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Removal [05/2018 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [10/2015 - ]

  2. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. GTY616501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 front clips. Continue to raise the V-bank cover sub-assembly to disengage the 2 rear clips to remove the V-bank cover sub-assembly.

      NOTE:

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  3. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 1

  4. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  5. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [10/2015 - ]

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [09/2017 - ]

  7. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  8. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 4

  9. REMOVE FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  10. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 13 screws, 3 clips and No. 1 engine under cover assembly.
      GTY657480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip
  11. REMOVE SUSPENSION TOWER DAMPER (w/ Performance Damper) 

    Refer to PROCEDURE - Step 2

  12. REMOVE REAR ENGINE UNDER COVER LH 
    1. Remove the screw.
      GTY616424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw and remove the rear engine under cover LH from the vehicle.
  13. REMOVE REAR ENGINE UNDER COVER RH 

    HINT: 

    Perform the same procedure as for the LH side.

  14. SEPARATE FRONT FENDER LINER LH 
    1. Remove the 5 screws and separate the front fender liner LH.
  15. SEPARATE FRONT FENDER LINER RH 

    HINT: 

    Perform the same procedure as for the LH side.

  16. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY 
    1. Remove the 6 bolts, 4 nuts and front suspension member brace sub-assembly.
      GTY515784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Remove the 4 bolts and front lower suspension member protector.
      GTY515783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE NO. 2 ENGINE UNDER COVER 
    1. Remove the 2 screws and No. 2 engine under cover.
      GTY670913Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET 
    1. Remove the 2 bolts and engine under cover air guide bracket.
      GTY616426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  21. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 4

  22. DRAIN AUTOMATIC TRANSMISSION FLUID 

    Refer to PROCEDURE - Step 3

  23. REMOVE INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 7

  24. DISCONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 5

  25. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 6

  26. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  27. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disengage the 2 clamps and disconnect the vacuum hose assembly.
      GTY498693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp and disconnect the vacuum switching valve connector.
      GTY670912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and air cleaner case sub-assembly.
  28. REMOVE RADIATOR RESERVE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 12

  29. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 1 radiator hose from the front water by-pass joint.
      GTY670908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT NO. 2 RADIATOR HOSE 
    GTY670906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
  31. DISCONNECT NO. 2 OIL COOLER INLET HOSE 
    1. Slide the clip and disconnect the No. 2 oil cooler inlet hose from the oil cooler assembly.
      GTY498685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 2 OIL COOLER OUTLET HOSE 
    1. Slide the clip and disconnect the No. 2 oil cooler outlet hose from the oil cooler assembly.
      GTY498687Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT OIL COOLER HOSE SUB-ASSEMBLY 
    1. Remove the 2 bolts and disconnect the oil cooler hose sub-assembly.
      GTY516412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the oil cooler hose sub-assembly.
      GTY510542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT HEATER WATER OUTLET HOSE 
    1. Slide the clip and disconnect the heater water outlet hose from the No. 3 water by-pass pipe.
      GTY515786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT HEATER WATER INLET HOSE 
    1. Slide the clip and disconnect the heater water inlet hose from the No. 3 water by-pass pipe.
      GTY515785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disengage the union to check valve hose from the clamp.
      GTY670905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.
  37. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. GTY521520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).

  38. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp.
      GTY515790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the fuel tube connector and then pull off the No. 2 fuel tube sub-assembly.
      GTY515789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter in the fuel pipe and around the fuel tube connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel pipe and fuel tube connector.
      • Do not use any tools to separate the fuel pipe and fuel tube connector.
      • Do not forcibly bend or twist the nylon tube.
      • Put the fuel pipe and fuel tube connector ends in plastic bags to prevent damage and contamination.
      • If the fuel pipe and fuel pipe connector are stuck together, pinch the fuel pipe between your fingers and turn it carefully to free it. Then disconnect the No. 2 fuel tube sub-assembly.
  39. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the fuel pipe clamp.
      GTY515819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the fuel tube connector and then pull off the fuel tube sub-assembly.
      GTY521528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check for any dirt and foreign matter in the fuel pipe and around the fuel tube connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel pipe and fuel tube connector.
      • Do not use any tools to separate the fuel pipe and fuel tube connector.
      • Do not forcibly bend or twist the nylon tube.
      • Put the fuel pipe and fuel tube connector ends in plastic bags to prevent damage and contamination.
      • If the fuel pipe and fuel tube connector are stuck together, pinch the fuel pipe between your fingers and turn it carefully to free it. Then disconnect the fuel tube sub-assembly.
  40. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 9

  41. DISCONNECT SUCTION HOSE 

    Refer to PROCEDURE - Step 10

  42. REMOVE ENGINE ROOM ECU COVER 

    Refer to PROCEDURE - Step 4

  43. DISCONNECT WIRE HARNESS 

    HINT: 

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.

    1. Engine room LH side:
      1. Disengage the engine wire clamp.
        GTY515709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Separate the engine wire from the engine room ECU box.

