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Engine Assembly: Removal

WARNING: This page is about a different car, the 2006 Lexus IS 350. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 11 clips and intake duct seal.
      Fig 1: Identifying Cool Air Intake Duct Seal Clips
      G04055936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE ENGINE ROOM SIDE COVER LH 
    1. Remove the 5 clips and side cover.
      Fig 2: Locating Clips On Engine Room Side Cover LH
      G04055937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE ROOM SIDE COVER RH 
    1. Remove the 2 clips and side cover.
      Fig 3: Locating Clips On Engine Room Side Cover RH
      G04055938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
      Fig 4: Locating Clips On V-Bank Cover Sub-Assembly
      G04055939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
  5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REMOVAL  ) 
  6. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM .

  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 
  12. REMOVE ENGINE UNDER COVER REAR LH 
    1. Remove the bolt and engine under cover LH.
  13. REMOVE ENGINE UNDER COVER REAR RH 
    Fig 5: Identifying Engine Under Cover
    G04055940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

  14. DRAIN ENGINE OIL (See  REPLACEMENT  ) 
  15. DRAIN ENGINE COOLANT (See  COOLANT  ) 
  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See REMOVAL .

  17. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING 

    HINT:

    See REMOVAL .

  18. REMOVE NO. 1 INLET AIR CLEANER 
    1. Remove the bolt, clip and inlet air cleaner.
  19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See  REMOVAL  ) 
    Fig 6: Locating Inlet Air Cleaner Bolts
    G04055941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts, clamp and air cleaner case.
      Fig 7: Locating Bolts And Clamp Of Air Cleaner Case
      G04055942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Remove the clamp and disconnect the union to check valve hose.
  22. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE 
    1. Remove the clamp and disconnect the No. 2 fuel vapor feed hose.
      Fig 8: Locating Fuel Vapor Feed Hose Clamp
      G04055943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INLET RADIATOR HOSE 
    1. Remove the clamp and disconnect the inlet radiator hose.
  24. DISCONNECT OUTLET RADIATOR HOSE 
    1. Remove the clamp and disconnect the outlet radiator hose.
  25. DISCONNECT RADIATOR RESERVOIR TANK HOSE 
    1. Remove the clamp and disconnect the radiator reservoir tank hose.
      Fig 9: Locating Radiator Reservoir Tank Hose Clamp
      G04055944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
      Fig 10: Identifying Inlet Heater Water Hose Clamp
      G04055945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
      Fig 11: Identifying Outlet Heater Water Hose Clamp
      G04055946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE (See  REMOVAL  ) 
  29. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See  REMOVAL  ) 
  30. REMOVE ECM COVER (See  ON-VEHICLE INSPECTION  ) 
  31. 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: Identifying Connector Holder
      G04055947Courtesy 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: Locating Clamps
      G04055948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt, clamp and engine wire No. 3.
    8. Remove the bolt and disconnect the ground cable.
      Fig 14: Locating Bolt And Clamp On Engine Wire No.3
      G04055949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT FUEL MAIN TUBE 

    HINT:

    See FUEL SYSTEM .

  33. DISCONNECT NO. 3 FUEL HOSE 
    1. Remove the clamp and disconnect the No. 3 fuel hose.
      Fig 15: Locating Clamp On No.3 Fuel Hose
      G04055950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp.
      Fig 16: Identifying Fuel Pipe Clamp
      G04055951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch and pull the fuel tube's connector to disconnect it from the fuel tube sub-assembly.
      NOTE:
      • Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the Oring's ability to seal the connector and fuel main pipe.
      • Do not use any tools to separate the connector and pipe.
      • Do not forcefully bend or twist the hose.
      • Keep the connector and pipe free from foreign matter.
      • If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
      • Put the connector in a plastic bag to prevent damage and contamination.
        Fig 17: Disconnecting Connector From Fuel Tube Sub-Assembly
        G04055952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Remove the 4 bolts and suspension member protector.
      Fig 18: Identifying Bolts On Suspension Member Protector
      G04055953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (See  REMOVAL  ) 
  37. DISCONNECT HEIGHT CONTROL SENSOR LINK 
    1. Remove the nut and disconnect the height control sensor link.
      Fig 19: Locating Nut For Disconnecting Height Control Sensor Link
      G04055954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH 
    1. Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.
  39. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH 
    Fig 20: Identifying Front Shock Absorber Assembly
    G04055955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

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

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

    HINT:

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

  42. DISCONNECT POWER STEERING LINK WIRE HARNESS 
    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 22: Identifying Power Steering Link Wire Harness
      G04055957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (See  REMOVAL  ) 
  44. REMOVE ENGINE AND TRANSMISSION ASSEMBLY 
    1. Set the engine lifter.
    2. Remove the 4 bolts, then separate the engine rear mounting member.
      Fig 23: Identifying Bolts On Engine Rear Mounting Member
      G04055958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 12 bolts shown in the illustration.
    4. Operate the engine lifter, then slowly remove the engine from the vehicle.
      Fig 24: Identifying 12 Bolts
      G04055959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Make sure that the engine is clear of all wiring and hoses.
  45. INSTALL ENGINE HANGERS 
    1. Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts as shown in the illustration.

