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Engine Assembly: Removal

WARNING: This page is about a different variant/trim than selected.
  1. DISCHARGE FUEL SYSTEM PRESSURE  (See REMOVAL )
  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  4. REMOVE FRONT WHEELS 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE ENGINE UNDER COVER RH 
  7. DRAIN ENGINE COOLANT  (See COOLANT )
  8. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

    See REMOVAL for U250E.

  9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for E351.

  10. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Remove the 2 nuts and No. 1 engine cover sub-assembly.
    Fig 1: Locating Nuts And No. 1 Engine Cover Sub-Assembly
    G06008364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. SEPARATE RADIATOR RESERVE TANK ASSEMBLY 
    1. Remove the 3 bolts and separate the radiator reserve tank assembly.
  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See ON-VEHICLE INSPECTION )
  13. REMOVE AIR CLEANER CASE 
    1. Remove the air cleaner filter element.
      Fig 2: Locating Bolts And Radiator Reserve Tank Assembly
      G06008365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the clamp of the engine wire.
    3. Remove the 3 bolts and air cleaner case.
    Fig 3: Locating Bolts And Air Cleaner Case
    G06008366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE BATTERY 
    1. Remove the bolt, nut and battery clamp.
    2. Remove the battery and battery insulator.
  15. REMOVE BATTERY CARRIER 
    1. Remove the battery tray.
      Fig 4: Locating Bolt, Nut And Battery Clamp
      G06008367Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the 2 wire harness clamps from the battery carrier.
    3. Remove the 4 bolts and battery carrier.
    Fig 5: Locating Bolts And Battery Carrier
    G06008368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. SEPARATE WIRE HARNESS 
    1. Disconnect the 3 connectors from the engine room relay block.
    2. Remove the 2 nuts and disconnect the wire harnesses from the engine room relay block.
    3. Using a screwdriver, unlock the 2 claws.
    4. Pull the engine room relay block upward.
      Fig 6: Locating Connectors And Engine Room Relay Block
      G06008369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Pull up the lever and disconnect the ECM connector.
    6. Disconnect the clamp.
      Fig 7: Disconnecting Clamp
      G05387316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt and disconnect the ground cable and clamp (for Manual Transaxle).
      Fig 8: Locating Bolt And Ground Cable
      G06008371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt and disconnect the ground cable and clamp (for Automatic Transaxle).
  17. REMOVE THROTTLE BODY ASSEMBLY  (See REMOVAL )
  18. REMOVE V-RIBBED BELT  (See ON-VEHICLE INSPECTION )
  19. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  20. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and 2 nuts.
      Fig 9: Locating Bolt And Ground Cable
      G06008372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 10: Identifying Bolts And Nuts
      G06008373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "TORX" socket wrench (E8), remove the 2 stud bolts and compressor with pulley assembly.

      HINT:

      Secure the compressor and hoses off to the side instead of discharging the A/C system.

      Fig 11: Identifying Stud Bolts
      G06008374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Disconnect the No. 2 radiator hose from the inlet water.
    Fig 12: Locating No. 2 Radiator Hose
    G06008375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disconnect the No. 1 radiator hose from the cylinder head.
    Fig 13: Locating No. 1 Radiator Hose
    G06008376Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT OIL COOLER HOSE (for Automatic Transaxle) 
    1. Disconnect the 2 oil cooler hoses.
    Fig 14: Locating Oil Cooler Hoses
    G06008377Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT BREATHER HOSE (for Automatic Transaxle) 
    1. Disconnect the breather hose.
    Fig 15: Locating Breather Hose
    G06008378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
    Fig 16: Locating Outlet Heater Water Hose
    G06008379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
    Fig 17: Locating Inlet Heater Water Hose
    G06008380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Release the claw and remove the No. 1 fuel pipe clamp.
      Fig 18: Identifying No. 1 Fuel Pipe Clamp
      G06008381Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
      NOTE:
      • Remove any dirt or foreign matter from the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
        Fig 19: Locating Fuel Tube Connector
        G04828757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not forcibly bend, kink or twist the nylon tube.
      • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull to release them.
  28. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose.
  29. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL for E351.

