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Engine Assembly: Removal

WARNING: This page is about a different car, the 2008 Toyota Tundra. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE  (See REMOVAL )
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: Some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  3. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  4. DRAIN AUTOMATIC TRANSMISSION FLUID  (See REMOVAL )
  5. DRAIN ENGINE OIL  (See REPLACEMENT )
  6. DISCONNECT HOOD SUPPORT ASSEMBLY  (See REMOVAL )
  7. REMOVE HOOD SUB-ASSEMBLY 
    1. Remove the 4 bolts and hood.
  8. REMOVE FRONT WIPER MOTOR AND LINK 
    1. Remove the front wiper motor and link (see REMOVAL ).
  9. REMOVE FRONT COWL TOP OUTER PANEL SUB-ASSEMBLY  (See REMOVAL )
  10. REMOVE V-BANK COVER  (See REMOVAL )
  11. REMOVE NO. 2 AIR CLEANER HOSE  (See REMOVAL )
  12. REMOVE AIR CLEANER ASSEMBLY WITH ELEMENT  (See REMOVAL )
  13. REMOVE NO. 1 ENGINE UNDER COVER  (See REMOVAL  )
  14. REMOVE INTAKE AIR SURGE TANK  (See REMOVAL )
  15. DISCONNECT ENGINE WIRE 
    1. Engine Room RH Side:
      1. Disconnect the ECM connector labeled A as shown below.
      2. Remove the junction block cover.
      3. Disconnect the 7 connectors from junction block labeled B shown below.
      4. Using a clip remover, detach the 2 wire harness clamps labeled B shown below.
      5. Remove the 2 bolts and ground cable labeled C shown below.
      6. Disconnect the 2 air pump connectors labeled D shown below.
      7. Using a clip remover, detach the 2 wire harness clamps labeled E shown below.
      8. Remove the bolt and bracket labeled F shown below.
        Fig 1: Identifying Engine Wire (Engine Room RH Side)
        G05682462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engine Room LH Side:
      1. Disconnect the 4 connectors from the air injection control driver labeled A shown below.
      2. Remove the engine room relay block cover.
      3. Disconnect the 2 connectors from the engine room junction block labeled B shown below.
      4. Remove the nut from the engine room junction block, and disconnect the No. 2 engine wire's cover labeled C shown below.
      5. Remove the nut and disconnect the wire harness bracket from the inner body panel side labeled D shown below.
      6. Disconnect the connector, and using a clip remover, detach the front ABS junction connector's clamp from the engine room relay block side labeled E shown below.
      7. Disconnect the connector from the crankshaft position sensor labeled F shown below.
      8. Using a clip remover, detach the wire harness clamp from the front engine mounting bracket LH labeled F shown below.
      9. Remove the bolt and ground cable labeled G shown below.
      10. Pull out the battery positive cable cover, and then remove the nut and battery positive cable labeled H shown below.
      Fig 2: Identifying Engine Wire (Engine Room LH Side)
      G05682463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE NO. 5 AIR INJECTION SYSTEM HOSE  (See REMOVAL )
  17. REMOVE NO. 4 AIR INJECTION SYSTEM HOSE 
  18. REMOVE NO. 1 AIR TUBE  (See REMOVAL )
  19. DISCONNECT NO. 2 AIR TUBE  (See REMOVAL )
  20. REMOVE AIR SWITCHING VALVE ASSEMBLY  (See REMOVAL )
  21. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY (for Regular Cab Standard Deck)  (See REMOVAL )
  22. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (for Regular Cab Standard Deck)  (See REMOVAL )
  23. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY (except Regular Cab Standard Deck)  (See REMOVAL )
  24. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  25. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH  (See REMOVAL )
  26. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  (See REMOVAL )
  27. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH  (See REMOVAL )
  28. DISCONNECT RADIATOR HOSE INLET 
  29. DISCONNECT RADIATOR HOSE OUTLET 
  30. REMOVE FAN SHROUD  (See REMOVAL )
  31. REMOVE RADIATOR SIDE DEFLECTOR RH  (See REMOVAL )
  32. REMOVE RADIATOR SIDE DEFLECTOR LH  (See REMOVAL )
  33. REMOVE RADIATOR ASSEMBLY  (See REMOVAL )
  34. DISCONNECT HEATER WATER HOSE 
    1. Remove the wire harness clamp.
    2. Disconnect the heater water inlet and outlet hose.
    3. Remove the nut and heater water pipe bracket.
      Fig 3: Locating Heater Water Pipe Bracket Nut And Wire Harness Clamp
      G05682464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT VANE PUMP ASSEMBLY 
    1. Disconnect the power steering oil pressure switch connector.
    2. Remove the 2 bolts, and disconnect the vane pump.
      NOTE: Do not hit other parts with the pulley when separating the vane pump.

