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Engine Assembly: Removal

WARNING: This page is about a different car, the 2008 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: Locating Intake Duct Seal And Clip
      G05823450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE ENGINE ROOM SIDE COVER LH 
    1. Remove the 5 clips and side cover.
      Fig 2: Identifying Side Cover And Clips
      G05823451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE ROOM SIDE COVER RH 
    1. Remove the 2 clips and side cover.
      Fig 3: Identifying Side Cover And Clips
      G05823452Courtesy 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.
      NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
      Fig 4: Locating V-bank Cover Clips
      G05823453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 

    HINT:

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

    Fig 5: Identifying Engine Under Cover
    G05823454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. DRAIN ENGINE OIL  (See REPLACEMENT )
  15. DRAIN ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  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.
    Fig 6: Locating Inlet Air Cleaner And Clip
    G05823455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE  (See REMOVAL )
  20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts, clamp and air cleaner case.
      Fig 7: Locating Air Cleaner Case And Clamp
      G05823456Courtesy 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 No. 2 Fuel Vapor Feed Hose
      G05823457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INLET RADIATOR HOSE 
    1. Remove the clamp and disconnect the inlet radiator hose.
      Fig 9: Locating Inlet Radiator Hose And Clamp
      G05823458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
  26. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
      Fig 10: Locating Inlet Heater Water Hose
      G05823459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
      Fig 11: Locating Outlet Heater Water Hose
      G05823460Courtesy 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 REMOVAL )
  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: Locating Engine Wire
      G05823461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and disconnect the wire from the engine room No. 1 junction block.
      Fig 13: Locating Engine Room No. 1 Junction Block
      G05823462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the nut and disconnect the battery positive (+) cable.
    6. Disconnect the connector and remove the 4 clamps from body.
    7. Remove the bolt, clamp and engine wire No. 3.
      Fig 14: Locating Engine Wire No. 3, Bolt And Clamp
      G05823463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt and disconnect the ground cable.
  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 No. 3 Fuel Hose
      G05823464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp.
      Fig 16: Locating Fuel Pipe Clamp
      G05823465Courtesy 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 O-ring'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: Locating Fuel Tube's Connector
        G05823466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Remove the 4 bolts and suspension member protector.
      2. Fig 18: Locating Suspension Member Protector And Bolts
      G05823467Courtesy 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: Disconnecting Height Control Sensor Link And Bolt
      G05823468Courtesy 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 

    HINT:

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

    Fig 20: Locating Front Suspension Lower Arm
    G05823469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH 
    1. Remove the 2 bolts from the front lower ball joint.
  41. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH 

    HINT:

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

    Fig 21: Locating Front Lower Ball Joint And Bolt
    G05823470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Locating Power Steering Link Wire Harness (For 2WD)
    G05823471Courtesy 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: Locating Engine Rear Mounting Member And Bolt
      G05823472Courtesy 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.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
      Fig 24: Locating Engine Lifter And Bolt
      G05823473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.: 

      ENGINE HANGERS TORQUE SPECIFICATION

      No. 1 engine hanger 12281 - 31070
      No. 2 engine hanger 12282 - 31050
      Bolts 91671 - 10825
      Fig 25: Locating No. 3 Engine Hangers With Bolts
      G05823474Courtesy 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: Locating No. 2 Oil Dipstick Guide And Bolts
      G05823475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
  49. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Disconnect the heated oxygen sensor connector.
      Fig 27: Locating No. 1 Oil Dipstick Guide, Bolt And Clamp
      G05823476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 nuts, exhaust manifold and gasket.
      Fig 28: Locating Exhaust Manifold And Bolt
      G05823477Courtesy 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.

      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 29: Inspecting Exhaust Manifold Sub-Assembly LH
      G05823478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Locating Heated Oxygen Sensor Connector And Nuts
      G05823479Courtesy 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.) 

      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 31: Inspecting Exhaust Manifold Sub-Assembly RH
      G05823480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.

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

      Fig 32: Holding Crankshaft
      G05823481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, front spacer, drive plate and rear spacer.
      Fig 33: Locating Front Spacer, Drive Plate And Rear Spacer Bolts
      G05823482Courtesy 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.
      2. Fig 34: Locating Front Suspension Crossmember Sub-Assembly (For 2WD)
      G05823483Courtesy 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: Locating No. 2 Engine Cover, Clips And Clamp
      G05823484Courtesy 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: Locating No. 1 Engine Cover And Clips
      G05823485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, plate and idler pulley.
      2. Fig 37: Locating Idler Pulley, Plate And Bolts
      G05823486Courtesy 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: Locating Mounting Bracket Bolts And Clamp
      G05823487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts and mounting bracket.
      Fig 39: Locating Mounting Bracket And Bolts
      G05823488Courtesy 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.
  65. REMOVE WATER PUMP PULLEY  (See REMOVAL )
  66. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine.
      Fig 40: Locating V-Ribbed Belt Tensioner Assembly Bolts
      G05823489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE INJECTOR DRIVER 
    1. Remove the bolt, 2 nuts and injector driver.
    Fig 41: Locating Injector Driver, Nuts And Bolts
    G05823490Courtesy 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: Precaution For Cylinder Head Surface
      G05823491Courtesy 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.
      2. Fig 43: Locating Water Hose Joint And Bolt
      G05823492Courtesy 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: Precaution For Cylinder Head Side And Surge Tank Side
        G05823493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Remove the 2 bolts and fuel tube sub-assembly.
    Fig 45: Locating Fuel Tube Sub-Assembly Bolts
    G05823494Courtesy 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: Locating Radio Setting Condenser And Bolt
      G05823495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY 
    1. Remove the bolt and V-bank cover bracket.
      2. Fig 47: Locating V-bank Cover Bracket And Bolt
      G05823496Courtesy 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: Locating Oil Level Sensor And Bolts
      G05823497Courtesy 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: Removing/Installing Oil Pressure Switch
      G05823498Courtesy 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
      G05823499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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