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Engine Assembly, Intake Manifold, Exhaust Manifold: Removal

WARNING: This page is about a different variant/trim than selected.
  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  (See REMOVAL )
  11. REMOVE WINDSHIELD WIPER LINK ASSEMBLY 

    See REMOVAL .

  12. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY  (See REMOVAL )
  13. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 7 clips and intake duct seal.
      Fig 1: Identifying Clips And Intake Duct Seal
      G04974445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
    NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
    Fig 2: Identifying Clips On Front Of Cover
    G04974446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE V-RIBBED BELT  (See REMOVAL )
  16. REMOVE AIR CLEANER INLET ASSEMBLY 
    1. Remove the 2 bolts, clamp and air cleaner inlet.
      Fig 3: Locating Bolts, Clamp And Air Cleaner Inlet
      G04974447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disconnect the vacuum hose and hose clamp.
    2. Remove the 3 bolts and air cleaner case.
      Fig 4: Locating Bolts And Air Cleaner Case
      G04974448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt and No. 1 air cleaner inlet.
      Fig 5: Locating No. 1 Air Cleaner Inlet Bolt
      G04974449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE BATTERY 
    1. Loosen the bolt and nut, and remove the battery clamp.
      Fig 6: Removing Battery Clamp With Bolt And Nut
      G04974450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the battery and battery tray.
  21. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY 
    1. Remove the clip, bolt and intake air resonator.
      Fig 7: Locating Intake Air Resonator Sub-Assembly Bolt And Clip
      G04974451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt, 2 nuts, and No. 2 mounting stay RH.
      Fig 8: Locating Bolt And Nuts For No. 2 Engine Mounting Stay RH
      G04974452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 
    1. Remove the 4 bolts and engine moving control rod.
      Fig 9: Locating Bolts And Engine Moving Control Rod
      G04974453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
      Fig 10: Identifying No. 1 Fuel Vapor Feed Hose
      G04974454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE 
    1. Remove the clamp and disconnect the check valve to brake booster hose.
      Fig 11: Identifying Check Valve To Brake Booster Hose
      G04974455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE RADIATOR HOSE INLET 
    1. Remove the clamp and disconnect the radiator hose inlet.
      Fig 12: Identifying Radiator Hose Inlet
      G04974456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE RADIATOR HOSE OUTLET 
    1. Remove the clamp and disconnect the radiator hose outlet.
      Fig 13: Identifying Radiator Hose Outlet And Clamp
      G04974457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT NO. 1 OIL COOLER INLET HOSE 
    1. Remove the clamp and disconnect the oil cooler inlet hose.
      Fig 14: Identifying Oil Cooler Outlet Hose
      G04974458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE 
    1. Remove the clamp and disconnect the oil cooler outlet hose.
  30. DISCONNECT HEATER INLET WATER HOSE 
    1. Disconnect the heater inlet water hose.
      Fig 15: Identifying Heater Inlet Water Hose
      G04974459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Disconnect the heater outlet water hose.
  32. REMOVE ECM 

    HINT:

    See REMOVAL .

  33. REMOVE RELAY BLOCK COVER UPPER 
  34. 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, unlock the engine room J/ B. Pull the engine room J/B upward.
      3. Disconnect the engine wire connectors.
      Fig 16: Disconnecting Engine Wire From Engine Room Junction Block
      G04974155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and 2 clamps from the body.
      Fig 17: Locating Body Bolts And Clamps
      G04974461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and clamp from the bracket.
      Fig 18: Locating Bracket Bolt And Clamp
      G04974462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the clip and nut, and separate the cable from the transaxle.
      Fig 19: Locating Transmission Control Cable Assembly Clip And Nut
      G04974463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. SEPARATE FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
      Fig 20: Removing 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 21: 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.
  37. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE 
    1. Disconnect the No. 1 oil reservoir to pump hose.
      Fig 22: Locating Oil Reservoir To Pump Hose
      G04974466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT RETURN TUBE SUB-ASSEMBLY 
    1. Disconnect the return tube sub-assembly.
      Fig 23: Disconnecting Return Tube Sub-Assembly
      G04974467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET  (See REMOVAL )
  40. REMOVE EXHAUST PIPE ASSEMBLY FRONT  (See REMOVAL )
  41. REMOVE FRONT AXLE HUB NUT LH  (See REMOVAL )
  42. REMOVE FRONT AXLE HUB NUT RH 

    HINT:

    Use the same procedures described for the LH side.

  43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  45. DISCONNECT FRONT SPEED SENSOR LH  (See REMOVAL )
  46. DISCONNECT FRONT SPEED SENSOR RH 

    HINT:

    Use the same procedures described for the LH side.

  47. DISCONNECT TIE ROD ASSEMBLY LH  (See REMOVAL )
  48. DISCONNECT TIE ROD ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  49. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH  (See REMOVAL )
  50. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH 

    HINT:

    Use the same procedures described for the LH side.

  51. SEPARATE FRONT AXLE ASSEMBLY LH  (See REMOVAL )
  52. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Use the same procedures described for the LH side.

  53. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Remove the No. 1 exhaust pipe support bracket with the 2 bolts.
  54. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT  (See REMOVAL )
  55. DISCONNECT STEERING SLIDING YOKE  (See REMOVAL )
  56. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  57. SEPARATE COOLER COMPRESSOR ASSEMBLY 
    1. Remove the 2 connector clamps.
    2. Remove the 4 bolts and separate the compressor.

