Engine Assembly: Removal

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

PLACE FRONT WHEELS FACING STRAIGHT AHEAD
DISCHARGE FUEL SYSTEM PRESSURE (See REMOVAL )
REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (See REMOVAL )
REMOVE BATTERY SERVICE HOLE COVER LH (See REMOVAL )
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.
NOTE:
- When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
- After the power switch is turned OFF, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the power switch OFF, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.
REMOVE SERVICE PLUG GRIP (See REMOVAL )
REMOVE V-BANK COVER SUB-ASSEMBLY
1. While using both hands, lift the rear side of the cover upwards to detach the 4 clips labeled B Slide the cover towards the front of the vehicle to detach the 2 clips labeled A, and remove the V-bank cover.
  NOTE: The V-bank cover may be damaged if its front and rear are lifted at the same time.
  
  Fig 1: Locating V-Bank Cover Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY
1. Remove the 5 clips labeled A.
2. Lift up the air cleaner inlet cover to detach the 4 clips labeled B, and remove the cover.
  
  Fig 2: Locating Air Cleaner Inlet Cover Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 AIR CLEANER INLET
1. Remove the 2 bolts
  
  Fig 3: Locating Air Cleaner Inlet Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Hold the air cleaner inlet by the protrusions labeled A and B, and detach the connections
3. Rotate the No 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled C.
4. Hold the air cleaner inlet by the protrusions labeled D and E, and detach the connections
5. Rotate the No 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled F
  
  Fig 4: Rotating Air Cleaner Inlet
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE ROOM SIDE COVER RH
1. Remove the 4 clips and side cover.
  HINT.
  
  The clip labeled A cannot be removed from the cover.
  
  NOTE: Remove the clip labeled A by turning it to prevent the engine room side cover RH and bracket from being damaged.
  
  Fig 5: Locating Engine Room Side Cover Clips (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE ROOM SIDE COVER LH
1. Remove the 4 clips and side cover.
RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (See REPLACEMENT )
REMOVE COWL TOP VENTILATOR LOUVER RH (See REMOVAL )

Fig 6: Locating Engine Room Side Cover Clips (LH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MOTOR CABLE COVER RH
1. Remove the 2 clips and cable cover.
  
  Fig 7: Locating Motor Cable Cover Clips (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INVERTER COVER ASSEMBLY RH
1. Detach the 2 clips and remove the inverter cover.
REMOVE CONNECTOR COVER ASSEMBLY (See REMOVAL )
CHECK TERMINAL VOLTAGE (See REMOVAL )
INSTALL CONNECTOR COVER ASSEMBLY (See INSTALLATION )

Fig 8: Identifying Inverter Cover Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT CENTER FLOOR COVER
1. Remove the 3 screws, 2 bolts, clip and floor cover
  
  Fig 9: Locating Front Center Floor Cover Screws And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 ENGINE UNDER COVER
1. Remove the 4 screws, 2 clips and under cover
REMOVE FRONT WHEEL OPENING EXTENSION PAD LH (See REMOVAL )
REMOVE FRONT WHEEL OPENING EXTENSION PAD RH (See REMOVAL )

Fig 10: Locating Engine Under Cover Screws And Clips
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 1 ENGINE UNDER COVER
1. Remove the 13 screws, 7 clips and under cover.
  
  Fig 11: Locating Engine Under Cover Screws And Clips
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR
1. Remove the 9 bolts and suspension member protector.
DRAIN ENGINE OIL (See REPLACEMENT )
DRAIN ENGINE COOLANT (See REPLACEMENT )
DRAIN COOLANT (for Inverter) (See ON-VEHICLE INSPECTION )
DRAIN FRONT DIFFERENTIAL OIL (See DIFFERENTIAL OIL )

Fig 12: Locating Front Lower Suspension Member Protector Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT INLET OIL COOLER HOSE
1. Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler hose
  HINT:
  
  Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.
  
  Fig 13: Locating Inlet Oil Cooler Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT OUTLET OIL COOLER HOSE
1. Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler hose.
  HINT:
  
  Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.
REMOVE FRONT BUMPER COVER
1. Remove the front bumper cover (see REMOVAL ).
  
  Fig 14: Locating Outlet Oil Cooler Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT WHEELS
DISCONNECT FRONT FENDER LINER LH (w/ Active Stabilizer System) (See REMOVAL )
REMOVE NO. 3 COOL AIR INTAKE DUCT SUB-ASSEMBLY (w/ Active Stabilizer System) (See REMOVAL )
REMOVE INLET ENGINE ROOM ECM DUCT (w/ Active Stabilizer System) (See REMOVAL )
DISCONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR CONNECTOR (w/ Active Stabilizer System) (See REMOVAL )
REMOVE REAR FRAME SIDE RAIL
1. Remove the 6 bolts, 4 nuts and 2 side rails.
  
