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Engine Assembly, Intake Manifold, Exhaust Manifold: Removal

WARNING: This page is about a different car, the 2008 Toyota RAV4. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See  REPLACEMENT  ) 
  2. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  4. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 4 bolts, 12 clips and under cover.
  5. REMOVE REAR ENGINE UNDER COVER RH 
    1. Remove the 2 clips and under cover.
  6. REMOVE REAR ENGINE UNDER COVER LH 
    1. Remove the 2 clips and under cover.
  7. REMOVE NO. 2 ENGINE UNDER COVER 
    1. Remove the 2 clips and under cover.
  8. REMOVE FRONT FLOOR COVER (See appropriate step(s) under  REMOVAL  ) 
  9. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  10. DRAIN ENGINE OIL (See  REPLACEMENT  ) 
  11. DRAIN AUTOMATIC TRANSAXLE FLUID 
    1. 2WD: Drain automatic transaxle fluid, (see appropriate step(s) under REMOVAL ).
    2. 4WD: Drain automatic transaxle fluid, , (see appropriate step(s) under REMOVAL ).
  12. DRAIN TRANSFER OIL (for 4WD) 
  13. REMOVE HOOD SUB-ASSEMBLY (See  REMOVAL  ) 
  14. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Detach the 3 clips and remove the V-bank cover.
      Fig 1: Identifying V-Bank Cover Claws
      G04485056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE RADIATOR SUPPORT OPENING COVER 
    1. Remove the 9 clips and cover.
      Fig 2: Identifying Clips And Radiator Support Opening Cover
      G04485057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
    1. Remove the bolt and loosen the nut.
    2. Detach the 2 wire harness clamps.
    3. Detach the hook of the battery clamp from the battery bracket front, and then remove the battery clamp.
      4. Fig 3: Identifying Battery Clamp Sub-Assembly
      G04485058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE BATTERY 
  18. REMOVE FRONT BATTERY BRACKET 
    1. Detach the 2 wire harness clamps.
    2. Remove the 4 bolts and front bracket.
      Fig 4: Identifying Front Battery Bracket Bolts
      G04485059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE BATTERY BRACKET REINFORCEMENT 
    1. Remove the 2 bolts and bracket reinforcement.
      Fig 5: Identifying Battery Bracket Reinforcement Bolts
      G04485060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 
    1. Disconnect the mass air flow meter connector.
    2. Disconnect the VSV (air intake control) connector.
    3. Disconnect the wire harness clamp and 3 vacuum hoses.
    4. Disconnect the No. 2 ventilation hose from the air cleaner hose.
    5. Loosen the No. 1 air cleaner hose clamp.
    6. Unfasten the 2 hook clamps, and then remove the air cleaner cap.
    7. Remove the air cleaner filter element from the air cleaner case.
      Fig 6: Identifying Air Cleaner Cap Sub-Assembly
      G04485061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE AIR CLEANER CASE 
    1. Disconnect the harness clamp.
    2. Remove the 3 bolts and air cleaner case.
    Fig 7: Identifying Air Cleaner Case Bolts
    G04485062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT HOSES AND CONNECTORS 
    1. Remove the engine room junction block cover (upper).
    2. Remove the nut and disconnect the engine room junction block cover (side) with 3 connectors and wire.
    3. Remove the nut and disconnect the starter wire.
    4. Disconnect the fuel hoses.
    5. Disconnect the 2 heater hoses.
    6. Disconnect the 2 ECM connectors.
  23. REMOVE ECM (See  REMOVAL  ) 
  24. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY 
    1. Remove the 2 bolts, 2 hoses and reservoir tank.
      Fig 8: Identifying Reservoir Tank Bolts
      G04485063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See  REMOVAL 
  26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (See  REMOVAL  ) 
  27. DISCONNECT RADIATOR HOSE INLET 
  28. DISCONNECT RADIATOR HOSE OUTLET 
  29. DISCONNECT OIL COOLER HOSE 
  30. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. 2WD: Disconnect the control cable (see TRANSMISSION CONTROL CABLE ASSEMBLY ).
    2. 4WD: Disconnect the control cable (see TRANSMISSION CONTROL CABLE ASSEMBLY ).
  31. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See  EXHAUST (2GR-FE)  ) 
  32. REMOVE CENTER EXHAUST PIPE ASSEMBLY (See  EXHAUST (2GR-FE)  ) 
  33. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See  REMOVAL  ) 
  34. REMOVE FRONT WHEELS 
  35. REMOVE FRONT AXLE HUB NUT LH 
    1. Remove the hub nut (see REMOVAL ).
  36. REMOVE FRONT AXLE HUB NUT RH 
    1. Remove the hub nut (see REMOVAL ).
  37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH (See  REMOVAL  ) 
  38. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH (See  REMOVAL  ) 
  39. DISCONNECT STEERING INTERMEDIATE SHAFT (See appropriate step(s) under  REMOVAL  ) 
  40. DISCONNECT TIE ROD END SUB-ASSEMBLY RH (See  INSPECTION  ) 
  41. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (See  INSPECTION  ) 
  42. REMOVE FRONT DRIVE SHAFT LH 
    1. 2WD: Remove the drive shaft (see appropriate procedure under FRONT DRIVE SHAFT ASSEMBLY (FOR 2WD) ).
    2. 4WD: Remove the drive shaft (see appropriate procedure under FRONT DRIVE SHAFT ASSEMBLY (FOR 4WD) ).
  43. REMOVE FRONT DRIVE SHAFT RH 
    1. 2WD: Remove the drive shaft (see appropriate procedure under FRONT DRIVE SHAFT ASSEMBLY (FOR 2WD) ).
    2. 4WD: Remove the drive shaft (see appropriate procedure under FRONT DRIVE SHAFT ASSEMBLY (FOR 4WD) ).
  44. REMOVE ENGINE WITH TRANSAXLE 
    1. Install the No. 1 and No. 2 engine hangers with the 4 bolts as shown in the illustration below.