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

      Part No.: 

      PART DESCRIPTION

      No. 1 engine hanger 12281 - 31070
      No. 2 engine hanger 12282 - 31050
      Bolts 91671 - 10825
      Fig 25: Identifying Engine Hangers
      G04055960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach an engine sling device and hang the engine with a chain block.
  46. REMOVE STARTER ASSEMBLY (See  REMOVAL  ) 
  47. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY 

    HINT:

    See REMOVAL .

  48. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY 
    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 26: Identifying Bolt And No.2 Oil Dipstick Guide
      G04055961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.
      Fig 27: Identifying Bolt And Clamp
      G04055962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the O-ring from the No. 1 oil dipstick guide.
  49. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 6 nuts, exhaust manifold and gasket.
      Fig 28: Identifying Exhaust Manifold Nuts
      G04055963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
      Fig 29: Measuring Warpage On Contact Surface Of Cylinder Head
      G04055964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  51. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 6 nuts, exhaust manifold and gasket.
      Fig 30: Identifying Nuts On Exhaust Manifold
      G04055965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

      Maximum warpage: 0.7 mm (0.028 in.) 

      Fig 31: Measuring Warpage On Contact Surface Of Cylinder Head
      G04055966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

  53. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY 
    1. Using SST, hold the crankshaft.
      Fig 32: Holding Crankshaft Using SST
      G04055967Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Remove the 8 bolts, front spacer, drive plate and rear spacer.
      Fig 33: Identifying 8 Bolts
      G04055968Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.
      Fig 34: Locating Front Suspension Crossmember Sub-Assembly Bolts
      G04055969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. FIX ENGINE ON ENGINE STAND 
    1. Fix the engine onto a engine stand with the bolts.
  56. REMOVE V-RIBBED BELT (See  REMOVAL   ) 
  57. REMOVE NO. 2 ENGINE COVER 
    1. Remove the 3 clips and clamp, then remove the No. 2 engine cover.
      Fig 35: Identifying 3 Clips And Clamp
      G04055970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE NO. 1 ENGINE COVER 
    1. Remove the 3 clips, then remove the No. 1 engine cover.
      Fig 36: Identifying 3 Clips
      G04055971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, plate and idler pulley.
      Fig 37: Locating Idler Pulley Bolt
      G04055972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE GENERATOR ASSEMBLY (See  REMOVAL  ) 
  61. REMOVE COOLER COMPRESSOR ASSEMBLY (See  REMOVAL  ) 
  62. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Disconnect the 2 clamps.
    2. Remove the 4 bolts and mounting bracket.
      Fig 38: Identifying Bolts For Removing Engine Mounting Bracket LH
      G04055973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts and mounting bracket.
      Fig 39: Identifying Bolts For Removing Engine Mounting Bracket RH
      G04055974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.
      Fig 40: Identifying V-Ribbed Belt Tensioner Assembly Bolts
      G04055975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE WATER PUMP PULLEY (See  REMOVAL  ) 
  66. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine.
  67. REMOVE INJECTOR DRIVER 
    1. Remove the bolt, 2 nuts and injector driver.
      Fig 41: Identifying Injector Driver, Bolt And Nuts
      G04055976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    HINT:

    See REMOVAL

  69. 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 42: Measuring Warpage On Contact Surface Of Cylinder Head
      G04055977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE NO. 2 SURGE TANK STAY 
    1. Remove the bolt and No. 2 surge tank stay.
  71. REMOVE WATER HOSE JOINT 
    1. Remove the bolt, and disconnect 2 hoses and water hose joint.
      Fig 43: Identifying Water Hose Joint
      G04055978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE INTAKE MANIFOLD (See  REMOVAL  ) 
  73. INSPECT INTAKE MANIFOLD 
    1. Surge tank side:
      1. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

        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 straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

        Maximum warpage: 0.1 mm (0.003 in.) 

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

        Fig 44: Measuring Warpage On Contact Surface Of Cylinder Head
        G04055979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Remove the 2 bolts and fuel tube sub-assembly.
      Fig 45: Identifying Fuel Tube Sub-Assembly Removing Bolts
      G04055980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE FUEL PUMP 

    HINT:

    See REMOVAL .

  76. REMOVE FUEL INJECTOR ASSEMBLY 

    HINT:

    See REMOVAL .

  77. REMOVE KNOCK SENSOR (See  REMOVAL  ) 
  78. REMOVE RADIO SETTING CONDENSER 
    1. Remove the 2 bolts and 2 radio setting condensers.
      Fig 46: Identifying Radio Setting Condenser Removing Bolts
      G04055981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE V-BANK COVER BRACKET SUBASSEMBLY 
    1. Remove the bolt and V-bank cover bracket.
      Fig 47: Identifying V-Bank Cover Bracket Removing Bolt
      G04055982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 6 bolts and 6 ignition coils.
  81. REMOVE ENGINE OIL LEVEL SENSOR 
    1. Remove the 4 bolts, then remove the oil level sensor and gasket.
      Fig 48: Identifying Engine Oil Level Sensor Removing Bolts
      G04055983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the oil pressure switch.
      Fig 49: Identifying Oil Pressure Switch
      G04055984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the temperature sensor.
      Fig 50: Identifying Temperature Sensor
      G04055985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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