    Fig 20: Locating Tube Hose
    G06008383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Remove the nut and disconnect the control cable assembly from the control shaft lever.
    2. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.
      Fig 21: Locating Nut And Control Cable Assembly
      G06011483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the control cable assembly from the control cable bracket.
    Fig 22: Locating Control Cable Assembly
    G06008385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the 2 clips and disconnect the 2 transmission control cables from the control cable bracket*1.
    2. Remove the 2 clips and disconnect the 2 transmission control cables from the transaxle*2.
    Fig 23: Identifying Clips And Transmission Control Cables
    G06008386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SECURE STEERING WHEEL  (See REMOVAL )
  33. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  34. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See REMOVAL )
  35. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See REMOVAL )
  36. REMOVE CENTER EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  38. REMOVE FRONT AXLE SHAFT LH NUT  (See REMOVAL )
  39. REMOVE FRONT AXLE SHAFT RH NUT 

    HINT:

    Perform the same procedure for the LH side.

  40. SEPARATE FRONT SPEED SENSOR LH  (See REMOVAL )
  41. SEPARATE FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure for the LH side.

  42. SEPARATE TIE ROD END SUB-ASSEMBLY LH  (See REMOVAL )
  43. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  44. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  45. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  46. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See REMOVAL )
  47. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  48. SEPARATE STEERING KNUCKLE WITH AXLE HUB LH 
    1. Put matchmarks on the drive shaft and axle hub.
      NOTE: Do not punch the marks.
    2. Using a plastic-faced hammer, disconnect the front axle assembly LH.
    NOTE:
    • Be careful not to damage the boot or speed sensor rotor.
    • Do not excessively push out the drive shaft from the axle assembly.
    Fig 24: Identifying Matchmarks On Drive Shaft And Axle Hub
    G06008387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. SEPARATE STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure for the LH side.

  50. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  51. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH  (See DISASSEMBLY )
  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See DISASSEMBLY )
  53. SEPARATE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) 

    HINT:

    See REMOVAL for U250E.

  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  (See REMOVAL )
  55. REMOVE CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See INSTALLATION )
  56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
      NOTE: Place the engine on wooden blocks or equivalent so that the engine is level.
      Fig 25: Identifying Engine Assembly With Transaxle On Engine Lifter
      G06008388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and 2 nuts, and separate the engine mounting insulator RH.
      Fig 26: Locating Bolt, Nuts And Engine Mounting Insulator RH
      G06008389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and nut, and separate the engine mounting insulator LH.
    4. Carefully remove the engine with transaxle from the vehicle.
    Fig 27: Locating Through Bolt And Nut
    G06008390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL ENGINE HANGERS 
    1. Install the No. 1 and No. 2 engine hangers with new bolts as shown in the illustration.

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

      PART SPECIFICATIONS

      Item Part No.
      No. 1 engine hanger 12281-28010
      No. 2 engine hanger 12282-28010
      Bolt 91512-B1020 or 91552-81020
      Fig 28: Identifying No. 1 And No. 2 Engine Hangers
      G06008391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.
    Fig 29: Installing Engine Sling Device And Chain Block
    G06008392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the through bolt and nut, and separate the front engine mounting insulator.
    Fig 30: Locating Through Bolt And Nut
    G06008393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE REAR ENGINE MOUNTING INSULATOR 
    1. Remove the through bolt and separate the rear engine mounting insulator.
    Fig 31: Locating Through Bolt And Nut
    G06008394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 4 bolts and engine mounting insulator LH.
    Fig 32: Locating Bolts And Engine Mounting Insulator LH
    G06008395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 
    1. Remove the 3 bolts and engine mounting insulator sub-assembly RH.
    Fig 33: Locating Bolts And Engine Mounting Insulator Sub-Assembly RH
    G06008396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and bracket.
  63. REMOVE STARTER ASSEMBLY (for Automatic Transaxle)  (See DISASSEMBLY )
  64. REMOVE STARTER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  65. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSTALLATION for E351.

    Fig 34: Locating Bolts And Bracket
    G06008397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT:

    See REMOVAL for U250E.

  67. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSPECTION for E351.

  68. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 

    HINT:

    See INSPECTION for E351.

  69. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  70. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  71. REMOVE ENGINE WIRE 
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