REMOVAL (To 08/2009): Removal
- PRECAUTION (w/ Air Suspension) NOTE:
Be sure to read Precaution thoroughly before servicing. Refer to PRECAUTION .
- PRECAUTION (w/ Navigation System for HDD) NOTE:
After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal. Refer to PRECAUTION .
- ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
- REMOVE ENGINE ROOM SIDE COVER . Refer to REMOVAL - Step 1
- REMOVE ENGINE ROOM SIDE COVER LH . Refer to REMOVAL - Step 2
- REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 3
- RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM . Refer to REPLACEMENT - Step 1
- DISCHARGE FUEL SYSTEM PRESSURE
HINT:
Refer to PRECAUTION .)
- DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to INITIALIZATION .
- REMOVE FRONT WHEEL
- REMOVE NO. 1 ENGINE UNDER COVER
- REMOVE NO. 2 ENGINE UNDER COVER
- REMOVE FRONT FLOOR COVER LH . Refer to REMOVAL - Step 2
- REMOVE FRONT FENDER LINER LH
- REMOVE FRONT FENDER LINER RH
- REMOVE FRONT FENDER APRON SEAL LH
- Remove the 2 bolts, clip and front fender apron seal LH.
- REMOVE FRONT FENDER APRON SEAL RH
- Remove the 2 bolts, clip and front fender apron seal RH.
- DRAIN ENGINE OIL . Refer to REPLACEMENT - Step 2
- DRAIN ENGINE COOLANT . Refer to REPLACEMENT - Step 7
- DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) . Refer to REPLACEMENT - Step 4
- DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) . Refer to REPLACEMENT - Step 4
- DRAIN TRANSFER OIL (for AWD) . Refer to REPLACEMENT - Step 2
- REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH . Refer to REMOVAL - Step 4
- REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH . Refer to REMOVAL - Step 5
- REMOVE FRONT FENDER TO COWL SIDE SEAL LH . Refer to REMOVAL - Step 6
- REMOVE FRONT FENDER TO COWL SIDE SEAL RH . Refer to REMOVAL - Step 7
- REMOVE FRONT WIPER ARM HEAD CAP . Refer to REMOVAL - Step 8
- REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH . Refer to REMOVAL - Step 9
- REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH . Refer to REMOVAL - Step 10
- REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY . Refer to REMOVAL - Step 11
- REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY . Refer to REMOVAL - Step 12
- REMOVE FRONT SHOCK ABSORBER CAP (w/ Air Suspension) . Refer to REMOVAL - Step 3
- REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY . Refer to REMOVAL - Step 11
- REMOVE V-BANK COVER SUB-ASSEMBLY
- Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.
NOTE:
Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.
- Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.
- REMOVE NO. 2 AIR CLEANER INLET
- Disconnect the 2 vacuum hose clamps from the No. 2 air cleaner inlet.
- Remove the 2 bolts and No. 2 air cleaner inlet.
- REMOVE NO. 1 AIR CLEANER INLET
- Disconnect the vacuum hose clamp from the No. 1 air cleaner inlet.
- Remove the bolt and No. 1 air cleaner inlet.
- REMOVE BATTERY
- Disconnect the positive (+) cable from the positive (+) battery terminal.
- Loosen the nut, and remove the bolt from the battery clamp.
- Remove the battery and battery tray.
- REMOVE AIR CLEANER ASSEMBLY . Refer to REMOVAL - Step 13
- REMOVE AIR CLEANER BRACKET
- Disconnect the engine wire clamp.
- Remove the 2 bolts and air cleaner bracket.
- SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
- Disconnect the connector from the brake master cylinder reservoir sub-assembly.
- Remove the bolt and separate the radiator reservoir tank assembly from the reservoir bracket.
- REMOVE RESERVOIR BRACKET
- Remove the 2 bolts and reservoir bracket.
- REMOVE NO. 1 RELAY BLOCK COVER
- Remove the No. 1 relay block cover.
- DISCONNECT ENGINE WIRE
- Remove the 2 bolts and separate the 2 earth wires.
- Disconnect the 2 wire clamps.
- Disconnect the 3 connectors.
- Remove the nut.
- Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
- Pull up the lever to disconnect the ECM connector.
- Disconnect the 2 wire clamps.
- DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
- Remove the nut from the control shaft lever.
