LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2007 >> GS 350 RWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FSE) >> Engine Assembly >> Removal

Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REPLACEMENT  ) 
  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  5. DRAIN ENGINE OIL (See  REPLACEMENT  ) 
  6. REMOVE ENGINE UNDER COVER (for 2WD) 
  7. REMOVE ENGINE UNDER COVER (for 4WD) 
  8. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD) 
    1. Remove the 4 screws, 2 grommets, 2 spacers and under cover.
  9. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET (for 2WD) 
    1. Remove the 2 bolts and bracket.
  10. REMOVE REAR ENGINE UNDER COVER RH (for 2WD) 
    1. Remove the bolt and under cover.
  11. REMOVE REAR ENGINE UNDER COVER LH (for 2WD) 
    1. Remove the bolt and under cover.
    Fig 1: Locating Bracket Bolts
    G05285869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER (for 2WD) 
    1. Remove the 4 bolts and protector.
      Fig 2: Locating Protector Bolts
      G05285870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DRAIN ENGINE COOLANT (See  COOLANT  ) 
  14. DRAIN FRONT DIFFERENTIAL OIL (for 4WD) 
  15. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 7 clips and intake duct seal.
    Fig 3: Identifying Intake Duct Seal Clips
    G05285871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE ENGINE ROOM SIDE COVER RH 
    1. Remove the 2 clips and side cover.
    Fig 4: Identifying Engine Room Side Cover RH Clips
    G05285872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE ENGINE ROOM SIDE COVER LH 
    1. Remove the 3 clips and side cover.
    Fig 5: Identifying Engine Room Side Cover LH Clips
    G05285873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the front of the V-bank cover and raise it to disengage the 3 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.
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
    Fig 6: Locating V-Bank Cover Clips
    G05285874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt and air cleaner inlet.
      Fig 7: Locating Air Cleaner Inlet Bolt
      G05285875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 2 VENTILATION HOSE (See  REMOVAL  ) 
  21. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See  REMOVAL  ) 
  22. REMOVE AIR CLEANER CASE 
    1. Remove the 3 bolts, clamp and case.
    Fig 8: Locating Air Cleaner Case Bolts And Clamp
    G05285876Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT PURGE LINE HOSE 
    1. Remove the clamp and disconnect the feed hose.
    Fig 9: Locating Purge Line Hose Clamp
    G05285877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT NO. 1 RADIATOR HOSE 
  25. DISCONNECT NO. 2 RADIATOR HOSE 
  26. DISCONNECT RADIATOR RESERVOIR HOSE 
    Fig 10: Locating Radiator Reservoir Hose
    G05285878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT HEATER WATER INLET HOSE A 
    Fig 11: Locating Heater Water Inlet Hose
    G05285879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT HEATER WATER OUTLET HOSE A 
  29. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube LH and RH side (see FUEL SYSTEM ).
    Fig 12: Locating Heater Water Outlet Hose
    G05285880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY 
    1. Disconnect the fuel hose from the pipe.
    Fig 13: Locating No 3 Fuel Hose And Clamp
    G05286937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the union to check valve hose from the intake air surge tunk.
  32. DISCONNECT ENGINE WIRE 
    1. for RH Side:
      1. Remove the nut and battery positive (+) cable, and disconnect the clamp from the battery (see illustration (A)).
      2. Remove the No. 1 relay block cover.
      3. Remove the nut and detach the 2 claws, and remove the wire harness from the No. 1 relay block (see illustration (B)).
      4. Remove the nut and No. 2 ground cable (see illustration (C)).
      5. Detach the 3 claws and remove the wire harness from the wire harness cover (see illustration (C)).
      6. Disconnect the clamp and connector, and remove the 2 bolts and No. 4 relay block (see illustration (D)).
    2. for LH Side:
      1. Remove the bolt and No. 2 ground cable (see illustration (E)).
      2. Remove the 3 bolts and ECM box cover.
      3. Using a screw driver, detach the 2 claws as shown in the illustration (F).

        HINT:

        Tape the screwdriver tip before use.

