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Engine Assembly: Removal: Removal

WARNING: This page is about a different variant/trim than selected.
  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  . Refer to REPLACEMENT - Step 1
  2. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT: 

    Refer to PRECAUTION .

  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. REMOVE FRONT WHEELS 
  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected, refer to INITIALIZATION .

  6. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 11 clips and cool air intake duct seal.
      Fig 1: Identifying 11 Clips And Cool Air Intake Duct Seal
      GTY299609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE NO. 1 ENGINE UNDER COVER 
  8. REMOVE NO. 2 ENGINE UNDER COVER 
  9. REMOVE FLOOR UNDER COVER LH 
  10. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY LH  . Refer to REMOVAL - Step 1
  11. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY RH  See step  3
  12. REMOVE FRONT FENDER LINER LH  . Refer to REMOVAL - Step 5
  13. REMOVE FRONT FENDER LINER RH  . Refer to REMOVAL - Step 6
  14. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH.
      Fig 2: Locating Front Fender Apron Seal LH Bolts And Clip
      GTY173990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      Fig 3: Identifying Front Fender Apron Seal RH Bolts
      GTY194004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DRAIN ENGINE OIL  . Refer to REPLACEMENT - Step 1
  17. DRAIN ENGINE COOLANT  . Refer to REPLACEMENT - Step 2
  18. DRAIN AUTOMATIC TRANSAXLE FLUID  . Refer to REPLACEMENT - Step 1
  19. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  . Refer to REMOVAL - Step 1
  20. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  . Refer to REMOVAL - Step 2
  21. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  . Refer to REMOVAL - Step 4
  22. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  . Refer to REMOVAL - Step 5
  23. SEPARATE EJECTOR TUBE  . Refer to REMOVAL - Step 1
  24. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY  . Refer to REMOVAL - Step 8
  25. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Lift the rear of the No. 1 engine cover sub-assembly to detach the cover from the 2 pins, and then lift the front of the No. 1 engine cover sub-assembly to detach the cover from the pin and remove the No. 1 engine cover sub-assembly.
      Fig 4: Locating No. 1 Engine Cover
      GTY195217Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

  26. REMOVE BATTERY 
    1. Remove the nut, and separate the positive (+) battery terminal.
      Fig 5: Locating Positive (+) Battery Terminal And Nut
      GTY195027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the nut, and remove the bolt and battery clamp.
    3. Remove the battery and battery tray.
  27. REMOVE NO. 2 INLET AIR CLEANER 
    1. Disconnect the 2 clamps and vacuum hose.
      Fig 6: Locating No. 2 Inlet Air Cleaner Bolts And Vacuum Hose With Clamp
      GTY195028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and No. 2 inlet air cleaner.
  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  . Refer to REMOVAL - Step 9
  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly.
  30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disconnect the 2 clamps.
      Fig 7: Locating Air Cleaner Case Sub-Assembly Bolts With Clamps
      GTY195029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and air cleaner case sub-assembly.
  31. REMOVE AIR CLEANER BRACKET 
    1. Remove the 2 bolts and air cleaner bracket.
      Fig 8: Locating Air Cleaner Bracket Bolts
      GTY188492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 1 INLET AIR CLEANER 
    1. Remove the bolt and No. 1 inlet air cleaner.
      Fig 9: Locating No. 1 Inlet Air Cleaner Bolt
      GTY175642Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disconnect the level warning switch connector.
      Fig 10: Locating Brake Master Cylinder Reservoir Assembly And Bolt
      GTY193994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, and separate the brake master cylinder reservoir assembly.
  34. REMOVE RESERVOIR BRACKET 
    1. Remove the 2 bolts and reservoir bracket.
      Fig 11: Identifying Reservoir Bracket Bolts
      GTY178494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disconnect the No. 1 radiator hose.
      Fig 12: Locating No. 1 Radiator Hose
      GTY195033Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Disconnect the No. 2 radiator hose.
      Fig 13: Locating No. 2 Radiator Hose
      GTY190213Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
      Fig 14: Locating Inlet Heater Water Hose
      GTY169356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
      Fig 15: Locating Outlet Heater Water Hose
      GTY167264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
      Fig 16: Locating No. 1 Fuel Pipe Clamp
      GTY195142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the fuel tube connector and then pull out the fuel main tube.
      NOTE:
      • Check for dirt and foreign objects on 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. DISCONNECT INLET OIL COOLER HOSE 
    1. Disconnect the inlet oil cooler hose.
      Fig 17: Locating Inlet Oil Cooler Hose And Outlet Oil Cooler Hose
      GTY195216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. DISCONNECT OUTLET OIL COOLER HOSE 
    1. Disconnect the outlet oil cooler hose.
  42. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut from the control shaft lever.
      Fig 18: Locating Control Shaft Lever Nut And Control Cable Bracket Clip With Claws
      GTY205521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disengage the 4 claws, and disconnect the control cable with clip from the control cable bracket.
    3. Remove the clip.
  43. DISCONNECT ENGINE WIRE 
    1. Remove the No. 1 relay block cover.
      Fig 19: Identifying No. 1 Relay Block Cover
      GTY186513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, and disconnect the engine wire connector from the engine room relay block.
      Fig 20: Identifying Engine Wire Connector
      GTY174120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
      Fig 21: Separating Engine Wire From Engine Room Relay Block
      GTY195031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the engine wire clamp.
      Fig 22: Identifying Engine Wire Clamp
      GTY167784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the engine wire clamp.
      Fig 23: Locating Ground Cables Bolt
      GTY167972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt, and separate the ground cables.
    7. Remove the 2 bolts, and separate the ground cable.
      Fig 24: Locating Ground Cable Bolts
      GTY185734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt, and separate the ground cable.
      Fig 25: Locating Ground Cable Bolt
      GTY195032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect the 2 clamps, remove the nut and separate the positive (+) cable.
      Fig 26: Identifying Positive (+) Cable Clamps And Nut
      GTY195030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Disconnect the 4 ECM connectors, 2 junction block connectors and clamp.
      Fig 27: Locating ECM Connectors, Junction Block Connectors With Clamp
      GTY190151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the 2 nuts and clamp, and separate the engine wire.
      Fig 28: Locating Engine Wire Nuts With Clamp
      GTY183102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the 2 bolts and No. 2 engine mounting stay RH.
      Fig 29: Locating No. 2 Engine Mounting Stay RH Bolts
      GTY195035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the 4 bolts and engine moving control rod.
      Fig 30: Locating Bolts And Engine Moving Control Rod
      GTY195233Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the 2 union to check valve hoses.
      Fig 31: Locating Union To Check Valve Hoses
      GTY177465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. DISCONNECT SUCTION HOSE SUB-ASSEMBLY  . Refer to REMOVAL - Step 8
  48. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY  . Refer to REMOVAL - Step 9
  49. SECURE STEERING WHEEL  . Refer to REMOVAL - Step 2
  50. REMOVE FRONT EXHAUST PIPE ASSEMBLY  . Refer to REMOVAL - Step 3
  51. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  . Refer to REMOVAL - Step 10
  52. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  53. REMOVE FRONT AXLE HUB NUT LH  . Refer to REMOVAL - Step 6
  54. REMOVE FRONT AXLE HUB NUT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  55. SEPARATE FRONT SPEED SENSOR LH  . Refer to REMOVAL - Step 3
  56. SEPARATE FRONT SPEED SENSOR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  57. SEPARATE TIE ROD ASSEMBLY LH  . Refer to REMOVAL - Step 10
  58. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  59. SEPARATE NO. 1 FRONT LOWER SUSPENSION ARM LH  . Refer to REMOVAL - Step 8
  60. SEPARATE NO. 1 FRONT LOWER SUSPENSION ARM RH 