  Fig 15: Locating Rear Frame Side Rail Bolts And Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE AIR CONNECTOR PIPE
1. Disconnect the No 1 ventilation hose and No. 2 ventilation hose from the intake air connector pipe.
2. Detach the 2 clips.
3. Loosen the 3 hose clamps, and remove the intake air connector pipe
REMOVE AIR CLEANER ASSEMBLY LH (See REMOVAL )
REMOVE AIR CLEANER ASSEMBLY RH (See REMOVAL )
REMOVE RADIATOR RESERVOIR ASSEMBLY (See REMOVAL )

Fig 16: Locating Intake Air Connector Pipe Clips And Hose Clamps
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTLET ENGINE ROOM ECM DUCT
REMOVE NO. 1 RADIATOR HOSE
REMOVE NO. 2 RADIATOR HOSE
REMOVE RESONATOR BRACKET SUB-ASSEMBLY (See REPLACEMENT )
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY (See REMOVAL )

Fig 17: Identifying Radiator Hose
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT NO. 1 FUEL HOSE (See REMOVAL )
DISCONNECT NO. 3 FUEL HOSE (See REMOVAL )
REMOVE INVERTER TERMINAL COVER (See REMOVAL )
DISCONNECT MOTOR CABLE (See REMOVAL )
DISCONNECT GENERATOR CABLE (See REMOVAL )
DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
1. Remove the bolt. Then disconnect the discharge hose.
2. Remove the O-ring from the discharge hose.
  NOTE: Seal the openings of the disconnected parts and motor compressor using vinyl tape and/or plastic bags to prevent moisture and foreign matter from entering them.
  
  Fig 18: Locating Discharge Hose Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT SUCTION HOSE SUB-ASSEMBLY
1. Remove the bolt. Then disconnect the suction hose
2. Remove the O-ring from the suction hose.
  NOTE: Seal the openings of the disconnected parts and motor compressor using vinyl tape and/or plastic bags to prevent moisture and foreign matter from entering them.
REMOVE WATER PUMP ASSEMBLY WITH MOTOR AND BRACKET (See INSTALLATION )

Fig 19: Locating Suction Hose Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT HOSES AND CONNECTORS
1. Remove the 3 bolts and ECM box cover.
  
  Fig 20: Locating ECM Box Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the 4 hybrid vehicle control ECU connectors and 2 wiring harness support connectors.
3. Detach the 2 wiring harness support clips, and then detach the clip of connector A from the ECM box.
  HINT:
  
  It is not necessary to disconnect the connection at A in the illustration.
  
  Fig 21: Locating Hybrid Vehicle Control ECU Connectors And Wiring Harness Support Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Lift up the wiring harness support and disconnect the 4 ECM connectors.
  
  Fig 22: Locating ECM Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the heater wire connector.
  
  Fig 23: Locating Heater Wire Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Disconnect the No. 5 inverter cooling hose.
7. Disconnect the purge line hose.
  
  Fig 24: Locating Purge Line Hose And Inverter Cooling Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Disconnect the 2 heater hoses.
  
  Fig 25: Locating Heater Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Detach the clamp and disconnect the 3 connectors from the front controller.
  
  Fig 26: Locating Front Controller Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Remove the nut and ground wire.
11. Disconnect the 2 oil pump motor controller connectors.
  HINT:
  
  Refer to the following procedures to disconnect the oil pump driver connector (see REMOVAL ).
  
  Fig 27: Locating Oil Pump Motor Controller Connectors
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. Disconnect the heater water pump connector.
13. Detach the 2 clamps. Then remove the nut and inverter cooling pipe bracket.
14. Remove the 2 nuts, heater water pump and bracket
  
  Fig 28: Locating Heater Water Pump Connector And Heater Water Pump Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
15. Disconnect the 2 connectors and detach the 5 clamps
REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
1. Remove the driver side knee airbag (see ON-VEHICLE INSPECTION ).
  
  Fig 29: Locating Connectors And Detach Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY
1. Detach the 2 claws, and remove the bolt and air duct.
  NOTE: Be careful not to damage the air duct as its connection to the vehicle is very tight.
REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (See REMOVAL )
REMOVE FRONT DRIVE SHAFT ASSEMBLY
1. Remove the drive shaft (see REMOVAL ).
  
  Fig 30: Locating Air Duct Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT EXHAUST PIPE ASSEMBLY
1. Remove the front exhaust pipe (See REMOVAL ).
REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
1. Remove the propeller shaft (see REMOVAL ).
DISCONNECT TRANSMISSION CONTROL SHAFT LEVER
1. Remove the nut and spring washer, and then disconnect the control shaft lever from the position sensor.
  
  Fig 31: Locating Transmission Control Shaft Lever Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH.
1. Remove the bolt. Then disconnect the absorber and absorber bracket
  
  Fig 32: Locating Front Lower Shock Absorber Bracket Bolt (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH
1. Remove the bolt. Then disconnect the absorber and absorber bracket.
  