      4. Disconnect the 2 connector holders and connectors (see illustration (F)).
      5. Disconnect the ECM's harness from the clamp (see illustration (F)).
      Fig 14: Locating Valve Hose
      G05285882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. for Engine Bank 1 Side:
      1. Disconnect the clamp, and remove the bolt and ground cable (see illustration (G)).
      Fig 15: Locating Ground Cable Bolts
      G05285883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. for Power Steering Link Side (for 2WD):
      1. Remove the bolt (A) and (B), and disconnect the ground cable.
      2. Disconnect the 2 connectors (C).
      3. Release the lock of connector (D), and then disconnect the connector.
      4. Detach the 2 clamps (E).
      Fig 16: Locating Connectors And Bolts - Power Steering Link Side (For 2WD)
      G05285884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. for Power Steering Link side (for 4WD):
      1. Remove the bolt (A) and (B), and disconnect the ground cable.
      2. Disconnect the 2 connectors (C).
      3. Release the lock of connector (E), and then disconnect the connector.
      4. Detach the 2 clamps (F).
      5. Remove the bolt (G) and disconnect the wire harness bracket.
      Fig 17: Locating Connectors And Bolts - Power Steering Link Side (For 4WD)
      G05285885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. for Automatic Transmission Side:
      1. Remove the nut and disconnect the ground cable from the RH side.
    Fig 18: Locating Ground Cable Nut
    G05285886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE FRONT FLOOR COVER CENTER LH (for 4WD) (See  INSTALLATION  ) 
  34. REMOVE FRONT FLOOR BRACE CENTER (See  REMOVAL  ) 
  35. REMOVE HEATED OXYGEN SENSOR 
    1. Remove the sensor (see ON-VEHICLE INSPECTION ).
  36. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See  REMOVAL  ) 
  37. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR (See  REMOVAL  ) 
  38. REMOVE AIR GUIDE PLATE OUTSIDE RH (See  REMOVAL  ) 
  39. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  40. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) (See  INSTALLATION  ) 
  41. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  42. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (for 2WD) (See  REMOVAL  ) 
  43. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  44. REMOVE COOLER COMPRESSOR ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  45. REMOVE OIL FILTER BRACKET (for 4WD) (See  REMOVAL  ) 
  46. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  47. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE (for 4WD) (See  REMOVAL  ) 
  48. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (for 4WD) (See  INSPECTION  ) 
  49. REMOVE COOLER COMPRESSOR ASSEMBLY (for 4WD) (See  INSPECTION  ) 
  50. REMOVE GENERATOR WITH CLUTCH PULLEY (See  DISASSEMBLY  ) 
  51. REMOVE FRONT WHEELS 
  52. REMOVE FRONT AXLE HUB NUT LH (for 4WD) 
    1. Using SST and hammer, release the staked part of the front axle hub nut.

      SST 09930-00010 

  53. REMOVE FRONT AXLE HUB NUT RH (for 4WD) 

    HINT:

    Perform the same procedure as for the LH side.

    Fig 19: Removing Front Axle Hub Nut
    G05296025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY (for 2WD) 
    1. for Interior Side:
      1. Fix the steering wheel in place with the seat belt in order to prevent rotation.

        HINT:

        This operation helps prevent damage to the spiral cable.

      Fig 20: Fixing Steering Wheel In Place With Seat Belt
      G05297648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Exterior Side:
      1. Loosen the bolt (A) and remove the bolt (B).
      2. Put matchmarks on the steering sliding yoke and No. 2 steering intermediate shaft.
      3. Remove the sliding yoke from the No. 2 steering intermediate shaft.
        Fig 21: Locating Steering Sliding Yoke Bolts
        G05285889Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE INSTRUMENT PANEL NO. 1 UNDER COVER SUB-ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  56. REMOVE NO. 1 AIR DUCT (for 4WD) 
  57. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) 
    1. for Interior Side:
      1. Fix the steering wheel in place with the seat belt in order to prevent rotation.

        HINT:

        This operation helps prevent damage to the spiral cable.