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

      ENGINE WITH TRANSAXLE

      Part Name Part No.
      No. 1 engine hanger 12281-31120
      No. 2 engine hanger 12282-31100
      Bolt 91671-10825
      Fig 9: Identifying No. 1 And No. 2 Engine Hangers
      G04485064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • Insert the claw of the hanger into hole of the cylinder head.
      • Fit the fork part of the hanger onto the rib of the cylinder head.
    2. Install an engine sling device to the engine and hold the engine with a chain block.
      CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
    3. Set an engine lifter underneath the engine.
    4. Remove the column hole cover. Loosen the bolt holding the intermediate shaft, and slide the intermediate shaft.
    5. Put matchmarks on the intermediate shaft and pinion.
    6. Remove the 2 bolts and 2 nuts, and disconnect the engine mounting insulator RH.
      Fig 10: Identifying Engine Mounting Insulator Bolts RH
      G04485065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt and nut, and disconnect the engine mounting insulator LH.
      Fig 11: Identifying Engine Mounting Insulator Bolt And Nut LH
      G04485066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the 6 bolts and front suspension member brace rear RH and LH.
      Fig 12: Identifying Front Suspension Member Brace Rear Bolts RH And LH
      G04485067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 6 bolts, crossmember and suspension member.
    10. Using the chain block, slowly remove the engine from the vehicle and the intermediate shaft from the pinion. Then set the engine on the engine lifter.
      NOTE:
      • Make sure that the engine is clear of all wiring and hoses.
      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.

      HINT:

      Place the engine on wooden blocks or an equivalent so that the engine is level.

