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Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM  (See REMOVAL )
  2. 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.
  3. REMOVE BATTERY 
    1. Loosen the 2 nuts and remove the battery clamp.
  4. REMOVE BATTERY TRAY 
  5. REMOVE FRONT WHEEL 
  6. REMOVE ENGINE UNDER COVER RH 
  7. REMOVE ENGINE UNDER COVER LH 
  8. REMOVE FRONT FENDER APRON SEAL RH  (See REMOVAL )
  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY  (See REMOVAL  )
  10. DRAIN ENGINE COOLANT  (See ON-VEHICLE INSPECTION )
  11. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)  (See REMOVAL )
  12. DRAIN TRANSAXLE OIL (for Manual Transaxle)  (See REMOVAL )
  13. DISCONNECT RADIATOR HOSE INLET 
  14. DISCONNECT RADIATOR HOSE OUTLET 
  15. DISCONNECT NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle) 
  16. DISCONNECT NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle) 
  17. REMOVE RADIATOR ASSEMBLY  (See REMOVAL )
  18. REMOVE AIR CLEANER ASSEMBLY 
    1. Remove the air cleaner cap and element (see REMOVAL ).
    2. Remove the clamp of the engine wire.
    3. Remove the 3 bolts from the air cleaner case.
      4. Fig 1: Identifying Air Cleaner Case Bolts
      G05538291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the air cleaner case from the No. 1 air cleaner inlet.
  19. REMOVE BATTERY CARRIER 
    1. Disconnect the clamp of the engine wire.
    2. Remove the 4 bolts and battery carrier.
    Fig 2: Identifying Battery Carrier Bolts
    G05538292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT FUEL MAIN TUBE  (See REMOVAL )
  21. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose from the booster vacuum tube.
      Fig 3: Disconnecting Union To Connector Tube Hose
      G05538293Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT HEATER WATER INLET HOSE 
    1. Disconnect the heater water inlet hose from the booster vacuum tube.
      Fig 4: Disconnecting Heater Water Inlet Hose
      G05538294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT HEATER WATER OUTLET HOSE 
    1. Disconnect the heater water outlet hose from the air conditioner tube.
    Fig 5: Disconnecting Heater Water Outlet Hose
    G05538295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  25. REMOVE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  26. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  27. REMOVE FAN AND GENERATOR V BELT  (See REMOVAL  )
  28. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  29. REMOVE COOLER COMPRESSOR ASSEMBLY 

    HINT:

    Disconnect the compressor together with the low-pressure and high-pressure hoses, then secure it to the vehicle side using rope.

  30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  (See REMOVAL )
  31. DISCONNECT ENGINE WIRE 
    1. Disconnect the engine wire from the ECM and junction block.
    2. Pull out the engine wire.
    3. Remove the engine room relay block cover.
    4. Remove the 2 claws and 2 connectors, and push the engine wire harness up.
      Fig 6: Identifying Engine Wire Harness Cpmmectors And Claws
      G05538296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 clamps of the engine wire.
      Fig 7: Identifying Clamps Of Engine Wire
      G05538297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the nut from the battery positive (+) terminal to disconnect the engine wire.
      Fig 8: Identifying Engine Wire To Battery Positive Terminal With Nut
      G05538298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt and ground cable.
    Fig 9: Identifying Ground Cable With Bolt
    G05538299Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  33. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  34. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See REMOVAL )
  35. REMOVE FRONT AXLE HUB NUT  (See REMOVAL )
  36. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH  (See REMOVAL )
  38. DISCONNECT FRONT SPEED SENSOR LH  (See REMOVAL )
  39. DISCONNECT FRONT SPEED SENSOR RH  (See REMOVAL )
  40. SEPARATE TIE ROD END LH SUB-ASSEMBLY  (See REMOVAL )
  41. REMOVE TIE ROD END RH SUB-ASSEMBLY  (See REMOVAL )
  42. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH  (See REMOVAL )
  43. SEPARATE FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER RH  (See REMOVAL )
  44. REMOVE FRONT AXLE HUB LH SUB-ASSEMBLY  (See REMOVAL )
  45. REMOVE FRONT AXLE HUB RH SUB-ASSEMBLY  (See REMOVAL )
  46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Disconnect the No. 1 pump hose.
      Fig 10: Identifying No. 1 Pump Hose
      G05538300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the return tube.
      3. Fig 11: Identifying Return Tube
      G05538301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Set the engine lifter.
    4. Remove the 2 bolts, 2 nuts and engine mounting insulator RH.
      Fig 12: Identifying Engine Mounting Insulator RH Bolts And Nuts
      G05538302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the through bolt, nut and engine mounting insulator LH.
      Fig 13: Identifying Engine Mounting Insulator LH With Through Bolt And Nut
      G05538303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 8 bolts and front suspension member brace rear RH and LH.
      Fig 14: Identifying Front Suspension Member Brace Rear RH And LH Bolts
      G05538304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts and 2 nuts shown in the illustration.
      8. Fig 15: Identifying Suspension Crossmember With 2 Bolts And 2 Nuts
      G05538305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Carefully remove the engine with transaxle from the vehicle.
    9. Install the No. 1 and No. 2 engine hangers with the bolts as shown in the illustration.

