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Engine Assembly: Removal

WARNING: This page is about a different car, the 2007 Lexus GX 470. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  ON-VEHICLE INSPECTION  ) 
  2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY 

    HINT:

    (See REMOVAL )

  3. REMOVE HOOD SUB-ASSEMBLY 
    1. Disconnect the windshield washer hose.
    2. Disconnect the hood dampers.
    3. Remove the 4 bolts and hood sub-assembly.
  4. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Remove the 2 nuts and V-bank cover sub-assembly.
  5. REMOVE ENGINE ROOM COVER SIDE 
  6. REMOVE ENGINE ROOM SIDE COVER LH 
  7. REMOVE AIR CLEANER HOSE ASSEMBLY 
    1. Disconnect the vacuum hoses (for P/S idle up and for fuel pressure regulator) and ventilation hose.
  8. REMOVE AIR CLEANER ASSEMBLY 
    1. Disconnect the intake air flow meter connector.
    2. Disconnect the ground cable from the body.
    3. Remove the air cleaner cap and air cleaner element.
    4. Remove the 3 bolts and air cleaner assembly.
  9. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 
  10. REMOVE ENGINE UNDER COVER ASSEMBLY REAR 
  11. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  12. DRAIN ENGINE OIL 
    1. Remove the oil pan drain plug and drain the engine oil.
    2. Clean the oil pan drain plug and install a new gasket and the drain plug.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

  13. REMOVE RADIATOR ASSEMBLY 

    HINT:

    (See REMOVAL )

  14. REMOVE FAN SHROUD 
    1. Disconnect the fasteners of the clamp and oil cooler hoses from the fan shroud in sequence.
    2. Remove the fan shroud with fan.
  15. DISCONNECT NO. 2 FUEL HOSE 
    Fig 1: Identifying No. 2 Fuel Hose Clamp
    G05264529Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Observe the following precautions when disconnecting the fuel tube connector:
      1. Remove the No. 2 fuel pipe clamp.
      2. Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
        3. Fig 2: Disconnecting Connector
        G04961675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the connector from the hose while pinching part A with fingers.
        4. Fig 3: Pinching Fuel Pipe With Fingers
        G04961676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time.
      5. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away.
        6. Fig 4: Covering Pipe & Connector With Plastic Bag
        G04961677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
  16. DISCONNECT FUEL HOSE 
    Fig 5: Identifying No. 1 Fuel Pipe Clamp
    G04961678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Observe the following precautions when disconnecting the fuel tube connector:
      1. Remove the No. 1 fuel pipe clamp.
      2. Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
        3. Fig 6: Disconnecting Connector From Hose
        G04961675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the connector from the hose while pinching part A with fingers.
        4. Fig 7: Pinching Fuel Pipe With Fingers
        G04961676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time.
      5. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away.
        6. Fig 8: Covering Pipe & Connector With Plastic Bag
        G04961677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
  17. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
  18. REMOVE FAN AND GENERATOR V BELT (See  REMOVAL   ) 
  19. SEPARATE VANE PUMP ASSEMBLY 
    1. Disconnect the vacuum hose.
      2. Fig 9: Identifying Vane Pump Assembly Bolts
      G04961524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, 2 bolts and vane pump assembly.

      HINT:

      Hang up the hose instead of detaching.

  20. SEPARATE COMPRESSOR 
    1. Disconnect the compressor connector.
      2. Fig 10: Identifying Compressor Stay Nut & Bolts
      G05264538Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, 3 bolts, compressor stay and compressor.

      HINT:

      Hang up the hoses instead of detaching.

  21. REMOVE FAN WITH FLUID COUPLING 
    Fig 11: Identifying Fan With Fluid Coupling Nuts
    G04961684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 nuts and fan with fluid coupling.
    2. Remove the fan pulley.
  22. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY 
    1. Remove the bolt and transmission oil filler tube.
  23. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Remove the bolt and oil level gauge guide.
    2. Remove the O-ring.
  24. DISCONNECT HEATER HOSE 
  25. SEPARATE ENGINE WIRE 
    1. Remove the front door scuff plate RH (See REMOVAL ).
    2. Remove the cowl side trim board RH (See REMOVAL ).
    3. Remove the glove compartment door (See REMOVAL ).
    4. Disconnect each connector for the ECM, four-wheel-drive-control ECU and instrument panel wire before pulling out the engine wire into the engine room.
      5. Fig 12: Identifying Ground Cables
      G04961685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the 3 ground cables from the body.
    6. Disconnect the No. 2 engine wire from the battery terminals (positive and negative) and engine room relay block.
  26. REMOVE ENGINE ASSEMBLY 
    1. Attach the engine chain hoist to the engine hangers.
      2. Fig 13: Identifying Engine Assembly Nuts & Bolts
      G04961686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and 4 bolts.
    3. Lift the engine out of the vehicle slowly and carefully.

