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Engine Unit: Removal

WARNING: This page is about a different variant/trim than selected.
  1. Remove engine under covers  .
  2. Drain transaxle oil  .
  3. Drain transfer oil  .
  4. Drain engine oil  .
  5. Drain engine coolant  .
  6. Remove hood  .
  7. Remove radiator reservoir  .
  8. Remove battery and tray  .
    1. Remove the cowl top ventilation louver (See REMOVAL ).
    2. Remove the hold-down clamp, battery and tray.
    3. Remove the 5 bolts and battery bracket.
      Fig 1: Locating Bolts & Battery Bracket
      G01083767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. Remove air cleaner assembly  .
      Fig 2: Removing Air Cleaner Assembly
      G01083768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Disconnect the MAF meter connector.
    2. Disconnect the 2 EVAP hoses from the VSV.
    3. Disconnect VSV connector for EVAP.
    4. Disconnect the CCV hose from the air cleaner.
    5. Disconnect the PCV hose from the cylinder head cover.
    6. Disconnect the air cleaner hose from the throttle body, and remove the 3 bolts and the air cleaner assembly.
  10. Remove engine room J/B  .
    1. Remove the engine room J/B cover.
    2. Loosen the bolt.
    3. Remove the engine room J/B.
    4. Pull out the engine wire connector.
      Fig 3: Identifying Engine Wire Connector
      G01083769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the connector.
    6. Disconnect the engine wire clamp.
  11. Disconnect engine wire from cabin  .
    1. Remove the 2 screws and glove compartment door.
    2. Disconnect the 6 engine wire connectors from the ECM and instrument panel wire.
    3. Pull out the engine wire from the cabin.
  12. Disconnect tubes, hoses, connector, cable and wire  .
    1. Disconnect the accelerator cable.
    2. Disconnect the ground wire from the cylinder head.
    3. Disconnect the discharge and liquid tubes from the compressor, and remove the 2 O-rings (See REMOVAL ).
      Fig 4: Locating Discharge & Liquid Tubes
      G01083770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the suction hose, pressure feed tube and gasket from the PS vane pump.
    5. Disconnect the upper radiator hose.
    6. Disconnect the lower radiator hose.
    7. Disconnect the fuel tube connector.
    8. Disconnect the 2 heater hoses.
      Fig 5: Locating Heater Hoses
      G01083771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect the connector from the fusible link block.
      Fig 6: Locating Fusible Link Block Connector
      G01083772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. M/T: Disconnect shift control cables from transaxle. 
    1. Remove the 2 clips and 2 washers.
    2. Remove the 2 clips, and disconnect the 2 control cables.
      3. Fig 7: Locating Clips & Washer & Control Cables
      G01083773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Remove starter  .
    1. A/T: Disconnect the hose from the dipstick guide.
    2. Disconnect the connector.
    3. Remove the 2 bolts, and disconnect the starter.
    4. Remove the nut, and disconnect the starter cable.
    5. Remove the starter.
      6. Fig 8: Locating Starter Bolts & Nuts
      G01083774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. M/T: Disconnect clutch release cylinder and line from transaxle 
    1. Remove the 2 bolts and heat insulator.
    2. Remove the 5 bolts and disconnect the release cylinder.
      3. Fig 9: Locating Heat Insulator Bolts & Release Cylinder Bolts
      G01083776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. A/T: Disconnect shift control cable from transaxle 
    1. Remove the nut holding the control shift lever to the control cable.
    2. Remove the clip, and disconnect the control cable.
    3. Disconnect the control cable from the cable clamp.
      4. Fig 10: Disconnecting Shift Control Cable
      G01083777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. A/T: Disconnect oil cooler hoses  .
    Fig 11: Disconnecting Oil Cooler Hoses
    G01083778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Disconnect ground cable from transaxle  .
  19. 4WD: Remove propeller shaft (See  REMOVAL  )  .
  20. Remove front drive shafts (See  REMOVAL  )  .
  21. Remove front exhaust pipe  .
    Fig 12: Locating Front Exhaust Pipe Bolts
    G01083775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    Remove the 4 bolts, 2 compression rings, 2 gaskets and exhaust pipe.

  22. Disconnect stabilizer bar links  .

    Remove the 2 nuts, and disconnect the LH and RH stabilizer links.

    Fig 13: Displaying LH & RH Stabilizer Nuts
    G01083779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. Disconnect PS gear assembly  .