      Parts No. 

      PARTS NO. REFERENCE

      Item Part No.
      No. 1 Engine hanger 12281-28010
      No. 2 Engine hanger 12282-28010
      Bolt 91512-61020
      Fig 16: Identifying No. 1 And No. 2 Engine Hangers With Bolts
      G05538121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    10. Attach the sling device and the engine with the chain block.
  47. REMOVE VANE PUMP ASSEMBLY 
  48. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY WITH CENTER MEMBER 
    1. Remove the through bolt, nut and engine mounting insulator FR from the engine mounting bracket FR.
      Fig 17: Identifying Front Engine Mounting Bracket Bolt And Nut
      G05538307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the through bolt and engine mounting insulator RR from the engine mounting bracket RR.
      3. Fig 18: Identifying Rear Engine Mounting Insulator Through Bolt
      G05538308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
  49. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  50. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See REMOVAL )
  51. REMOVE STARTER ASSEMBLY  (See REMOVAL )
  52. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY  (See REMOVAL )
  53. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY (for Automatic Transaxle) 
  54. REMOVE DRIVE PLATE SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Using SST, hold the crankshaft.

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

      Fig 19: Identifying Crankshaft Using SST
      G05538309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, rear spacer, drive plate and front spacer.
    Fig 20: Identifying Drive Plate And Front Spacer Bolts
    G05538310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE MANUAL TRANSAXLE ASSEMBLY  (See REMOVAL )
  56. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  57. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  58. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Using SST, hold the crankshaft.

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

      Fig 21: Identifying Crankshaft Using SST
      G05538309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts and flywheel.
      Fig 22: Identifying And Flywheel Bolts
      G05538312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
    Fig 23: Identifying Drive Shaft Bearing Bracket (For 2WD)
    G05387330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE OIL DIPSTICK 
  61. REMOVE OIL DIPSTICK GUIDE  (See REMOVAL  )
  62. REMOVE MANIFOLD STAY  (See REMOVAL  )
  63. REMOVE NO. 2 MANIFOLD STAY  (See REMOVAL  )
  64. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See REMOVAL  )
  65. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY  (See REMOVAL  )
  66. REMOVE WATER INLET  (See REMOVAL )
  67. REMOVE THERMOSTAT 
  68. REMOVE NO. 1 WATER BY-PASS PIPE 
    1. Remove the bolt, 2 nuts and water by-pass pipe.
    2. Remove the gasket from the cylinder block.
    Fig 24: Identifying Water By-Pass Pipe Bolt And Nuts
    G05538314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. REMOVE INTAKE MANIFOLD ASSEMBLY  (See REMOVAL )
  70. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR  (See REMOVAL )
  71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY  (See REMOVAL  )
  72. REMOVE IGNITION COIL ASSEMBLY  (See REMOVAL )
  73. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY  (See REMOVAL )
  74. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY  (See REMOVAL )
  75. REMOVE KNOCK SENSOR  (See REMOVAL )
  76. REMOVE RADIO SETTING CONDENSER 
    1. Remove the bolt and condenser.
      Fig 25: Identifying Condenser With Bolt
      G05538315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
  78. REMOVE ENGINE COOLANT TEMPERATURE SENSOR  (See REMOVAL )
  79. REPLACE PARTIAL ENGINE ASSEMBLY 
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