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Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See PRECAUTION .

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. REMOVE FRONT WHEELS 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE ENGINE UNDER COVER RH 
  7. REMOVE FRONT FENDER APRON SEAL RH 
  8. DRAIN ENGINE OIL  (See REPLACEMENT )
  9. DRAIN ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  10. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)  (See REMOVAL )
  11. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle)  (See REMOVAL )
  12. DRAIN BRAKE FLUID (for Manual Transaxle)  (See REMOVAL )
  13. REMOVE WINDSHIELD WIPER LINK ASSEMBLY 

    HINT:

    See REMOVAL .

  14. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY  (See REMOVAL )
  15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Remove the 2 nuts and cover.
      Fig 1: Locating Engine Cover Sub-Assembly And Nuts
      G04974142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE V-RIBBED BELT  (See REMOVAL )
  17. REMOVE AIR CLEANER INLET ASSEMBLY 
    1. Remove the 2 bolts, clamp and air cleaner inlet.
      Fig 2: Locating Clamp And Air Cleaner Inlet Bolts
      G04974143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disconnect the hose clamp.
    2. Remove the 3 bolts and air cleaner case.
      Fig 3: Locating Air Cleaner Case And Bolts
      G04974144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE BATTERY 
    1. Loosen the bolt and nut, and remove the battery clamp.
    2. Remove the battery and battery tray.
      Fig 4: Locating Battery Clamp Bolt And Nut
      G04974145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the 2 bolts and No. 2 mounting stay RH.
      Fig 5: Locating Mounting Stay And Bolts
      G04974146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the ground cable.
      Fig 6: Locating Ground Cable Bolts
      G04974147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and the engine moving control rod with bracket.
      Fig 7: Locating Engine Moving Control Rod, Bracket And Bolts
      G04974148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and No. 2 mounting bracket RH.
      Fig 8: Locating Mounting Bracket And Bolts
      G04974149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT NO. 1 VACUUM HOSE CONNECTOR 
    1. Remove the clamp and disconnect the vacuum hose connector.
      Fig 9: Identifying Vacuum Hose Connector
      G04974150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT RADIATOR HOSE INLET 
    1. Remove the clamp and disconnect the radiator hose inlet.
      Fig 10: Identifying Radiator Hose Inlet And Clamp
      G04974151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT RADIATOR HOSE OUTLET 
    1. Remove the clamp and disconnect the radiator hose outlet.
      Fig 11: Locating Heater Water Inlet Hose
      G04974153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT OIL COOLER INLET HOSE (for Automatic Transaxle)  (See REMOVAL )
  28. DISCONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle)  (See REMOVAL )
  29. DISCONNECT HEATER INLET WATER HOSE 
    1. Disconnect the heater inlet water hose.
      Fig 12: Identifying Heater Inlet Water Hose
      G04974152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Disconnect the heater outlet water hose.
      Fig 13: Locating Heater Water Outlet Hose
      G04974154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE ECM 

    HINT:

    See REMOVAL .

  32. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the engine room relay block.
      1. Remove the nut and separate the wire harness.
      2. Using a screwdriver, unlock the engine room R/B. Pull the engine room R/B upward.
      3. Disconnect the engine wire connectors.
        Fig 14: Locating Engine Wire And Engine Room Relay Block
        G04974155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp from the bracket.
      Fig 15: Locating Clamp And Bracket
      G04974156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and clamp from the body.
      Fig 16: Locating Clamp And Bolts
      G04974157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Remove the clip and nut, and separate the control lever.
    2. Separate the clamp and separate the cable from the transaxle.
      Fig 17: Locating Transmission Control Cable Assembly (For Automatic Transaxle)
      G04974158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the 2 clips and 2 washers and disconnect the 2 cables from the transaxle.
    2. Remove the 2 clips and disconnect the 2 cables from the control cable bracket.
      Fig 18: Locating Transmission Control Cable Assembly ( For Manual Transaxle)
      G04974159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE 
    1. Disconnect the No. 1 oil reservoir to pump hose.
      Fig 19: Locating Oil Reservoir To Pump Hose No. 1
      G04974160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT RETURN TUBE SUB-ASSEMBLY 
    1. Disconnect the return tube sub-assembly.
      Fig 20: Locating Return Tube Sub-Assembly
      G04974161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL .

  38. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See DISASSEMBLY .

  39. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
      Fig 21: Locating Fuel Pipe Clamp
      G04974162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration.
      Fig 22: Disconnecting Connector From Tube
      G04974163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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, fold or rotate the nylon tube.
      • If the pipe and connector are stuck together, push and pull the connector until it becomes free.
      • Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
  40. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  41. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH 
    1. Disconnect the connector.
    2. Remove the 4 bolts and separate the compressor.

      HINT:

      Hang up the hoses instead of detaching them.

      Fig 23: Locating Compressor Bolts
      G04974164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    HINT:

    See REMOVAL .

  43. REMOVE FRONT AXLE HUB NUT LH  (See REMOVAL )
  44. REMOVE FRONT AXLE HUB NUT RH 

    HINT:

    Use the same procedures described for the LH side.

  45. REMOVE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  46. REMOVE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  47. REMOVE FRONT SPEED SENSOR LH  (See REMOVAL )
  48. REMOVE FRONT SPEED SENSOR RH 

    HINT:

    Use the same procedures described for the LH side.

  49. DISCONNECT TIE ROD ASSEMBLY LH  (See REMOVAL )
  50. DISCONNECT TIE ROD ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  51. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH  (See REMOVAL )
  52. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH 

    HINT:

    Use the same procedures described for the LH side.

  53. SEPARATE FRONT AXLE ASSEMBLY LH  (See REMOVAL )
  54. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  55. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)  (See REMOVAL )
  56. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Remove the 2 bolts and exhaust pipe support bracket.
  57. SEPARATE STEERING SLIDING YOKE  (See REMOVAL )
  58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.
      Fig 24: Locating Bolts, Nuts And Frame Side Rail Plate RH And LH
      G04974165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
      Fig 25: Locating Bolts, Nuts And Front Suspension Member Brace Rear RH And LH
      G04974166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Carefully remove the engine assembly from the vehicle.
    5. Install the 2 engine hangers as shown in the illustration.
      Fig 26: Locating Engine Hangers
      G04974167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Parts No.: 

      ENGINE HANGERS SPECIFICATION

      Parts Parts No.
      No. 1 Engine hanger 12281-28010
      No. 2 Engine hanger 12282-28010
      Bolt 91512-61020

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

    6. Using a chain block and an engine sling device, hang the engine assembly.
  59. REMOVE VANE PUMP ASSEMBLY 
    1. Disconnect the oil pressure switch connector.
    2. Loosen the 2 bolts and remove the vane pump from the engine.
      Fig 27: Locating Vane Pump To Engine With Bolts
      G04974168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE FRONT FRAME ASSEMBLY 
    1. A/T:

      Remove the nut from the engine mounting insulator LH.

      Fig 28: Locating Engine Mounting Insulator LH With Nut (A/T)
      G04974169Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. M/T:

      Remove the bolt from the engine mounting insulator LH.

      Fig 29: Locating Engine Mounting Insulator LH With Bolt (M/T)
      G04974170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut from the engine mounting insulator RH.
      Fig 30: Locating Engine Mounting Insulator RH With Nut
      G04974171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt from the engine mounting insulator FR.
      Fig 31: Locating Engine Mounting Insulator FR With Bolt
      G04973959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. MIT.

      Remove the bolt from the engine lateral control rod.

      Fig 32: Locating Bolt From Engine Lateral Control Rod
      G04974173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Raise the engine assembly and separate the front frame.
  61. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See DISASSEMBLY )
  62. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See DISASSEMBLY )
  63. REMOVE ENGINE WIRE 
  64. REMOVE STARTER ASSEMBLY (for Manual transaxle)  (See REMOVAL )
  65. REMOVE STARTER ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  66. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT:

    See REMOVAL .