    HINT: 

    Perform the same procedure as for the LH side.

  61. SEPARATE FRONT AXLE ASSEMBLY LH  . Refer to REMOVAL - Step 4
  62. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  63. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  . Refer to REMOVAL - Step 9
  64. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
      Fig 32: Locating Flywheel Housing Under Cover
      GTY195034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft pulley.
      Fig 33: Holding Crankshaft Pulley
      GTY171704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-54015 
      • SST: 09330-00021 
      • SST: 91551-80650 
    2. Remove the 6 drive plate and torque converter clutch setting bolts.
      Fig 34: Locating Torque Converter Clutch Setting Bolt
      GTY182021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      There is one black colored bolt.

  66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 6 bolts, 2 nuts, and frame side rail plates RH and LH.
      Fig 35: Identifying Frame Side Rail Plates RH & LH Bolts
      GTY193995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts, 2 nuts, and front suspension member rear braces RH and LH.
      Fig 36: Identifying Front Suspension Member Rear Braces RH & LH Bolts
      GTY193997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Operate the engine lifter, then remove the engine assembly with transaxle from the vehicle.
      NOTE:

      Make sure that the engine is clear of all wiring and hoses.

  67. INSTALL ENGINE HANGERS 
    1. Install the 2 engine hangers with the 2 bolts as shown in the illustration.
      Fig 37: Locating Engine Hangers Bolts
      GTY189711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Item Part No.
      No. 1 engine hanger 12281-36020
      No. 2 engine hanger 12282-36020
      Bolt 91552-81040, 91552-81025

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT: 

      Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

    2. Attach the engine sling device and hang the engine with the chain block.
  68. REMOVE ENGINE WIRE 
  69. REMOVE V-RIBBED BELT  See step  6
  70. REMOVE GENERATOR ASSEMBLY  . Refer to REMOVAL - Step 3
  71. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY  . Refer to REMOVAL - Step 10
  72. REMOVE STARTER ASSEMBLY  . Refer to REMOVAL - Step 11
  73. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  . Refer to REMOVAL - Step 12
  74. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH  . Refer to DISASSEMBLY - Step 1
  75. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  . Refer to REMOVAL - Step 13
  76. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      Fig 38: Locating Drive Shaft Bearing Bracket Bolts
      GTY195039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE FRONT FRAME ASSEMBLY 
    1. Loosen the 3 nuts.
      Fig 39: Locating Front Frame Assembly Nuts
      GTY195036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 hole plugs.
      Fig 40: Locating Hole Plugs
      GTY172272Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 9 nuts, and separate the front frame assembly.
      Fig 41: Locating Front Frame Assembly Nuts
      GTY194079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the nut and front engine mounting insulator.
      Fig 42: Locating Front Engine Mounting Insulator Nut
      GTY195037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the nut and engine mounting insulator LH.
      Fig 43: Locating Engine Mounting Insulator LH Nut
      GTY195038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the nut and engine mounting insulator RH.
      Fig 44: Locating Engine Mounting Insulator RH Nut
      GTY189199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      Fig 45: Locating Engine Mounting Bracket RH Bolts
      GTY178051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY  . Refer to REMOVAL - Step 10
  83. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY  See step  3
  84. INSTALL ENGINE ON ENGINE STAND 
    1. Install the engine onto an engine stand with the bolts.
  85. REMOVE ENGINE HANGERS 
    1. Remove the 2 bolts and No. 1 and No. 2 engine hangers.
      Fig 46: Locating Engine Hangers Bolts
      GTY189711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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