        Fig 22: Fixing Steering Wheel In Place With Seat Belt
        G05297648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the bolt and steering column hole cover's clamp.
        Fig 23: Locating Steering Column Hole Cover's Clamp Bolt
        G05285891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Put matchmarks on the No. 2 steering intermediate shaft and steering column.
        Fig 24: Identifying Matchmarks On No. 2 Steering Intermediate Shaft And Steering Column
        G05285892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for Exterior Side:
      1. Remove the bolt and slide the No. 2 steering intermediate shaft.
        Fig 25: Locating No. 2 Steering Intermediate Shaft Bolt
        G05297676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Put matchmarks on the No. 2 steering intermediate shaft and power steering link.
      3. Remove the No. 2 steering intermediate shaft.
    Fig 26: Putting Matchmarks On No. 2 Steering Intermediate Shaft And Power Steering Link
    G05285894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. SEPARATE HEIGHT CONTROL SENSOR LINK LH (for 2WD) 
    1. Remove the nut and disconnect the height control sensor link.
  59. SEPARATE HEIGHT CONTROL SENSOR LINK RH (for 2WD) 

    HINT:

    Perform the same procedure as for the LH side.

    Fig 27: Locating Height Control Sensor Link Nut
    G05285895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. SEPARATE HEIGHT CONTROL SENSOR LINK LH (for 4WD) 
    1. Remove the bolt and disconnect the height control sensor link.
  61. SEPARATE HEIGHT CONTROL SENSOR LINK RH (for 4WD) 

    HINT:

    Perform the same procedure as for the LH side.

    Fig 28: Locating Height Control Sensor Link Bolt
    G05285896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY (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.
      NOTE: Do not remove the nut.
  63. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) 

    HINT:

    Perform the same procedure as for the LH side.

    Fig 29: Locating Front Shock Absorber Nut
    G05296589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD) 
    1. Remove the bolt, and separate the front shock absorber and bracket lower.
      Fig 30: Locating Front Shock Absorber Bolt
      G05285898Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD) 

    HINT:

    Perform the same procedure as for the LH side.

  66. SEPARATE FRONT SPEED SENSOR LH (for 4WD) (See  REMOVAL  ) 
  67. SEPARATE FRONT SPEED SENSOR RH (for 4WD) 

    HINT:

    Perform the same procedure as for the LH side.

  68. SEPARATE TIE ROD ASSEMBLY LH (for 2WD) (See  REMOVAL  ) 
  69. SEPARATE TIE ROD ASSEMBLY RH (for 2WD) 

    HINT:

    Perform the same procedure as for the LH side.

  70. SEPARATE TIE ROD ASSEMBLY LH (for 4WD) (See  REMOVAL  ) 
  71. SEPARATE TIE ROD ASSEMBLY RH (for 4WD) 

    HINT:

    Perform the same procedure as for the LH side.

  72. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD) 
    1. Remove the 2 bolts and separate the lower ball joint from the steering knuckle.
  73. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD) 

    HINT:

    Perform the same procedure as for the LH side.

    Fig 31: Locating Front Lower Ball Joint Bolts (For 2WD)
    G05285899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD) 
    1. Remove the 2 bolts and separate the lower ball joint from the steering knuckle.
  75. SEPARATE FRONT LOWER BALL JOINT RH (for 4WD) 

    HINT:

    Perform the same procedure as for the LH side.

    Fig 32: Locating Front Lower Ball Joint Bolts (For 4WD)
    G05285900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD) (See  REMOVAL  ) 
  77. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) (See  REMOVAL  ) 
  78. SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  79. SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD) (See  DISASSEMBLY  ) 
  80. REMOVE ENGINE AND TRANSMISSION (for 2WD) 
    1. Set an engine lifter.
    2. Remove the 4 bolts, and separate the engine rear mounting member.
      Fig 33: Locating Engine Rear Mounting Member Bolts
      G05285901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 10 bolts and 2 nuts as shown in the illustration.
    4. Operate the engine lifter, then slowly remove the engine from the vehicle.
      NOTE: Make sure the engine is clear of all wiring and hoses.
      Fig 34: Locating Engine And Transmission Bolts And Nuts
      G05285902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part No.: 