      HINT:

      Make sure to suspend the vane pump securely.

      Fig 4: Locating Power Steering Oil Pressure Switch Connector And Vane Pump Bolts
      G05682465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  37. DISCONNECT COOLER COMPRESSOR 
    1. Remove the 2 nuts, 2 bolts and disconnect the cooler compressor.
      Fig 5: Locating Cooler Compressor Nuts And Bolts
      G05682466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT NO. 1 AND NO. 2 FUEL PIPE 
    Fig 6: Locating Fuel Tube Connector
    G05682467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the No. 1 and No. 2 fuel pipe.
      1. Remove the fuel pipe clamp from the fuel tube connector.

        HINT:

        Check for dirt or mud on the pipe and around the connector before disconnection. Clean if necessary.

        Fig 7: Identifying Fuel Pipe Clamp
        G05682468Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Pinch the connector and disconnect the connector and pipe.

        HINT:

        If the connector and the pipe are stuck together, pinch the connector, push and pull the pipe to disconnect the pipe and pull it out.

        NOTE: Do not use any tools.
      3. Check for dirt or mud on the seal surface of the disconnected pipe. Clean if necessary.
        Fig 8: Pinching Connector And Disconnecting Connector And Pipe
        G05682469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.
        Fig 9: Covering Connector With Plastic Bag
        G05682470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE BATTERY 
  40. REMOVE FRONT FENDER APRON SEAL LH 
  41. REMOVE FRONT FENDER APRON SEAL RH 
  42. REMOVE STARTER ASSEMBLY 
    1. Remove the starter (for 1.6 kW Type) (see REMOVAL ).
    2. Remove the starter (for 2.0 kW Type) (see REMOVAL ).
  43. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Remove the flywheel housing side cover.
      Fig 10: Locating Flywheel Housing Side Cover
      G05682471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the crankshaft to gain access to the 6 bolts and remove the 6 bolts while holding the crankshaft pulley set bolt with a wrench.
      Fig 11: Locating Crankshaft Pulley Set Bolt
      G05682472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
      Fig 12: Identifying Flywheel Housing Under Cover
      G05682473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE PROPELLER SHAFT ASSEMBLY (for 2 Joint Type)  (See REMOVAL )
  46. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 3 Joint Type)  (See REMOVAL )
  47. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY  (See REMOVAL )
  48. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY  (See REMOVAL )
  49. REMOVE NO. 3 FRAME CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the 4 bolts of the rear No. 1 engine mounting insulator.
      Fig 13: Locating Rear No. 1 Engine Mounting Insulator Bolts
      G05682474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts, 4 washers, 4 bolts and No. 3 frame crossmember.
      Fig 14: Locating No. 3 Frame Crossmember Nuts, Washers And Bolts
      G05682475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR 
    1. Remove the 4 bolts and engine mounting insulator.
      Fig 15: Locating Rear No. 1 Engine Mounting Insulator Bolts
      G05682476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. DISCONNECT WIRE HARNESS AND CONNECTOR  (See REMOVAL )
  52. DISCONNECT NO. 1 WATER BY-PASS PIPE  (See REMOVAL )
  53. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY  (See REMOVAL )
  54. REMOVE ENGINE ASSEMBLY 
    1. Install the 2 engine hangers with the 4 bolts shown below.

      Part No.: 

      ITEM REFERENCE

      Item Part No.
      No. 1 engine hanger 12281-31060
      No. 2 engine hanger 12282-31040
      Bolt 90119-08A87

      Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

      Fig 16: Locating Engine Hangers & Bolts
      G05682477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the engine sling device and hang the engine with the chain block.
      Fig 17: Hanging Engine With Chain Block Using Engine Sling Device
      G05682478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts and 4 bolts from the front engine mounting insulator LH and RH.
    4. Lift the engine out of the vehicle carefully.
      NOTE: Make sure the engine is clear of all wiring and hoses.
    5. Remove the front engine mounting insulator LH and RH.
    6. Place the engine onto a working bench.
      Fig 18: Locating Front Engine Mounting Insulator Nuts & Bolts
      G05682479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE DRIVE PLATE AND RING GEAR 
    1. Using SST, hold the crankshaft.

      SST 09213-54015 (91651-60855), 09330-00021 

      Fig 19: Holding Crankshaft Using SST
      G05682480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, rear spacer, drive plate and front spacer.
      Fig 20: Locating Drive Plate And Ring Gear Bolts
      G05682481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. INSTALL ENGINE STAND 
    1. Install the engine onto an engine stand with the bolts.
  57. REMOVE ENGINE HANGER 
    1. Remove the 4 bolts and 2 engine hangers.
      Fig 21: Locating Engine Hangers & Bolts
      G05682482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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