  67. SEPARATE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL .

  68. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  69. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See DISASSEMBLY )
  70. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See DISASSEMBLY )
  71. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  72. INSTALL ENGINE STAND 
    1. Fix the engine onto a engine stand with the bolts.
  73. REMOVE FUEL DELIVERY PIPE WITH INJECTOR  (See REMOVAL )
  74. REMOVE INTAKE MANIFOLD 
    1. Remove the 5 bolts, 2 nuts, and intake manifold.
      Fig 33: Locating Intake Manifold, Bolts And Nut
      G04974174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket from the intake manifold.
      Fig 34: Identifying Intake Manifold Gasket
      G04974175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE INTAKE AIR CONTROL VALVE (for PZEV)  (See REMOVAL )
  76. REMOVE NO. 2 VENTILATION HOSE 
  77. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR 
    1. Remove the intake manifold insulator from the cylinder block.
      Fig 35: Identifying Intake Manifold Insulator And Cylinder Block
      G04974176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      Fig 36: Locating Drive Shaft Bearing Bracket And Bolts
      G04974177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 
  80. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Remove the bolt and oil level gauge guide.
      Fig 37: Locating Oil Level Gauge Guide Bolt
      G04974178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the oil level gauge guide.
  81. REMOVE MANIFOLD STAY 
    1. Remove the bolt, nut and stay.
      Fig 38: Installing Stay With Bolt And Nut
      G04974179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and stay.
      Fig 39: Locating Stay With Bolt And Nut
      G04974180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. For PZEV:
      1. Disconnect the air-fuel ratio sensor connector.
        Fig 40: Locating Air-Fuel Ratio Sensor Connector
        G04974181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the 5 nuts, manifold converter and gasket.
        Fig 41: Identifying Manifold Converter And Nuts
        G04974182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Except for PZEV:
      1. Remove the 4 bolts and No. 1 insulator.
        Fig 42: Locating Exhaust Manifold Heat Insulator With Bolts
        G04974183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the air-fuel ratio sensor connector.
        Fig 43: Locating Air-Fuel Ratio Sensor Connector
        G04974184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Remove the 5 nuts, manifold converter and gasket.
        Fig 44: Removing Nuts Manifold Converter And Gasket
        G04974185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. REMOVE WATER INLET  (See REMOVAL )
  85. REMOVE THERMOSTAT  (See REMOVAL )
  86. REMOVE NO. 1 WATER BY-PASS PIPE 
    1. Remove the bolt, 2 nuts and No. 1 water by-pass pipe with the gasket.
      Fig 45: Locating No. 1 Water By-Pass Pipe Bolt And Nuts
      G04974186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE OIL COOLER PIPE (w/ Oil Cooler) 
    1. Remove the bolt, 2 nuts and oil cooler pipe with the gasket.
      Fig 46: Locating Oil Cooler Pipe, Nuts And Bolts
      G04974187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      Fig 47: Locating Engine Mounting Bracket With Bolts
      G04973963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the bolt, nut and belt tensioner
      Fig 48: Locating V-Ribbed Belt Tensioner Assembly
      G04973958Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 4 bolts and 4 ignition coils.
  91. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY  (See REMOVAL )
  92. REMOVE KNOCK SENSOR 
    1. Disconnect the sensor connector.
    2. Remove the nut and sensor.
  93. REMOVE RADIO SETTING CONDENSER 
    1. Remove the bolt and radio setting condenser.
      Fig 49: Locating Radio Setting Condenser Bolt
      G04974190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
      Fig 50: Removing Engine Oil Pressure Switch Assembly
      G04974191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the sensor and gasket.

      SST 09817-33190 

      Fig 51: Locating Gasket And ECT Sensor
      G04974192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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