      ENGINE HANGERS SPECIFICATION

      No. 1 engine hanger 12281-31070
      Bolt 91671-F0822

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

    6. Attach an engine sling device and hang the engine with a chain block.
    Fig 35: Identifying Engine Hangers
    G05285903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE ENGINE AND TRANSMISSION (for 4WD) 
    1. Set an engine lifter.
    2. Remove the 4 bolts, and separate the engine rear mounting member.
      Fig 36: Locating Engine Rear Mounting Member Bolts
      G05285904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and 2 nuts as shown in the illustration.
    4. Operate the engine lifter, then slowly remove the engine from the vehicle.
      NOTE: Make sure the engine is clear of all wiring and hoses.
      Fig 37: Locating Bolts And Nuts
      G05285905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part No.: 

      ENGINE HANGERS SPECIFICATION

      No. 1 engine hanger 12281-31070
      Bolt 91671-F0822

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

    6. Attach an engine sling device and hang the engine with a chain block.
    Fig 38: Identifying Engine Hangers
    G05285903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE OIL DIPSTICK GUIDE (for 2WD) 
    1. Remove the dipstick.
    2. Remove the bolt and No. 2 guide.
      Fig 39: Locating No. 2 Guide Bolt
      G05285907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and No. 1 guide.
    4. Remove the 2 O-rings from the dipstick guides.
    Fig 40: Locating No 1 Oil Dipstick Guide
    G05285908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE OIL DIPSTICK GUIDE (for 4WD) 
    1. Remove the dipstick.
    2. Remove the bolt and No. 2 guide.
      Fig 41: Locating No 2 Oil Dipstick Guide With Bolt
      G05285909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and No. 1 guide.
    4. Remove the 2 O-rings from the dipstick guides.
    Fig 42: Locating No 1 Oil Dipstick Guide With Bolt
    G05285910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Disconnect the A/F sensor (for bank 1 sensor 1) connector.
      Fig 43: Locating A/F Sensor Connector (Bank 1 Sensor 1)
      G05287789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 nuts, exhaust manifold and gasket.
    Fig 44: Locating Exhaust Manifold Nuts
    G05285912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the A/F sensor (for bank 2 sensor 1) connector.
      Fig 45: Locating A/F Sensor (Bank 2 Sensor 1) Connector
      G05287285Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 nuts, exhaust manifold and gasket.
      Fig 46: Locating Exhaust Manifold Nuts
      G05287286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE STARTER ASSEMBLY (See  REMOVAL  ) 
  87. DISCONNECT WATER BYPASS HOSE 
    1. Remove the bolt and clamp.
      Fig 47: Locating Water Bypass Hose Bolt And Clamp
      G05285915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 hoses.
      Fig 48: Locating Hose Clamp Connection
      G05285916Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. DISCONNECT HARNESS AND CONNECTOR FROM AUTOMATIC TRANSMISSION (for 2WD) (See  REMOVAL  ) 
  89. DISCONNECT HARNESS AND CONNECTOR FROM AUTOMATIC TRANSMISSION (for 4WD) 
    1. Disconnect the connector (see DISASSEMBLY ) and harness (see INSPECTION ).
  90. REMOVE FLYWHEEL HOUSING SIDE COVER (See  REMOVAL  ) 
  91. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (See  REMOVAL  ) 
  92. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  93. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) (See  ADJUSTMENT  ) 
  94. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.