- Using a screwdriver, disengage the 4 claws and disconnect the control cable with clip from the control cable bracket.
- Remove the clip.
- DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
- Disconnect the No. 1 fuel vapor feed hose.
- DISCONNECT NO. 1 RADIATOR HOSE
- Disconnect the No. 1 radiator hose.
- Separate the No. 1 radiator hose from the radiator pipe clamp.
- DISCONNECT NO. 2 RADIATOR HOSE
- Disconnect the No. 2 radiator hose.
- DISCONNECT INLET HEATER WATER HOSE
- Disconnect the inlet heater water hose.
- DISCONNECT OUTLET HEATER WATER HOSE
- Disconnect the outlet heater water hose.
- DISCONNECT FUEL MAIN TUBE
- Remove the No. 1 fuel pipe clamp.
- Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 hose.
- DISCONNECT NO. 1 INLET OIL COOLER HOSE
- Disconnect the No. 1 inlet oil cooler hose.
- DISCONNECT NO. 1 OUTLET OIL COOLER HOSE
- Disconnect the No. 1 outlet oil cooler hose.
- DISCONNECT UNION TO CHECK VALVE HOSE
- Disconnect the union to check valve hose.
- SEPARATE NO. 2 EARTH WIRE
- Remove the 2 bolts and separate the No. 2 earth wire clamps.
- REMOVE NO. 2 ENGINE MOUNTING STAY RH
- Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
- REMOVE ENGINE MOVING CONTROL ROD BRACKET
- Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.
- REMOVE ENGINE MOVING CONTROL ROD
- Remove the bolt and engine moving control rod from the engine moving control rod bracket.
HINT:
Perform this procedure only when replacement of the engine moving control rod is necessary.
- Remove the bolt and engine moving control rod from the engine moving control rod bracket.
- DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
- Remove the nut and disconnect the discharge hose sub-assembly.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
- Remove the nut and disconnect the discharge hose sub-assembly.
- DISCONNECT SUCTION HOSE SUB-ASSEMBLY
- Remove the nut and disconnect the suction hose sub-assembly.
NOTE:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.
- Remove the nut and disconnect the suction hose sub-assembly.
- REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY . Refer to REMOVAL - Step 3
- REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to REMOVAL - Step 8
- REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
- Remove the 2 nuts and No. 1 exhaust pipe support bracket.
- REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) . Refer to REMOVAL - Step 2
- SECURE STEERING WHEEL . Refer to REMOVAL - Step 4
- SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to REMOVAL - Step 5
- SEPARATE HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension)
- Remove the nut and separate the height control sensor link sub-assembly from the lower suspension arm.
- REMOVE FRONT AXLE SHAFT NUT LH . Refer to REMOVAL - Step 6
- REMOVE FRONT AXLE SHAFT NUT RH
HINT:
Perform the same procedure as for the LH side.
- SEPARATE FRONT STABILIZER LINK ASSEMBLY LH . Refer to REMOVAL - Step 5
- SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Perform the same procedure as for the LH side.
- SEPARATE FRONT SPEED SENSOR LH . Refer to REMOVAL - Step 5
- SEPARATE FRONT SPEED SENSOR RH
HINT:
Perform the same procedure as for the LH side.
- SEPARATE TIE ROD ASSEMBLY LH . Refer to REMOVAL - Step 6
- SEPARATE TIE ROD ASSEMBLY RH
HINT:
Perform the same procedure as for the LH side.
- SEPARATE FRONT LOWER SUSPENSION ARM LH . Refer to REMOVAL - Step 9
- SEPARATE FRONT LOWER SUSPENSION ARM RH
HINT:
Perform the same procedure as for the LH side.
- SEPARATE FRONT DRIVE SHAFT ASSEMBLY . Refer to REMOVAL - Step 5
- REMOVE FRONT DRIVE SHAFT ASSEMBLY LH . Refer to REMOVAL - Step 12
- REMOVE FRONT DRIVE SHAFT HOLE SNAP RING . Refer to DISASSEMBLY - Step 1
- REMOVE FRONT DRIVE SHAFT ASSEMBLY RH . Refer to REMOVAL - Step 13
- REMOVE FLYWHEEL HOUSING UNDER COVER
- Remove the 2 bolts and flywheel housing under cover.
- REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT
- Using SST, hold the crankshaft pulley.
- SST: 09213-70011
- 09213-70020
- SST: 09330-00021
- SST: 09213-70011
- Remove the 6 drive plate and torque converter clutch setting bolts.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
HINT:
There will be one black colored bolt.
- Using SST, hold the crankshaft pulley.
- REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
- Set the engine lifter.NOTE:
- Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
- Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
- Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
- Remove the 6 bolts, 2 nuts and frame side rail plates RH and LH.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION*1 Nut - Remove the 6 bolts, 2 nuts and front suspension member rear braces RH and LH.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEXT IN ILLUSTRATION*1 Nut - Operate the engine lifter, then remove the engine assembly from the vehicle.NOTE:
- Make sure that the engine is clear of all wiring and hoses.
- While lowering the engine from the vehicle, do not allow it to contact the vehicle.
- Install the No. 1 and No. 2 engine hangers with the 4 bolts.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)
PART NO.Item Part No. No. 1 engine hanger 12281-31120 No. 2 engine hanger 12282-31100 Bolt 91671-10825 - Attach the sling device to the engine hangers and chain block.
- Set the engine lifter.
- REMOVE NO. 2 EARTH WIRE
- Remove the bolt and No. 2 earth wire from the engine assembly.
- REMOVE V-RIBBED BELT See step 5
- REMOVE GENERATOR ASSEMBLY . Refer to REMOVAL - Step 8
- REMOVE COMPRESSOR AND MAGNETIC CLUTCH . Refer to REMOVAL - Step 38
- REMOVE STARTER ASSEMBLY . Refer to REMOVAL - Step 12
- REMOVE RADIATOR PIPE CLAMP
- Separate the breather plug hose and sensor wire from the radiator pipe clamp.
- Remove the bolt and radiator pipe clamp.
- REMOVE ENGINE WIRE
- Remove the engine wire from the engine with transaxle.
- REMOVE NO. 1 FRONT STABILIZER BRACKET LH (for AWD) . Refer to REMOVAL - Step 4
- REMOVE NO. 1 FRONT STABILIZER BRACKET RH (for AWD)
HINT:
Perform the same procedure as for the LH side.
- REMOVE FRONT STABILIZER BAR (for AWD)
- REMOVE STEERING LINK ASSEMBLY (for AWD) . Refer to REMOVAL - Step 12
- REMOVE FRONT FRAME ASSEMBLY
- Remove the nut and separate the engine mounting insulator LH.
- Disconnect the wire clamp and connector.
- Remove the bolt and separate the front engine mounting insulator.
- Remove the nut and separate the engine mounting insulator RH.
- Remove the 2 bolts and separate the rear engine mounting insulator assembly.
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE:Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.
- Remove the front frame assembly.
- REMOVE FRONT ENGINE MOUNTING INSULATOR
- Remove the 2 hole plugs.
- Remove the 3 nuts and front engine mounting insulator.
HINT:
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
- REMOVE ENGINE MOUNTING INSULATOR LH
- Remove the 2 hole plugs.
- Remove the 3 nuts and engine mounting insulator LH.
HINT:
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
- REMOVE ENGINE MOUNTING INSULATOR RH
- Remove the 2 hole plugs.
- Remove the 3 nuts and engine mounting insulator RH.
HINT:
Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
- REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY
- Remove the 2 hole plugs.
- Remove the 2 nuts and rear engine mounting insulator assembly.NOTE:
Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.
HINT:
Perform this procedure only when replacement of the engine mounting insulator assembly is necessary.
- REMOVE MANIFOLD STAY
- Remove the bolt, nut and manifold stay.
- REMOVE TRANSFER STIFFENER PLATE RH (for AWD)
- Remove the 4 bolts and transfer stiffener plate RH.
- REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) . Refer to REMOVAL - Step 8
- REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) . Refer to REMOVAL - Step 13
- REMOVE ENGINE MOUNTING BRACKET RH
- Remove the 3 bolts and engine mounting bracket RH.
- REMOVE REAR ENGINE MOUNTING BRACKET (for 2WD)
- Remove the 3 bolts and rear engine mounting bracket.
- REMOVE REAR ENGINE MOUNTING BRACKET (for AWD)
- Remove the 3 bolts and rear engine mounting bracket.
- REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY See step 3