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Engine Assembly, Intake Manifold, Exhaust Manifold: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    See PRECAUTION

  2. REMOVE FRONT WHEELS 
  3. REMOVE ENGINE UNDER COVER RH 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE FRONT FENDER APRON SEAL RH 
  6. DRAIN ENGINE OIL 
  7. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  8. DRAIN AUTOMATIC TRANSAXLE FLUID  (See REMOVAL )
  9. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  13. REMOVE COWL TOP PANEL OUTER  (See REMOVAL )
  14. REMOVE BATTERY 
  15. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 6 clips and intake duct seal.
  16. REMOVE V-BANK COVER SUB-ASSEMBLY  (See REMOVAL )
  17. REMOVE V-RIBBED BELT  (See REMOVAL  )
  18. REMOVE RADIATOR RESERVE TANK ASSEMBLY 
    Fig 1: Locating Intake Duct Seal Clips
    G05404860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
    Fig 2: Locating Engine Mounting Stay Bolt And Nut RH
    G05248057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the 4 bolts and engine moving control rod.
      Fig 3: Locating Engine Moving Control Rod Bolts
      G05248058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 2 AIR CLEANER INLET 
    1. Disconnect the clamp and 2 vacuum hoses.
    2. Remove the 2 bolts and No. 2 air cleaner inlet.
  22. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE  (See REMOVAL )
  23. REMOVE AIR CLEANER CASE 
    1. Remove the air cleaner filter element from the air cleaner case.
      Fig 4: Locating Air Cleaner Filter Element From Air Cleaner Case And Bolts
      G05404863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector, vacuum hose, and hose clamp.
    3. Remove the 3 bolts and air cleaner case.
      Fig 5: Locating Air Cleaner Case Bolts
      G05404864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt and No. 1 air cleaner inlet.
      Fig 6: Locating No.1 Air Cleaner Inlet
      G05404865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY 
    1. Disconnect the wire harness clamp.
    2. Remove the clip, bolt and intake air resonator.
      Fig 7: Locating Intake Air Resonator Clip And Bolt
      G05404866Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 1 FUEL VAPOR FEED HOSE 
    1. Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
  27. REMOVE INTAKE AIR SURGE TANK ASSEMBLY  (See REMOVAL )
    Fig 8: Locating No. 1 Fuel Vapor Feed Hose Clamp
    G05248059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. SEPARATE FUEL TUBE SUB-ASSEMBLY 
    1. Release the claw and remove the No. 1 fuel pipe clamp.
      Fig 9: Locating No. 1 Fuel Pipe Clamp Claw
      G05404868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the tube while pinching parts A with your fingers as shown in the illustration.
      NOTE:
      • Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
      • Disconnect the connector by hand.
      • Do not bend, kink or twist the nylon tube.
      • If the pipe and connector are stuck together, push and pull on the connector to release them.
      • Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
        Fig 10: Disconnecting Connector From Tube
        G04974163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE RADIATOR HOSE INLET 
    1. Remove Identifying the clamp and disconnect the radiator hose inlet.
      Fig 11: Locating Radiator Hose Inlet Clamp
      G05248061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE RADIATOR HOSE OUTLET 
    1. Remove the clamp and disconnect the radiator hose outlet.
  31. DISCONNECT NO. 1 OIL COOLER INLET HOSE  (See REMOVAL )
  32. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE  (See REMOVAL )
    Fig 12: Locating Radiator Hose Outlet Clamp
    G05404871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT HEATER WATER INLET HOSE A 
    1. Disconnect the heater water inlet hose.
  34. DISCONNECT HEATER WATER OUTLET HOSE A 
    1. Disconnect the heater water outlet hose.
  35. REMOVE ECM  (See REMOVAL )
  36. REMOVE STARTER ASSEMBLY  (See REMOVAL )
  37. REMOVE UPPER RELAY BLOCK COVER 
    Fig 13: Locating Heater Water Outlet Hose
    G05248064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the engine room junction block.
      1. Remove the nut and separate the wire harness.
      2. Using a screwdriver, release the engine room junction block. Pull the engine room junction block upward.
      3. Disconnect the 2 engine wire connectors.
        Fig 14: Locating Engine Wire Connectors
        G04996606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine wire connector and 3 clamps.
    3. Remove the 2 bolts and disconnect the 2 ground cables.
      Fig 15: Locating Ground Cables Bolts
      G05404874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the ground cable from the wire bracket.
    5. Disconnect the engine wire clamp.
    6. Remove the 2 bolts and ground cable from the cylinder head.
  39. SEPARATE WIRE HARNESS  (See REMOVAL )
  40. DISCONNECT CONNECTOR  (See REMOVAL )
  41. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See REMOVAL )
    Fig 16: Locating Ground Cable Bracket Bolts
    G05404875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE 
    1. Disconnect the No. 1 oil reservoir to pump hose.
      Fig 17: Locating No. 1 Oil Reservoir To Pump Hose
      G04974466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. DISCONNECT STEERING GEAR OUTLET RETURN TUBE 
    1. Disconnect the steering gear outlet return tube.
  44. REMOVE FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET  (See REMOVAL )
  45. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  46. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
    Fig 18: Locating Steering Gear Outlet Return Tube
    G05404877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  48. REMOVE FRONT AXLE SHAFT LH NUT  (See REMOVAL )
  49. REMOVE FRONT AXLE SHAFT RH NUT 

    HINT:

    Use the same procedures described for the LH side.

  50. SEPARATE FRONT SPEED SENSOR LH  (See REMOVAL )
  51. SEPARATE FRONT SPEED SENSOR RH 

    HINT:

    Use the same procedures described for the LH side.