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

      Fig 49: Holding Crankshaft
      G05285917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, front spacer, drive plate and rear spacer.
    Fig 50: Locating Drive Plate Bolts
    G05285918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. SEPARATE ENGINE FROM FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD) 
    1. Remove the 2 bolts, then remove the crossmember from the engine.
    Fig 51: Locating Crossmember Bolts
    G05285919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. SEPARATE ENGINE FROM FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 4WD) 
    1. Remove the 2 bolts, then remove the crossmember from the engine.
  97. INSTALL ENGINE STAND 
    1. Install the engine onto an engine stand with the bolts.
      Fig 52: Locating Crossmember Bolts
      G05285920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and 2 engine hangers.
  98. REMOVE ENGINE MOUNTING BRACKET (for 2WD) 
    1. Disconnect the 2 clamps from the LH side.
    2. Remove the 8 bolts and 2 brackets.
    Fig 53: Identifying Engine Hangers
    G05285903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 54: Locating Engine Mounting Bracket Bolts
    G05285922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. REMOVE ENGINE MOUNTING BRACKET (for 4WD) 
    1. Disconnect the 2 clamps from the LH side.
    2. Remove the 8 bolts and 2 brackets.
    Fig 55: Locating Engine Mounting Bracket Bolts
    G05285923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  101. REMOVE V-RIBBED BELT (See  REMOVAL  ) 
  102. REMOVE NO. 2 ENGINE COVER 
    1. Disconnect the harness clamp.
    2. Remove the 3 clips and cover.
    Fig 56: Locating No 2 Engine Cover With Clips
    G05285924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. REMOVE NO. 1 ENGINE COVER 
    1. Remove the 3 clips and cover.
    Fig 57: Locating No 1 Engine Cover With Clips
    G05285925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  104. REMOVE INJECTOR DRIVER 
    1. Remove the bolt, 2 nuts and injector driver.
    Fig 58: Locating Injector Driver Bolt And Nuts
    G05286996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  105. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, idler pulley cover plate and pulley.
    Fig 59: Locating Idler Pulley Bolt
    G05285927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD) 
    1. Remove the 5 bolts and tensioner.
    Fig 60: Identifying V-Ribbed Belt Tensioner Assembly Bolts - 2WD
    G05285928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  107. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD) 
    1. Remove the 4 bolts and tensioner.
      Fig 61: Identifying V-Ribbed Belt Tensioner Assembly Bolts - 4WD
      G05285929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. REMOVE WATER PUMP PULLEY (See  INSPECTION  ) 
  109. REMOVE INTAKE AIR SURGE TANK SUB-ASSEMBLY (See  REMOVAL  ) 
  110. REMOVE NO. 2 SURGE TANK STAY 
    1. Remove the bolt and stay.
  111. REMOVE WATER HOSE JOINT 
    Fig 62: Locating Water Hose Joint
    G05285930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the bolt.
    2. Disconnect the 2 hoses and remove the pipe.
  112. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine.
  113. REMOVE INTAKE MANIFOLD (See  REMOVAL  ) 
  114. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Pinch and pull the fuel tube connector to disconnect the connector from the delivery pipe.
      NOTE:
      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
      • Do not use any tools to separate the pipe and connector.
      • Do not forcefully bend or twist the nylon tube.
      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.
      Fig 63: Pulling Fuel Tube Connector
      G05285931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and tube.
      Fig 64: Locating Tube Bolts
      G05285932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  115. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See  REMOVAL  ) 
  116. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Disconnect the 2 hoses.
    2. Remove the 2 bolts and pipe.
      Fig 65: Locating No. 1 Fuel Pipe Bolts
      G05286938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  117. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  118. REMOVE HIGH PRESSURE SIDE FUEL PUMP (See  INSTALLATION  ) 
  119. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  120. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  121. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  122. REMOVE NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  123. REMOVE FUEL INJECTOR ASSEMBLY 
  124. REMOVE KNOCK SENSOR (See  INSPECTION  ) 
  125. REMOVE RADIO SETTING CONDENSER 
    1. Remove the 2 bolts and 2 condensers.
    Fig 66: Locating Radio Setting Condenser Bolts
    G05285934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  126. REMOVE V-BANK COVER BRACKET 
    1. Remove the bolt and bracket.
      Fig 67: Locating V-Bank Cover Bracket Bolt
      G05285935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  127. REMOVE IGNITION COIL ASSEMBLY (See  REMOVAL  ) 
  128. REMOVE ENGINE OIL LEVEL SENSOR 
    1. Remove the 4 bolts, then remove the sensor and gasket.
    Fig 68: Locating Engine Oil Level Sensor Bolts
    G05285936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  129. REMOVE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the switch.
    Fig 69: Removing Oil Pressure Switch
    G05285937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  130. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the sensor and gasket.
    Fig 70: Removing Engine Coolant Temperature Sensor
    G05285938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals