL  ) 
    Fig 11: Disconnecting Outlet Heater Water Hose
    G04044023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT ENGINE WIRE 
    1. Disconnect the 6 ECM connectors.
    2. Using a screwdriver, disconnect the connector holder.
    3. Remove the engine room No. 1 relay block cover.
      Fig 12: Disconnecting Connector Holder
      G04044024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and disconnect the wire from the engine room No. 1 junction block.
    5. Remove the nut and disconnect the battery positive (+) cable.
    6. Disconnect the connector and remove the 4 clamps from body.
      Fig 13: Disconnecting Battery Positive (+) Cable
      G04044025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt, clamp and engine wire No. 3.
    8. Remove the bolt and disconnect the ground cable.
  33. DISCONNECT FUEL MAIN TUBE 

    HINT:

    See PRECAUTION .

    Fig 14: Disconnecting Fuel Main Tube
    G04044026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT NO. 3 FUEL HOSE 
    1. Remove the clamp and disconnect the No. 3 fuel hose.
    Fig 15: Disconnecting No. 3 Fuel Hose
    G04044027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD) 
    1. Remove the 4 bolts and suspension member protector.
  36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  37. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See Step 5 in  REMOVAL  ) 
    Fig 16: Removing Bolts & Suspension Member Protector
    G04044028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. SEPARATE FRONT SPEED SENSOR LH (for 4WD) (See Step 3 in  REMOVAL  ) 
  39. SEPARATE FRONT SPEED SENSOR RH (for 4WD) 

    HINT:

    Remove the RH side following the same procedures as with the LH side.

  40. REMOVE FRONT AXLE HUB LH NUT (for 4WD) (See Step 5 in  REMOVAL  ) 
  41. REMOVE FRONT AXLE HUB RH NUT (for 4WD) 

    HINT:

    Remove the RH side following the same procedures as with the LH side.

  42. REMOVE TIE ROD ASSEMBLY LH (for 4WD) (See Step 6 in  REMOVAL  ) 
  43. REMOVE TIE ROD ASSEMBLY RH (for 4WD) 

    HINT:

    Remove the RH side following the same procedures as with the LH side.

  44. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 2WD) 
    1. Remove the nut and disconnect the height control sensor link.
    Fig 17: Disconnecting Height Control Sensor Link (2WD)
    G04044029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 4WD) 
    1. Remove the bolt and disconnect the height control sensor link.
    Fig 18: Disconnecting Height Control Sensor Link (4WD)
    G04044030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD) 
    1. Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.
      Fig 19: Loosening Bolt (2WD)
      G04044031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) 

    HINT:

    Remove the RH side following the same procedures as for the LH side.

  48. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD) 
    1. Loosen the bolt and separate the lower part of the front shock absorber from the front absorber bracket lower.
    Fig 20: Loosening Bolt (4WD)
    G04044032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD) 

    HINT:

    Remove the RH side following the same procedures as for the LH side.

  50. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD) 
    1. Remove the 2 bolts from the front lower ball joint.
  51. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD) 

    HINT:

    Remove the RH side following the same procedures as for the LH side.

    Fig 21: Identifying Lower Ball Joint To Steering Knuckle Bolts
    G04029203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD) 
    1. Remove the 2 bolts from the front lower ball joint.
  53. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD) 

    HINT:

    Remove the RH side following the same procedures as for the LH side.

    Fig 22: Removing Bolts From Front Lower Ball Joint
    G04044034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. SEPARATE FRONT AXLE ASSEMBLY LH (for 4WD) (See Step 8 in  REMOVAL  ) 
  55. SEPARATE FRONT AXLE ASSEMBLY RH (for 4WD) 

    HINT:

    Remove the RH side following the same procedures as with the LH side.

  56. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission) 
    1. Remove the 2 bolts and exhaust pipe No. 1 support bracket sub-assembly.
    Fig 23: Removing Bolts & Exhaust Pipe No. 1 Support Bracket Sub-Assembly
    G04044035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 2WD) 
    1. Remove the bolt (A) to disconnect the earth wire from the bracket.
    2. Remove the 2 clamps to disconnect the wire harness from the bracket.
    3. Disconnect the 2 connectors (C) and (D) from the power steering link assembly.
    4. Release the lock of connector (E) and disconnect the connector from the power steering link assembly.
    5. Remove the bolt (B) and the power steering earth wire from the power steering link assembly.
    Fig 24: Disconnecting Power Steering Link Wire Harness (For 2WD)
    G04044036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 4WD) 
    1. Remove the bolt (A) and the power steering earth wire from the power steering link assembly.
    2. Remove the bolt (B) to disconnect the earth wire from the bracket.
    3. Remove the 2 clamps to disconnect the wire harness from the front frame.
    4. Disconnect the 2 connectors (C) and (D) from the power steering link assembly.
    5. Release the lock of connector (E) and disconnect the connector from the power steering link assembly.
    6. Remove the bolt (F) to disconnect the bracket from the front frame.
    Fig 25: Disconnecting Power Steering Link Wire Harness (For 4WD)
    G04044037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) (See Step 20 in  REMOVAL  ) 
  60. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD) (See Step 20 in  REMOVAL  ) 
  61. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 2WD) 
    1. Set the engine lifter.
    2. Remove the 4 bolts, then separate the engine rear mounting member.
      Fig 26: Separating Engine Rear Mounting Member
      G04044038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 12 bolts.
    4. Operate the engine lifter, then slowly remove the engine from the vehicle.
    NOTE: Make sure that the engine is clear of all wiring and hoses.
    Fig 27: Removing Bolts
    G04044039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 4WD) 
    1. Set the engine lifter.
    2. Remove the 4 bolts, then separate the engine rear mounting member.
      Fig 28: Separating Engine Rear Mounting Member
      G04044040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 8 bolts.
    4. Operate the engine lifter, then slowly remove the engine from the vehicle.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
      Fig 29: Removing Bolts
      G04044041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL ENGINE HANGERS 
    1. Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts.

      Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

      Part No.: 

      ENGINE HANGERS REFERENCE

      No. 1 engine hanger 12281 - 31070
      No. 2 engine hanger 12282 - 31050 (2WD)
      No. 3 engine hanger 12283 - 31010 (4WD)
      Bolts 91671 - 10825
      Fig 30: Identifying Engine Hangers
      G04044042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach an engine sling device and hang the engine with a chain block.
  64. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See Step 2 in  REMOVAL  ) 
  65. REMOVE STARTER ASSEMBLY (See Step 12 in  REMOVAL  ) 
  66. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission) 

    HINT:

    See Step 34 in REMOVAL .

  67. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission) 

    HINT:

  68. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD) 
    1. Remove the oil level gauge.
    2. Remove the bolt, then remove the No. 2 oil dipstick guide.
      Fig 31: Removing Bolt & No. 2 Oil Dipstick Guide
      G04044043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the No. 2 oil dipstick guide.
    4. Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.
    5. Remove the O-ring from the No. 1 oil dipstick guide.
    Fig 32: Identifying Oil Dipstick Guide
    G04044044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD) 
    1. Remove the oil level gauge.
    2. Remove the bolt, then remove the No. 2 oil dipstick guide.
    3. Remove the O-ring from the No. 2 oil dipstick guide.
      Fig 33: Removing Bolt & No. 2 Oil Dipstick Guide
      G04044045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt, then remove the No. 1 oil dipstick guide.
    5. Remove the O-ring from the No. 1 oil dipstick guide.
  70. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Disconnect the heated oxygen sensor connector.
      Fig 34: Identifying Oil Dipstick Guide
      G04044046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 nuts, exhaust manifold and gasket.
    Fig 35: Identifying Nuts, Exhaust Manifold & Gasket
    G04044047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Using a precision straight edge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

      Maximum warpage: 

      0.7 mm (0.028 in.) 

      HINT:

      The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.). If the warpage is greater than the maximum, replace the manifold.

    Fig 36: Measuring Warpage On Contact Surface Of Cylinder Head Using Straight Edge & Feeler Gauge
    G04044048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 6 nuts, exhaust manifold and gasket.
    Fig 37: Identifying Nuts, Exhaust Manifold & Gasket
    G04044049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Using a precision straight edge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

      Maximum warpage: 

      0.7 mm (0.028 in.) 

      HINT:

      The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.). If the warpage is greater than the maximum, replace the manifold.

    Fig 38: Measuring Warpage On Contact Surface Of Cylinder Head Using Straight Edge & Feeler Gauge
    G04044050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD) (See Step 9 in  REMOVAL  ) 
  75. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) (See Step 10 in  REMOVAL  ) 
  76. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) 
    1. Using SST, hold the crankshaft.

      SST 09213-70011 (09213-70020), 09330-00021 

      Fig 39: Holding Crankshaft
      G04044051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts and the flywheel.
    Fig 40: Identifying Bolts & Flywheel
    G04044052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) 
    1. Using SST, hold the crankshaft.

      SST 09213-70011 (09213-70020), 09330-00021 

      Fig 41: Holding Crankshaft
      G04044053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, front spacer, drive plate and rear spacer.
    Fig 42: Identifying Bolts, Front Spacer, Drive Plate & Rear Spacer
    G04044054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD) 
    1. Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.
    Fig 43: Identifying Bolts (2WD)
    G04044055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE FRONT FRAME ASSEMBLY (for 4WD) 
    1. Remove the 2 bolts, then separate the front frame assembly from the engine.
  80. FIX ENGINE ON ENGINE STAND 
    1. Fix the engine onto a engine stand with the bolts.
  81. REMOVE V-RIBBED BELT (See Step 4 in  REMOVAL   ) 
    Fig 44: Identifying Bolts (4WD)
    G04044056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE NO. 2 ENGINE COVER 
    1. Remove the 3 clips and clamp, then remove the No. 2 engine cover.
    Fig 45: Identifying Clips & Clamp
    G04044057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE NO. 1 ENGINE COVER 
    1. Remove the 3 clips, then remove the No. 1 engine cover.
    Fig 46: Identifying Clips
    G04044058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, plate and idler pulley.
  85. REMOVE GENERATOR ASSEMBLY (See Step 12 in  REMOVAL  ) 
  86. REMOVE COOLER COMPRESSOR ASSEMBLY (for 2WD) (See Step 10  REMOVAL  ) 
  87. REMOVE OIL FILTER BRACKET (for 4WD) (See Step 7 in  REMOVAL  ) 
    Fig 47: Identifying Bolt, Plate & Idler Pulley
    G04044059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE COOLER COMPRESSOR ASSEMBLY (for 4WD) (See Step 11  REMOVAL  ) 
  89. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Disconnect the 2 clamps.
    2. Remove the 4 bolts and mounting bracket.
    Fig 48: Identifying Bolts & Mounting Bracket (LH)
    G04044060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts and mounting bracket.
    Fig 49: Identifying Bolts & Mounting Bracket (RH)
    G04044061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly. (2WD)
    2. Remove the 4 bolts, then remove the V-ribbed belt tensioner assembly. (4WD)
      3. Fig 50: Identifying V-Ribbed Belt Tensioner Assembly
      G04044062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (See Step 3 in  REMOVAL  ) 
  93. REMOVE WATER PUMP PULLEY (See Step 21 in  REMOVAL  ) 
  94. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine.
  95. REMOVE INJECTOR DRIVER 
    1. Remove the bolt, 2 nuts and injector driver.
  96. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    HINT:

    See Step 20 in REMOVAL .

    Fig 51: Identifying Injector Driver, Bolt & Nuts
    G04055976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. INSPECT INTAKE AIR SURGE TANK ASSEMBLY 
    1. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

      Maximum warpage: 

      2.5 mm (0.098 in.) 

      If the warpage is greater than the maximum, replace the surge tank.

    Fig 52: Measuring Warpage On Contact Surface Of Cylinder Head
    G04044064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. REMOVE NO. 2 SURGE TANK STAY 
    1. Remove the bolt and No. 2 surge tank stay.
  99. REMOVE WATER HOSE JOINT 
    1. Remove the bolt, and disconnect 2 hoses and water hose joint.
  100. REMOVE INTAKE MANIFOLD (See Step 21 in  REMOVAL  ) 
    Fig 53: Disconnecting Hoses & Water Hose Joint
    G04044065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. INSPECT INTAKE MANIFOLD 
    1. Surge tank side:
      1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

        Maximum warpage: 

        0.1 mm (0.003 in.) 

        If the warpage is greater than the maximum, replace the intake manifold.

    2. Cylinder head side:
      1. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage.

        Maximum warpage: 

        0.1 mm (0.003 in.) 

        If the warpage is greater than the maximum, replace the intake manifold.

      3. Fig 54: Measuring Surface Contacting Cylinder Head For Warpage Using Straight Edge & Feeler Gauge
      G04044066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. REMOVE FUEL PUMP 

    HINT:

    See Step 26 in REMOVAL .

  103. REMOVE FUEL INJECTOR ASSEMBLY 

    HINT:

    See Step 31 in REMOVAL .

  104. REMOVE KNOCK SENSOR (See Step 29 in  REMOVAL  ) 
  105. REMOVE RADIO SETTING CONDENSER 
    1. Remove the 2 bolts and 2 radio setting condensers.
    Fig 55: Identifying Bolts & Radio Setting Condensers
    G04044067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY 
    1. Remove the bolt and V-bank cover bracket.
  107. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 6 bolts and 6 ignition coils.
    Fig 56: Identifying Bolts & Ignition Coils
    G04044068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. REMOVE ENGINE OIL LEVEL SENSOR 
    1. Remove the 4 bolts, then remove the oil level sensor and gasket.
    Fig 57: Identifying Bolts, Oil Level Sensor & Gasket
    G04044069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  109. REMOVE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the oil pressure switch.
    Fig 58: Identifying Oil Pressure Switch
    G04044070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the temperature sensor.
Fig 59: Installing Engine Coolant Temperature Sensor
G04044071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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