    11. Remove the sling device from the engine.
  45. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY 
    1. Install a chain block.
    2. Remove the bolt, nut and crossmember.
      Fig 13: Identifying Bolt, Nut And Crossmember
      G04485068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the bolt and suspension crossmember.
      Fig 14: Identifying Suspension Crossmember Bolt
      G04485069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine.
  48. REMOVE STARTER ASSEMBLY (See  REMOVAL  ) 
  49. REMOVE TRANSFER ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  50. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. 2WD: Remove the automatic transaxle (see REMOVAL ).
    2. 4WD: Remove the automatic transaxle (see REMOVAL ).
  51. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.

      SST 09213-70011, 09330-00021 

      Fig 15: Holding Crankshaft Using SST
      G04485070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, front spacer, drive plate and rear spacer.
      NOTE: Do not reuse the bolts.
      Fig 16: Identifying Front Spacer, Drive Plate And Rear Spacer
      G04485071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL ENGINE TO ENGINE STAND 
    1. Install the engine to an engine stand. Remove the sling device and chain block from the engine.
  53. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 
    1. Disconnect the 2 water by-pass hoses from the throttle body.
    2. Disconnect the vapor feed hose.
    3. Disconnect the throttle body connector and clamp.
      Fig 17: Identifying Water By-Pass Hoses From Throttle Body
      G04485072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 2 ventilation hose.
    5. Disconnect the union to check valve hose.
      Fig 18: Identifying No. 2 Ventilation Hose
      G04485073Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and vacuum hose clamp.
      Fig 19: Identifying Bolt And Vacuum Hose Clamp
      G04485074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect the connector.
      Fig 20: Identifying Connector
      G04485075Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Using a 5 mm socket hexagon wrench, remove the 4 bolts.
    9. Remove the 2 nuts, 2 bolts and surge tank.
      Fig 21: Identifying Nuts, Bolts And Surge Tank
      G04485076Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Remove the gasket from the surge tank.
  54. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 6 bolts and 6 coils from the cylinder head.
  55. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt and mounting stay.
  56. REMOVE FUEL INJECTOR ASSEMBLY (See  REMOVAL  ) 
  57. REMOVE INTAKE MANIFOLD 
    1. Remove the 6 bolts, 4 nuts, intake manifold and 2 gaskets.
      Fig 22: Identifying Intake Manifold Bolts, Nuts And Gaskets
      G04485077Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the air fuel ratio sensor connector clamp.
    2. Uniformly loosen and remove the 6 nuts.
    3. Remove the manifold and gasket.
      4. Fig 23: Identifying Exhaust Manifold Nuts
      G04485078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE FAN AND GENERATOR V BELT (See  REMOVAL  ) 
  60. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY (See  REMOVAL  ) 
  61. REMOVE GENERATOR ASSEMBLY (See  REMOVAL  ) 
  62. REMOVE OIL DIPSTICK GUIDE 
    1. Remove the dipstick.
    2. Remove the 2 bolts, and the No. 1 and No. 2 guides.
    3. Remove the O-rings from the guide.
      Fig 24: Identifying Oil Dipstick Guide
      G04485079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and manifold stay.
      2. Fig 25: Identifying No. 2 Manifold Stay Bolt And Nut
      G04485080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 3 bolts and insulator.
  65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Uniformly loosen and remove the 6 nuts.
    2. Remove the manifold and gasket.
    Fig 26: Identifying Exhaust Manifold Sub-Assembly Nuts LH
    G04485081Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and bracket.
  67. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
  68. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the 5 bolts and V-ribbed belt tensioner assembly.
  69. REMOVE NO. 2 TIMING GEAR COVER 
    1. Remove the 2 bolts and gear cover.
  70. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, plate and idler pulley.
      Fig 27: Identifying Idler Pulley Plate And Bolt
      G04485082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE WATER PUMP PULLEY (See  REMOVAL  ) 
  72. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Remove the 6 bolts and bracket.
  73. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the pressure switch.
      2. Fig 28: Removing Pressure Switch
      G04485083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE KNOCK SENSOR (See  REMOVAL  ) 
  75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the sensor and gasket.
      Fig 29: Identifying ECT Sensor
      G04485084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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