      HINT:

      Hang up the hoses instead of detaching them.

      Fig 24: Locating Cooler Compressor Assembly Bolts
      G04974468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 4 bolts, 2 nuts, and frame side rail plates RH and LH.
      Fig 25: Removing Bolts, Nuts, Front Suspension Member Brace Rear RH And LH
      G04974469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.
    4. 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.
  59. REMOVE VANE PUMP ASSEMBLY 
    1. Disconnect the power steering oil pressure switch connector.
    2. Remove the pressure feed tube clamp bolt.
    3. Loosen the bolt A.
    4. Remove the bolt B and vane pump.
      Fig 26: Removing Bolt And Vane Pump
      G04974470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL ENGINE HANGERS 
    1. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part No.: 

      No. 1 Engine hanger 12281-31070 

      No. 2 Engine hanger 12282-31050 

      Bolts 91671-10825 

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

      Fig 27: Installing Engine Hangers With Bolts
      G04974471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the engine sling device and hang the engine with the chain block.
  61. REMOVE FRONT FRAME ASSEMBLY 
    1. Disconnect the connector and clamp.
      Fig 28: Disconnecting Connector And Clamp
      G04974472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 clamps.
      Fig 29: Disconnecting Clamps
      G04974473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts and disconnect the engine mounting insulators RH and LH.
      Fig 30: Disconnecting Engine Mounting Insulators RH And LH
      G04974474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the engine mounting insulator FR.
      Fig 31: Disconnecting Engine Mounting Insulator FR
      G04974475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See DISASSEMBLY )
  63. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See DISASSEMBLY )
  64. REMOVE ENGINE WIRE 
  65. REMOVE STARTER ASSEMBLY  (See REMOVAL )
  66. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 

    HINT:

    See REMOVAL

  67. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY  (See REMOVAL )
  68. SECURE ENGINE 
    1. Secure the engine onto an engine stand with the bolts.
  69. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disconnect the 2 water by-pass hoses from the throttle with motor body assembly.
      Fig 32: Disconnecting Water By-Pass Hoses From Throttle W/ Motor Body Assembly
      G04974476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the vapor feed hose.
    3. Disconnect the throttle with motor body assembly connector and clamp.
    4. Disconnect the No. 1 ventilation hose.
    5. Remove the bolt and vacuum hose clamp.
      Fig 33: Installing Vacuum Hose Clamp
      G04974477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the connector.
    7. Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket.
      Fig 34: Connecting Connector
      G04974478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a 5 mm socket hexagon wrench, remove the 4 bolts.
      Fig 35: Identifying Bolts Using Socket Hexagon Wrench
      G04974479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 2 nuts and intake air surge tank.
    10. Remove the gasket from the intake air surge tank.
  70. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 6 bolts and 6 ignition coils.
  71. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt and No. 2 engine mounting stay RH.
  72. REMOVE INTAKE MANIFOLD 
    1. Uniformly loosen and remove the 6 bolts and 4 nuts.
    2. Remove the intake manifold and 2 gaskets.
      Fig 36: Locating Intake Manifold Bolts
      G04974480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the A/F sensor connector clamp.
    2. Uniformly loosen and remove the 6 nuts.
    3. Remove the manifold and gasket.
      Fig 37: Removing Exhaust Manifold Sub-Assembly Nuts
      G04974481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY 
    1. Remove the oil level gauge.
    2. Remove the 2 bolts, oil level gauge guides No. 1 and No. 2.
    3. Remove the O-rings from the oil level gauge guide.
      Fig 38: Removing Dipstick
      G04974482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the 2 bolts and No. 2 manifold stay.
      Fig 39: Locating Manifold Stay
      G04974483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 3 bolts and No. 2 insulator.
      Fig 40: Locating Insulator
      G04974484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Uniformly loosen and remove the 6 nuts.
    2. Remove the manifold and gasket.
      Fig 41: Removing Manifold
      G04974485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      Fig 42: Installing Engine Mounting Bracket RH With Bolts
      G04974486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      Fig 43: Installing Drive Shaft Bearing Bracket
      G04974487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the 5 bolts and V-ribbed belt tensioner assembly.
      Fig 44: Removing Bolts And Timing Gear Cover
      G04974488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE NO. 2 TIMING GEAR COVER 
    1. Remove the 2 bolts and No. 2 timing gear cover.
      Fig 45: Removing Bolts And No. 2 Timing Gear Cover
      G04974489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, plate and No. 2 idler pulley sub-assembly.
      Fig 46: Installing Idler Pulley Sub-Assembly And Cover Plate With Bolt
      G04974490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE WATER PUMP PULLEY  (See REMOVAL )
  84. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH 
    1. Remove the 6 bolts and No. 1 engine mounting bracket front LH.
      Fig 47: Removing Bolts And No. 1 Engine Mounting Bracket Front LH
      G04974491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE RADIO SETTING CONDENSER 
    1. Remove the 2 bolts and 2 radio setting condensers.
      Fig 48: Removing Bolts And Radio Setting Condensers
      G04974492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY 
    1. Remove the bolt and No. 1 vacuum switching valve.
      Fig 49: Removing Bolt And No. 1 Vacuum Switching Valve
      G04974493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
      Fig 50: Installing Oil Pressure Switch
      G04974494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE KNOCK CONTROL SENSOR  (See REMOVAL )
  89. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket.
      Fig 51: Installing EFI Engine Coolant Temperature Sensor
      G04974495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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