      HINT:

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

  27. REMOVE ENGINE WIRE 
    1. Disconnect the VSV connector.
    2. Disconnect the solenoid connector.
  28. REMOVE INTAKE MANIFOLD ASSEMBLY (See  REMOVAL  ) 
  29. REMOVE NO. 2 WIRING HARNESS HEAT INSULATOR 
    1. Remove the 2 bolts and No. 2 wiring harness heat insulator.
  30. REMOVE NO. 2 ENGINE WIRE 
    1. Remove the bolt and separate the ground cable wire.
    2. Remove the nut, 2 bolts and No. 2 engine wire.
  31. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT RH 
    1. Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front.
  32. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH 
    1. Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front.
  33. REMOVE GENERATOR ASSEMBLY (See  REMOVAL  ) 
  34. REMOVE HEATER HOSE 
  35. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (See  REMOVAL   ) 
  36. REMOVE OIL COOLER PIPE 
    1. Disconnect the 3 hoses.
    2. Remove the bolt, nut and oil cooler pipe.
  37. REMOVE PUMP BRACKET 
    1. Remove the 4 bolts and pump bracket.
  38. REMOVE NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH 
    1. Remove the grommet and separate the cam position sensor connector from the No. 3 timing belt cover sub-assembly LH.
    2. Remove the 4 bolts and No. 3 timing belt cover sub-assembly LH.
    Fig 14: Identifying No. 3 Timing Belt Cover Sub-Assembly Bolts
    G04961527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 TIMING CHAIN OR BELT COVER 
    1. Remove the nut, 3 bolts and No. 2 timing belt cover.
    Fig 15: Identifying No. 2 Timing Belt Cover Nut & Bolts
    G04961688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 2 TIMING BELT COVER SUB-ASSEMBLY 
    1. Remove the 2 bolts and No. 2 timing belt cover sub-assembly.
    Fig 16: Identifying No. 2 Timing Belt Cover Sub-Assembly Bolts
    G05264544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the bolt, 2 nuts and V-ribbed belt tensioner.
    Fig 17: Identifying V-Ribbed Belt Tensioner Bolt & Nuts
    G05264545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FAN BRACKET SUB-ASSEMBLY 
    Fig 18: Identifying Fan Bracket Sub-Assembly Nut & Bolts
    G04961691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 nuts, 2 bolts and fan bracket sub-assembly.
  43. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 8 bolts and 8 ignition coils.
  44. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt, stud bolt and camshaft position sensor.
  45. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the bolt and crankshaft position sensor.
  46. REMOVE VVT SENSOR 
    1. Remove the 2 bolts and VVT sensors.
  47. REMOVE WATER BYPASS PIPE SUB-ASSEMBLY 
    1. Remove the wire clamp.
    2. Remove the bolt and water bypass.
      3. Fig 19: Identifying Bypass Pipe Sub-Assembly O-Ring
      G04961692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the water bypass pipe sub-assembly.
  48. REMOVE NO. 2 AIR SWITCHING VALVE (See  REMOVAL  ) 
  49. REMOVE WATER BYPASS JOINT RR 
    Fig 20: Identifying Water Bypass Joint Nuts
    G04961693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 nuts and water bypass joint.
    2. Remove the 2 gaskets from the water bypass joint.
  50. REMOVE AIR PUMP ASSEMBLY WITH BRACKET (See  REMOVAL  ) 
  51. REMOVE STARTER ASSEMBLY 
    1. Disconnect the No. 2 engine wire.
    2. Remove the 2 bolts and starter assembly.
  52. REMOVE KNOCK SENSOR (See  REMOVAL  ) 
  53. REMOVE WATER INLET HOUSING (See  REMOVAL   ) 
  54. REMOVE WATER BYPASS JOINT FR 
    1. Remove the 4 nuts, water bypass joint and 2 gaskets.
  55. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    Fig 21: Identifying No. 1 Exhaust Manifold Heat Insulator Bolts
    G04961694Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.
    2. Disconnect the oxygen sensor connector.
    3. Remove the 8 nuts and exhaust manifold sub-assembly.
  56. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Remove the 4 bolts and No. 2 exhaust manifold heat insulator.
    2. Disconnect the oxygen sensor connector.
    3. Remove the 8 nuts and exhaust manifold sub-assembly.
  57. REMOVE OIL COOLER ASSEMBLY 
    1. Remove the 2 bolts and nut.
    2. Remove the oil cooler assembly with bracket and gasket.
  58. REMOVE VENTILATION VALVE SUB-ASSEMBLY 
    1. Remove the ventilation valve cover.
    2. Remove the ventilation valve sub-assembly.
  59. REPLACE PARTIAL ENGINE ASSEMBLY 
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