  52. SEPARATE TIE ROD ASSEMBLY LH  (See REMOVAL )
  53. SEPARATE TIE ROD ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  54. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See REMOVAL )
  55. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  56. SEPARATE FRONT AXLE ASSEMBLY LH  (See REMOVAL )
  57. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  58. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Remove the nut and No. 1 exhaust pipe support bracket.
  59. REMOVE FLYWHEEL HOUSING UNDER COVER  (See REMOVAL )
  60. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT  (See REMOVAL )
  61. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY  (See REMOVAL )
  62. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  63. SEPARATE COOLER COMPRESSOR ASSEMBLY 
    1. Remove the 2 connector clamps.
    2. Remove the 4 bolts and separate the compressor.

      HINT:

      Hang up the compressor and hoses instead of detaching them.

  64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      Fig 19: Locating Cooler Compressor Assembly Bolts
      G04996616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts, 2 nuts, frame side rail plates RH and LH.
    3. Remove the 4 bolts, 2 nuts, front suspension member brace rears RH and LH.
    4. Operate the engine lifter, and then remove the engine assembly from the vehicle.
      NOTE: Make sure that the engine is clear of all wiring and hoses.
      Fig 20: Locating Frame Side Rail Plates RH And LH Bolts And Nuts
      G04974469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part NO.: 

      No. 1 engine hanger 12281-31120 

      No. 2 engine hanger 12282-31100 

      Bolts 90119-A0117 

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

    6. Attach the engine sling device and hang the engine with the chain block.
      Fig 21: Locating Engine Hangers With Bolts
      G05404880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE VANE PUMP ASSEMBLY 
    1. Remove the pressure feed tube clamp bolt.
    2. Remove the 2 bolts and vane pump.
      Fig 22: Locating Frame Side Rail Plates RH And LH Bolts
      G04996619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE FRONT FRAME ASSEMBLY 
    1. Disconnect the connector and clamp.
      Fig 23: Identifying Connector And Clamp
      G04974472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps.
      Fig 24: Locating Clamps
      G04974473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts and disconnect the engine mounting insulators RH and LH.
      Fig 25: Locating Engine Mounting Insulators Bolts
      G05404884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the front engine mounting insulator.
  67. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  68. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See REMOVAL )
  69. REMOVE ENGINE WIRE 
  70. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY  (See REMOVAL )
    Fig 26: Locating Front Engine Mounting Insulator Bolts
    G04974475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY  (See REMOVAL  )
  72. INSTALL ENGINE STAND 
    1. Secure the engine onto an engine stand with the bolts.
  73. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 6 bolts and 6 ignition coils.
  74. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt and No. 2 engine mounting stay RH.
  75. REMOVE INTAKE MANIFOLD 
    1. Uniformly loosen and remove the 6 bolts and 4 nuts.
    2. Remove the intake manifold and 2 gaskets.
      Fig 27: Locating Intake Manifold Bolts And Nuts
      G04974480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Uniformly loosen and remove the 6 nuts.
    2. Remove the manifold and gasket.
      Fig 28: Locating Exhaust Manifold Sub-Assembly Nuts
      G04974481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY 
    1. Remove the oil level gauge.
    2. Remove the 2 bolts, No. 1 oil level gauge guide and No. 2 oil level gauge guide.
    3. Remove the 2 O-rings from the oil level gauge guides.
      Fig 29: Locating No. 1 Oil Level Gauge Guide And No. 2 Oil Level Gauge Guide Bolts
      G04974515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and No. 2 manifold stay.
      Fig 30: Locating No. 2 Manifold Stay Bolt And Nut
      G05248084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 3 bolts and No. 2 exhaust manifold heat insulator.
      Fig 31: Locating No. 2 Exhaust Manifold Heat Insulator With Bolts
      G04974484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Uniformly loosen and remove the 6 nuts.
    2. Remove the manifold and gasket.
      Fig 32: Locating Exhaust Manifold Sub-Assembly LH Nuts
      G04974485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      Fig 33: Locating Engine Mounting Bracket RH Bolts
      G04974486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      Fig 34: Locating Drive Shaft Bearing Bracket Bolts
      G04974487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the 5 bolts and V-ribbed belt tensioner assembly.
      Fig 35: Locating Ribbed Belt Tensioner Assembly Bolts
      G04974488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE NO. 2 TIMING GEAR COVER 
    1. Remove the 2 bolts and No. 2 timing gear cover.
      Fig 36: Locating No. 2 Timing Gear Cover Bolts
      G04974489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the 2 bolts, 2 plates and 2 No. 2 idler pulley sub-assemblies.
  86. REMOVE WATER PUMP PULLEY  (See REMOVAL )
    Fig 37: Locating No. 2 Idler Pulley Sub-Assembly Bolts
    G05404896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Remove the 6 bolts and front No. 1 engine mounting bracket LH.
      Fig 38: Locating Front No. 1 Engine Mounting Bracket LH. Bolts
      G04974505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE RADIO SETTING CONDENSER 
    1. Remove the 2 bolts and 2 radio setting condensers.
      Fig 39: Locating Radio Setting Condensers And Bolts
      G04974492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 
    1. Remove the bolt and No. 1 vacuum switching valve.
      Fig 40: Locating No. 1 Vacuum Switching Valve Bolt
      G04974493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
  91. REMOVE KNOCK CONTROL SENSOR  (See REMOVAL )
    Fig 41: Removing/Installing Engine Oil Pressure Switch Assembly
    G04974494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.
  93. REPLACE PARTIAL ENGINE ASSEMBLY 
    Fig 42: Removing/Installing Engine Coolant Temperature Sensor
    G04974495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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