  Fig 33: Locating Front Lower Shock Absorber Bracket Bolt (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE ENGINE AND TRANSMISSION

Place a mark (with spray, etc.) over the rear right vehicle side attachment area of the front frame, which is indicated in the illustration
Place a mark (with spray, etc.) over the rear left vehicle side attachment area of the front frame.
Set an engine lifter underneath the engine
HINT

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

Fig 34: Identifying Mark Over Rear Right Vehicle Side Attachment Area Of Front Frame
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 4 rear engine mounting member's bolts

Fig 35: Locating Rear Engine Mounting Member's Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
Remove the 4 bolts shown in the illustration.
Operate the engine lifter, then slowly remove the engine from the vehicle.
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.
  
  Fig 36: Locating Front Frame Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install 2 engine hangers with 2 bolts as shown in the illustration.

ENGINE HANGER PART NO.

ENGINE HANGER PART NO REFERENCE

Item	Part No.
Engine hanger	12281-38030
Bolt	90119-14120

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

Fig 37: Locating Engine Hangers Bolts

Attach an engine sling device and hang the engine with a chain block.
NOTE: When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

Fig 38: Identifying Sling Device's Hanging Angle
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE FRONT FRAME ASSEMBLY
1. Disconnect the heater wire connector and detach the 2 clips.
  
  Fig 39: Locating Heater Wire Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 4 nuts and front frame
  
  Fig 40: Locating Front Frame Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
1. Remove the dipstick.
2. Remove the bolt and dipstick guide.
3. Remove the O-ring from the dipstick guide.
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (See REMOVAL )
REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (See REMOVAL )

Fig 41: Removing Engine Oil Level Dipstick Guide
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT ENGINE MOUNTING INSULATOR
1. Remove the 2 nuts, 2 spacers and 2 insulators.
  
  Fig 42: Identifying Front Engine Mounting Insulator Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH
1. Remove the 5 bolts and mounting bracket.
  
  Fig 43: Locating Front No 1 Engine Mounting Bracket Bolts (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
1. Remove the 5 bolts and mounting bracket.
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See REMOVAL )
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (See REMOVAL )

Fig 44: Locating Front No 1 Engine Mounting Bracket Bolts (LH)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET RH
1. Remove the 2 bolts and mounting bracket.
  
  Fig 45: Locating Front No 2 Engine Mounting Bracket Bolts (RH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH
1. Remove the 2 bolts and mounting bracket.
  
  Fig 46: Locating Front No 2 Engine Mounting Bracket Bolts (LH)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT PROPELLER SHAFT ASSEMBLY
1. Put matchmarks on the transfer companion flange and the front propeller shaft.
  
  Fig 47: Identifying Matchmarks On Transfer Companion Flange And Front Propeller Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver or equivalent, hold the transfer companion flange.
3. Using a 6 mm socket hexagon wrench, loosen the 6 bolts.
  NOTE: Be careful not to damage the front propeller shaft.
  
  Fig 48: Removing Front Propeller Shaft Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Put matchmarks on the front differential companion flange and the front propeller shaft
  
  Fig 49: Identifying Matchmarks On Front Differential Companion Flange And Front Propeller Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a screwdriver or equivalent, hold the differential companion flange.
6. Using a 6 mm socket hexagon wrench, loosen the 6 bolts.
  NOTE: Be careful not to damage the front propeller shaft.
7. Remove the 12 bolts, 4 constant velocity universal joint washers and front propeller shaft assembly.
  
  Fig 50: Removing Differential Companion Flange Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR ENGINE MOUNTING MEMBER
HINT:

Only perform this procedure when replacement of the engine mounting insulator is necessary.
1. Remove the 5 nuts, No. 3 mounting insulator and mounting member.
  
  Fig 51: Locating Mounting Insulator And Mounting Member Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT:

Only perform this procedure when replacement of the engine mounting insulator is necessary.
1. Remove the 4 bolts and 2 mounting insulators.
  
  Fig 52: Locating Rear No 1 Engine Mounting Insulator Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE REAR NO. 2 ENGINE MOUNTING INSULATOR
HINT:

Only perform this procedure when replacement of the engine mounting insulator is necessary.
1. Remove the 2 bolts and mounting insulator.
REMOVE OIL COOLER TUBE SUB-ASSEMBLY (See REMOVAL )

Fig 53: Locating Rear No 2 Engine Mounting Insulator Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE OUTLET NO. 1 HYBRID WATER PUMP PIPE
1. Remove the 2 bolts and outlet pipe.
REMOVE STARTER HOLE INSULATOR (See REMOVAL )
REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY (See REMOVAL )

Fig 54: Locating Hybrid Water Pump Pipe Bolts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INPUT TRANSMISSION DAMPER COVER ASSEMBLY
1. Remove the 9 bolts and damper cover.
  
  Fig 55: Locating Input Transmission Damper Cover Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FLYWHEEL SUB-ASSEMBLY
1. Using SST, hold the crankshaft.
  SST 09213-54015 (90119-08216), 09330-00021
  
  Fig 56: Removing Sensor Plate And Flywheel
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 10 bolts, sensor plate and flywheel.
INSTALL ENGINE TO ENGINE STAND
1. Install the engine onto an engine stand with the bolts.
2. Remove the 2 bolts and 2 engine hangers.
  
  Fig 57: Locating Flywheel Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002