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Removal [09/2015 - ]: Procedure

  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PROCEDURE - Step 2

  4. REMOVE COWL TOP VENTILATOR LOUVER RH 

    Refer to PROCEDURE - Step 2

  5. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Refer to PRECAUTION [09/2015 - ] ).

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    WARNING:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2015 - ] ).

  7. REMOVE V-BANK COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. REMOVE AIR CLEANER INLET COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 2

  9. REMOVE NO. 1 AIR CLEANER INLET 

    Refer to PROCEDURE - Step 3

  10. REMOVE ENGINE ROOM SIDE COVER RH 

    Refer to PROCEDURE - Step 7

  11. REMOVE ENGINE ROOM SIDE COVER LH 

    Refer to PROCEDURE - Step 6

  12. REMOVE FRONT CENTER FLOOR COVER 
    1. Remove the 3 screws, 2 bolts, clip and front center floor cover.
      GTY411116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE NO. 2 ENGINE UNDER COVER 
    1. Remove the 4 screws, 2 clips and No. 2 engine under cover.
      GTY411117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 7

  15. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 

    Refer to PROCEDURE - Step 8

  16. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 6

  17. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER 
    1. Remove the 9 bolts and front suspension member protector lower.
      GTY148059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  19. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 7

  20. DRAIN FRONT DIFFERENTIAL OIL 

    Refer to PROCEDURE - Step 1

  21. DRAIN AUTOMATIC TRANSMISSION FLUID 

    Refer to PROCEDURE - Step 3

  22. DISCONNECT NO. 1 OIL COOLER INLET HOSE 

    Refer to PROCEDURE - Step 11

  23. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE 

    Refer to PROCEDURE - Step 12

  24. REMOVE FRONT BUMPER COVER 

    (Refer to REMOVAL [09/2015 - ] )

  25. REMOVE FRONT SUSPENSION LOWER CROSSMEMBER 

    Refer to PROCEDURE - Step 17

  26. REMOVE REAR FRAME SIDE RAIL 
    1. Remove the 6 bolts, 4 nuts and 2 rear frame side rails.
      GTY410589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE INTAKE AIR CONNECTOR PIPE 

    Refer to PROCEDURE - Step 9

  28. REMOVE AIR CLEANER ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  29. REMOVE AIR CLEANER ASSEMBLY RH 

    Refer to PROCEDURE - Step 10

  30. REMOVE RADIATOR RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 9

  31. REMOVE ENGINE ROOM ECU OUTLET DUCT 
    1. Remove the engine room ECU outlet duct from the fan shroud and ECU box.
      GTY410582Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 1 RADIATOR HOSE 
  33. DISCONNECT NO. 2 RADIATOR HOSE 
  34. REMOVE RESONATOR BRACKET SUBASSEMBLY 

    See step  2

  35. REMOVE V-RIBBED BELT 

    See step  5

  36. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 4

  37. DISCONNECT NO. 3 FUEL HOSE 

    Refer to PROCEDURE - Step 4

  38. DISCONNECT NO. 1 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  39. DISCONNECT DISCHARGE HOSE SUBASSEMBLY 

    Refer to PROCEDURE - Step 7

  40. DISCONNECT SUCTION HOSE SUBASSEMBLY 

    Refer to PROCEDURE - Step 6

  41. DISCONNECT HOSES AND CONNECTORS 
    1. Remove the 3 bolts and engine room ECU cover.
      GTY634634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 TCM connectors and 2 wiring harness support connectors.
      GTY667980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Detach the 2 wiring harness support clamps, and then detach the clamp of connector A from the ECU box.

      HINT: 

      It is not necessary to disconnect the connection at A in the illustration.

    4. Lift up the wiring harness support and disconnect the 4 ECM connectors.
      GTY622154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Detach the 2 clamps. Then remove the 2 nuts and disconnect the wires with No. 1 engine room junction block.
      GTY616063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Detach the clamp and disconnect the 3 connectors with front controller.
      GTY685738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Release the locks of the power steering ECU connector A and disconnect the connectors B.
      GTY627767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Detach the 2 clamps.
    9. Remove the bolt and disconnect the ground wire.
      GTY629181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Disconnect the 2 connectors and detach the 5 clamps.
      GTY613429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Disconnect the 2 heater hoses.
      GTY685814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. Disconnect the purge line hose.
      GTY659873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY 

    (Refer to REMOVAL [09/2015 - ] )

  43. REMOVE NO. 1 AIR DUCT SUBASSEMBLY 
    1. Detach the 2 claws, and remove the bolt and No. 1 air duct SUBASSEMBLY.
      GTY402263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the air duct as its connection to the vehicle is very tight.