    Remove the 2 bolts of the PS gear assembly.

    Fig 14: Disconnect PS Gear Assembly
    G01083780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Attach engine sling device to engine hangers  .
    1. Install No. 1 and No. 2 engine hangers in the correct direction.
      Fig 15: Installing No. 1 & 2 Engine Hangers
      G01083782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 16: Displaying Installing Specifications
      G01083781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Torque: 38 N.m (390 kgf. cm, 28 ft. lbf) 
    2. Attach the sling device to the engine hangers.
    CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
  25. Remove engine, transaxle, front suspension crossmember and center engine mounting member assembly 
    1. Remove the 2 nuts and bolt holding the RH engine mounting insulator to the tinning chain cover.
      Fig 17: Removing RH Nuts & Bolts
      G01083783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt holding the LH engine mounting insulator to the mounting bracket.
      Fig 18: Removing LH Nuts & Bolts
      G01083784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Support the suspension crossmember with a jack.
    4. Remove the 6 bolts holding the suspension crossmember engine mounting member to the body.
      Fig 19: Removing Crossmember Bolts
      G01083785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Lower the engine out of the vehicle slowly and carefully.
      6. Fig 20: Displaying Engine Lowering
      G01083786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: Make sure the engine is clear of all wiring, hoses and cables.
  26. Remove engine and transaxle assembly from front suspension crossmember and center engine mounting member 
    1. Remove the bolt holding the front engine mounting bracket to the mounting insulator.
      Fig 21: Removing Bolt Holding Front Engine Mounting Bracket
      G01083787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt holding the rear engine mounting bracket to the mounting insulator.
      Fig 22: Removing Bolt Holding Rear Engine Mounting Bracket
      G01083788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Separate the engine and transaxle assembly from the suspension crossmember and engine mounting member.
  27. 4WD: Remove stiffener plate  .

    Remove the 5 bolts and stiffener plate.

    Fig 23: Locating Stiffener Plate Bolts
    G01083789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 2WD: Remove center bearing bracket  .

    Remove the 3 bolts and bearing bracket.

    Fig 24: Removing Center Bearing Bracket
    G01083790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. A/T: Remove torque converter clutch bolts  .
    1. Remove the hole plug.
    2. Turn the crankshaft to gain access to each bolt.
    3. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
      4. Fig 25: Removing Torque Converter Clutch Bolts
      G01083791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. Remove transaxle from engine  .
    1. Remove the 4 lower bolts holding the engine to the transaxle.
      Fig 26: Removing Engine Lower Bolts
      G01083792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. M/T: Disconnect the connectors.
      1. Disconnect the vehicle speed sensor connector.
      2. Disconnect the back-up light switch connector.
        3. Fig 27: Locating M/T Connectors
        G01083793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. A/T: Disconnect the connectors and clamps.
      1. Disconnect the park/neutral position switch connector.
      2. Disconnect the solenoid wire connector.
      3. Disconnect the input turbine speed sensor connector.
      4. Disconnect the counter gear speed sensor connector.
      5. Disconnect the vehicle speed sensor.
        Fig 28: Locating A/T Connectors & Clamp
        G01083794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Disconnect the wire clamp from the bracket.
      7. Disconnect the wire clamp from the engine mounting bracket.
    4. Remove the 6 upper bolts holding the transaxle to the engine.
      Fig 29: Locating Bolts Holding Transaxle
      G01083795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the transaxle together with the torque converter clutch (A/T) from the engine.
  31. Remove drive belt (See  CHARGING SYSTEM  )  .
  32. M/T: Remove clutch cover and disc  .
  33. A/T: Remove drive plate  .
  34. M/T: Remove flywheel  .
  35. Remove A/C compressor  .
    1. Disconnect the magnetic clutch and lock sensor connector from the compressor.
    2. Remove the 3 bolts, nut and compressor.
      Fig 30: Removing A/C Compressor
      G01083796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. Remove PS vane pump  .
    1. Disconnect the oil pressure switch connector.
    2. Remove the 2 bolts and vane pump.
      3. Fig 31: Removing PS Vane Pump
      G01083797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. Remove generator  .
      Fig 32: Locating & Removing Generator
      G01083798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the terminal cover and nut, and disconnect the generator wire.
    2. Disconnect the generator connector.
    3. Disconnect the A/C wire.
    4. Remove the 2 bolts and generator.
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