        Refer to PROCEDURE - Step 5

    2. Engine room RH side:
      1. Disengage the No. 2 engine wire clamp.
        GTY616419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the nut and disconnect the No. 2 engine wire from the positive (+) battery terminal.
      3. Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block.
      4. Remove the nut from the No. 1 engine room relay block.
        GTY616482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Disengage the No. 4 engine wire clamp.
        GTY616481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Disengage the 2 claws and disconnect the No. 4 engine wire from the No. 1 engine room relay block.
      7. Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.
        GTY616467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disengage the clamp.
      GTY495709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the ground cable from the generator assembly.
  44. REMOVE POWER STEERING ECU ASSEMBLY 

    Refer to REMOVAL [09/2017 - ]

  45. REMOVE BATTERY TRAY 

    Refer to PROCEDURE - Step 5

  46. SEPARATE NO. 1 ENGINE ROOM RELAY BLOCK 

    Refer to PROCEDURE - Step 6

  47. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY 

    Refer to REMOVAL [10/2015 - ]

  48. SEPARATE FRONT SKID CONTROL SENSOR WIRE LH 

    Refer to PROCEDURE - Step 2

  49. SEPARATE FRONT SKID CONTROL SENSOR WIRE RH 

    HINT: 

    Perform the same procedure as for the LH side.

  50. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH 
    1. Remove the bolt and nut, and disconnect the front shock absorber assembly LH from the front suspension lower arm assembly LH.
      NOTE:
      • Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut secured.
      GTY497501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  52. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  53. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  54. REMOVE STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY 

    Refer to REMOVAL [09/2017 - ]

  55. SEPARATE TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 19

  56. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as the LH side.

  57. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  58. DISCONNECT WIRE HARNESS 
    1. Disconnect the 3 power steering link assembly connectors.

      HINT: 

      For the connector with lock lever, pull up the lock lever to disengage the lock.

      GTY504189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 wire harness clamps from the power steering link assembly.
  59. REMOVE ENGINE WITH TRANSMISSION ASSEMBLY 
    1. Remove the 8 nuts, 2 bolts and 2 oil cooler brackets.
      GTY618085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
    2. Remove the 6 bolts and 2 No. 2 frame crossmember assemblies.
      GTY515942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine with transmission assembly.
      GTY657055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachment Installation Position
      NOTE:
      • Using height adjustment attachments and plate lift attachments, place the engine with transmission assembly horizontally.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan of the engine with transmission assembly.
      • 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.
    4. Remove the 4 bolts and separate the rear engine mounting member from the vehicle body.
      GTY520407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and disconnect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH.
      GTY666042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    6. Remove the 6 bolts, 2 nuts, strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.
    7. Operate the engine lifter and remove the engine with transmission assembly from the vehicle.
      NOTE:
      • Make sure that the engine with transmission assembly is clear of all wiring and hoses.
  60. INSTALL NO. 1 ENGINE HANGER 
    1. Install the 2 No. 1 engine hangers with the 2 bolts as shown in the illustration.
      GTY517105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      No. 1 Engine Hanger 12081-38040
      Bolt 90119-14120
    2. Attach an engine sling device and hang the engine with transmission assembly with a chain block.
      GTY499693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a No. 1 Engine Hanger
      *b Engine Assembly
      *c 50° or Less
      NOTE:

      When hanging the engine assembly, make sure to hang it with the chains at an angle of 50° or less. Otherwise, the engine assembly or engine hangers may be damaged.

  61. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  62. REMOVE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 8

  63. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH 
    1. Disengage the 2 clamps and remove the engine under cover sub-assembly LH from the front suspension crossmember sub-assembly.
      GTY498688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH 
    1. Disengage the 2 clamps and remove the engine under cover sub-assembly RH from the front suspension crossmember sub-assembly.
      GTY517756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE ENGINE MOUNTING DAMPER 
    1. Remove the 2 bolts and 2 engine mounting dampers.
      GTY507542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 9

  67. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 10

  68. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3

  69. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 4

  70. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  71. REMOVE FAN AND GENERATOR V BELT 

    Refer to PROCEDURE - Step 2

  72. DISCONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 12

  73. REMOVE OIL COOLER TUBE 
    1. Disengage the clamp from the oil cooler tube.
      GTY121430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and oil cooler tube.
  74. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY 
    1. Remove the 2 bolts, 2 nuts and compressor with pulley assembly.
      GTY518367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  76. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  77. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 8

  78. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 13

  79. REMOVE REAR ENGINE MOUNTING MEMBER 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting member is necessary.

    1. GTY518955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 4 nuts and rear engine mounting member from the rear engine mounting insulator.

  80. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    1. Remove the 4 nuts and rear engine mounting insulator from the No. 1 engine mounting bracket.
      GTY515341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE REAR ENGINE MOUNTING HEAT INSULATOR 
    1. Remove the rear engine mounting heat insulator from the rear engine mounting insulator.
      GTY515650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE NO. 1 ENGINE MOUNTING BRACKET 
    1. Remove the 4 bolts and No. 1 engine mounting bracket from the automatic transmission assembly.
      GTY515340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  84. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the 2 nuts and front suspension crossmember sub-assembly from the engine assembly.
      GTY498552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.

    1. Remove the 2 engine mounting spacers.
      GTY505854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and 2 front engine mounting insulators from the front suspension crossmember sub-assembly.
      GTY498686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL ENGINE TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
      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.
      • 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.
    2. Remove the 2 bolts and 2 No. 1 engine hangers.
  87. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Using a precision straightedge and feeler gauge.

      Check the surface which contacts the cylinder head LH for warpage.

      GTY105540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Warpage

      0.50 mm (0.0197 in.)

      If the warpage is more than the maximum, replace the exhaust manifold sub-assembly LH.

  88. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Using a precision straightedge and feeler gauge.

      Check the surface which contacts the cylinder head sub-assembly for warpage.

      GTY105539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Maximum Warpage

      0.50 mm (0.0197 in.)

      If the warpage is more than the maximum, replace the exhaust manifold sub-assembly RH.

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