  44. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 13

  45. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    (Refer to REMOVAL [09/2015 - ] )

  46. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    (Refer to REMOVAL [09/2015 - ] )

  47. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    (Refer to REMOVAL [09/2015 - ] )

  48. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  49. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUBASSEMBLY RH 
    1. Remove the bolt. Then disconnect the front lower shock absorber bracket SUBASSEMBLY RH.
      GTY402126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUBASSEMBLY LH 
    1. Remove the bolt. Then disconnect the front lower shock absorber bracket SUBASSEMBLY LH.
      GTY402039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE ENGINE AND TRANSMISSION 
    1. Place a mark (with spray, etc.) over the rear right vehicle side attachment area of the front frame, which is indicated in the illustration.
      GTY685715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Place a mark (with spray, etc.) over the rear left vehicle side attachment area of the front frame.
    3. Set an engine lifter underneath the engine.
      NOTE:
      • Place wooden blocks or plate lift attachments so that the engine is level.
      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
    4. Remove the 4 rear engine mounting member's bolts.
      GTY633946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts shown in the illustration.
      GTY613162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Operate the engine lifter and slowly remove the engine from the vehicle.
      NOTE:
      • Make sure that the engine is clear of all wiring and hose.
      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.
  52. INSTALL NO. 1 ENGINE HANGER 
    1. Install the 2 No. 1 engine hangers with the 2 bolts as shown in the illustration.
      GTY629187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT: 

      No. 1 engine hanger 12281-38150
      Bolt 90119-14120
    2. Attach an engine sling device and hang the engine with a chain block.
      GTY409598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or No. 1 engine hangers may be damaged.

  53. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the 4 nuts and front frame assembly.
      GTY682356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Remove the engine oil level dipstick.
      GTY658480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and engine oil level dipstick guide.
    3. Remove the O-ring from the engine oil level dipstick guide.
  55. REMOVE GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 16

  56. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  57. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 5

  58. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the 2 nuts, 2 engine mounting spacers and 2 front engine mounting insulators.
      GTY621451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH 
    1. Remove the 5 bolts and front No. 1 engine mounting bracket RH.
      GTY685790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Remove the 5 bolts and front No. 1 engine mounting bracket LH.
      GTY685808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE EXHAUST MANIFOLD SUBASSEMBLY RH 

    Refer to PROCEDURE - Step 9

  62. REMOVE EXHAUST MANIFOLD SUBASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  63. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET RH 
    1. Remove the 2 nuts and front No. 2 engine mounting bracket RH.
      GTY674961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH 
    1. Remove the 2 nuts and front No. 2 engine mounting bracket LH.
      GTY623707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 6

  66. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 7

  67. REMOVE FRONT PROPELLER SHAFT ASSEMBLY 

    (Refer to REMOVAL [09/2015 - ] )

  68. REMOVE NO. 1 OIL COOLER TUBE 

    Refer to PROCEDURE - Step 13

  69. REMOVE NO. 3 COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 4

  70. DISCONNECT WIRE HARNESS AND CONNECTOR 

    Refer to PROCEDURE - Step 14

  71. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT 

    Refer to PROCEDURE - Step 15

  72. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 16

  73. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY 
    1. Using SST, hold the crankshaft.
      GTY674074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
        1. 90119-08216
      • SST: 09330-00021 
    2. Remove the 10 bolts, rear spacer plate, drive plate and ring gear SUBASSEMBLY and crankshaft position sensor rotor.
      GTY282272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL ENGINE ON ENGINE STAND 
    1. Install the engine onto an engine stand with the bolts.
      NOTE:
      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hangers may be damaged or deformed if the angle is incorrect.
      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
    2. Remove the 2 bolts and 2 No. 1 engine hangers.
  75. REMOVE COOLER COMPRESSOR ASSEMBLY 
    1. Remove the 2 bolts, 2 nuts, 2 stud bolts and cooler compressor assembly.
      GTY658754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  77. REMOVE NO. 5 ENGINE COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 18

  78. REMOVE NO. 6 ENGINE COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 19

  79. REMOVE ENGINE WIRE 
    1. for Engine LH Side:
      1. Disconnect the camshaft timing control valve connector.
        GTY685709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the 4 ignition coil connectors.
      3. Disconnect the 2 VVT sensor connectors.
      4. Disconnect the fuel pump connector (for high pressure).
      5. Disconnect the No. 8 engine wire connector.
      6. Disconnect the 4 wire harness clamps.
    2. for Engine Front Side:
      1. Disconnect the engine coolant temperature sensor connector.
        GTY623746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the 2 camshaft timing control motor connectors (for Bank 1).
      3. Disconnect the 2 camshaft timing control motor connectors (for Bank 2).
      4. Remove the 3 bolts and disconnect the clamp and ground wire.
      5. Remove the bolt and clamp bracket.
    3. for Engine RH Side:
      1. Disconnect the camshaft timing control valve connector.
        GTY674970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the 4 ignition coil connectors.
      3. Disconnect the 2 VVT sensor connectors.
      4. Disconnect the fuel pump connector (for high pressure).
      5. Disconnect the camshaft position sensor connector.
      6. Detach the 4 wire harness clamps.
      7. Disconnect the crankshaft position sensor connector.
      8. Remove the 2 bolts and disconnect the engine oil level sensor connector.
    4. for Engine Rear Side:
      1. Disconnect the engine wire connector.
        GTY623744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the fuel relief valve connector.
      3. Detach the 8 wire harness clamps.
      4. Remove the 2 bolts and disconnect the ground wire.
    5. Disconnect the throttle body connector.
    6. Disconnect the 8 injector driver connectors and detach the 2 clips as shown in the illustration.
      GTY128852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the purge VSV connector.
      GTY288417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disconnect the intake air control valve actuator connector.
    9. Remove the 2 bolts and disconnect the 2 clamp brackets and 2 clamps.
    10. Remove the 4 nuts and engine wire.
  80. REMOVE INJECTOR DRIVER 

    Refer to PROCEDURE - Step 15

  81. REMOVE NO. 1 ENGINE COVER 
    1. Remove the No. 1 engine cover.
      GTY397374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE WATER BY-PASS PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 16

  83. REMOVE PURGE VSV 

    Refer to PROCEDURE - Step 17

  84. REMOVE VENTILATION HOSE 
  85. REMOVE THROTTLE BODY ASSEMBLY 

    Refer to PROCEDURE - Step 9

  86. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 18

  87. REMOVE FUEL TUBE SUBASSEMBLY 

    Refer to PROCEDURE - Step 5

  88. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  89. REMOVE NO. 3 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 2

  90. REMOVE NO. 2 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 3

  91. REMOVE ENGINE COVER SUBASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 4

  92. REMOVE ENGINE COVER SUBASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 4

  93. REMOVE FUEL PUMP ASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 6

  94. REMOVE FUEL PUMP ASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 7

  95. REMOVE FUEL DELIVERY PIPE (for Port Injection) 

    Refer to PROCEDURE - Step 6

  96. REMOVE FUEL INJECTOR ASSEMBLY (for Port Injection) 

    Refer to PROCEDURE - Step 7

  97. REMOVE NO. 1 ENGINE COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 5

  98. REMOVE NO. 2 ENGINE COVER SUBASSEMBLY 

    Refer to PROCEDURE - Step 6

  99. REMOVE NO. 2 ENGINE COVER SUBASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  100. REMOVE NO. 4 FUEL PIPE SUBASSEMBLY 

    Refer to PROCEDURE - Step 8

  101. REMOVE FUEL DELIVERY PIPE (for Direct Injection) 

    Refer to PROCEDURE - Step 11

  102. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection) 

    Refer to PROCEDURE - Step 10

  103. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 12

  104. REMOVE FUEL INJECTOR SEAL (for Direct Injection) 

    Refer to PROCEDURE - Step 13

  105. REMOVE SEPARATOR CASE 

    Refer to PROCEDURE - Step 7

  106. REMOVE ENGINE WIRE 
    1. Detach the 5 clamps and remove the 2 bolts and engine wire.
      GTY271250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 knock sensor connectors.
  107. REMOVE NO. 4 ENGINE COVER SUBASSEMBLY 
    1. Remove the No. 4 engine cover SUBASSEMBLY.
      GTY685859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. REMOVE KNOCK SENSOR 

    Refer to PROCEDURE - Step 8

  109. REMOVE NO. 2 IDLER PULLEY SUBASSEMBLY 
    1. Remove the bolt and No. 2 idler pulley SUBASSEMBLY.
      GTY409551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. REMOVE NO. 1 IDLER PULLEY SUBASSEMBLY 
    1. Remove the bolt and No. 1 idler pulley SUBASSEMBLY.
      GTY630894Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  111. REMOVE WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 18

  112. REMOVE WATER INLET HOUSING 
    1. Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the water by-pass hose and water inlet hose.
      GTY685794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, water inlet housing and gasket.
      GTY512208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  113. REMOVE ENGINE OIL LEVEL SENSOR 

    Refer to PROCEDURE - Step 8

  114. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 3

  115. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 20

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