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Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 
    1. Discharge fuel system pressure (See FUEL SYSTEM ).
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. REMOVE FRONT WHEELS 
  4. REMOVE ENGINE UNDER COVER RH 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE CYLINDER HEAD COVER NO.2 
    1. Remove the cylinder head cover No. 2 (See REMOVAL  ).
  7. DRAIN ENGINE COOLANT 
    1. Drain the engine coolant (See COOLANT ).
  8. DISCONNECT RADIATOR HOSE INLET 
  9. DISCONNECT RADIATOR HOSE OUTLET 
  10. DISCONNECT OIL COOLER INLET HOSE NO.1 (for Automatic Transaxle) 
  11. DISCONNECT OIL COOLER OUTLET HOSE NO.1 (for Automatic Transaxle) 
  12. REMOVE RADIATOR ASSEMBLY (w/ Air Conditioning System) 
    1. Remove the radiator assembly (See REMOVAL ).
  13. REMOVE BATTERY 
  14. REMOVE BATTERY TRAY 
  15. REMOVE BATTERY CARRIER 
    1. Remove the 4 bolts, then remove the battery carrier.
    Fig 1: Removing Battery Carrier
    G05194247Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 
    1. Remove the air cleaner cap sub-assembly (See ON-VEHICLE INSPECTION ).
  17. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disconnect the clamp [A] of the engine wire.
    2. Remove the 3 bolts [B] from the air cleaner case.
    3. Disconnect the air cleaner case from the air cleaner inlet No. 1 [C].
      Fig 2: Removing Air Cleaner Case Sub-Assembly
      G05192941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. SEPARATE CRUSE CONTROL ACTUATOR ASSEMBLY (w/ Cruise Control) 
    1. Disconnect the actuator connector [A].
      2. Fig 3: Disconnecting Actuator Connector
      G05233194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts [B], then separate the actuator from the body.
  19. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Disconnect the fuel tube sub-assembly (See REMOVAL ).

      SST 09268-21010 

  20. DISCONNECT UNION TO CHECK VALVE HOSE 
  21. DISCONNECT HEATER INLET WATER HOSE 
    1. Disconnect the heater inlet water hose from the air conditioner tube.
      Fig 4: Disconnecting Heater Inlet Water Hose From Air Conditioner Tube
      G05192942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT HEATER OUTLET WATER HOSE 
    1. Disconnect the heater outlet water hose from the air conditioner tube.
      2. Fig 5: Disconnecting Heater Outlet Water Hose From Air Conditioner Tube
      G05233196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Separate the transmission control cable assembly (See REMOVAL ).
  24. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Separate the transmission control cable assembly (See REMOVAL ).
  25. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Separate clutch release cylinder assembly (See REMOVAL ).
  26. REMOVE FAN AND GENERATOR V BELT 
    1. Remove the fan and generator V belt (See REMOVAL  ).
  27. REMOVE GENERATOR ASSEMBLY 
    1. Remove the generator assembly (See REMOVAL ).
  28. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System) 
    1. Separate the compressor and magnetic clutch (See ON-VEHICLE INSPECTION ).

      HINT:

      Secure the compressor and hoses off to the side instead of discharging the A/C system.

  29. SEPARATE RETURN TUBE SUB-ASSEMBLY 
    1. Separate the vane pump oil reservoir from the oil reservoir bracket.
    2. Remove the 2 bolts, then separate the return tube.
      3. Fig 6: Removing Bolts And Separating Return Tube
      G05192944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY 
    1. Remove the glove compartment door assembly (See REMOVAL ).
  31. REMOVE FRONT DOOR SCUFF PLATE RH 
    1. Remove the front door scuff plate LH (See REMOVAL ).
  32. REMOVE COWL SIDE TRIM BOARD RH 
    1. Remove the cowl side trim board RH (See REMOVAL ).
  33. 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. Disconnect the 3 connectors [D].
    5. Disconnect the engine wire harness by pulling it upward [E].
      Fig 7: Disconnecting Connectors [D]
      G05192945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the clamp of the engine wire.
      Fig 8: Removing Clamp Of Engine Wire
      G05192946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt, then disconnect the ground terminal.
      8. Fig 9: Removing Bolt And Disconnecting Ground Terminal
      G05192947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE FLOOR PANEL BRACE FRONT 
    1. Remove the floor panel brace front (See REMOVAL ).
  35. REMOVE EXHAUST PIPE ASSEMBLY FRONT 
    1. Remove the exhaust pipe assembly front (See REMOVAL ).
  36. REMOVE COLUMN HOLE COVER SILENCER SHEET 
  37. SEPARATE STEERING INTERMEDIATE SHAFT 
    1. Separate the steering intermediate shaft (See REMOVAL ).
  38. REMOVE FRONT AXLE HUB LH NUT 
    1. Remove the front axle hub LH nut (See REMOVAL ).

      SST 09930-00010 

  39. REMOVE FRONT AXLE HUB RH NUT 

    SST 09930-00010 

    HINT:

    Perform the same procedure as above on the opposite side.

  40. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 
    1. Separate the front stabilizer link assembly LH (See REMOVAL ).
  41. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  42. SEPARATE SPEED SENSOR FRONT LH (w/ ABS) 
    1. Separate the speed sensor front (See REMOVAL ).
  43. SEPARATE SPEED SENSOR FRONT RH (w/ ABS) 

    HINT:

    Perform the same procedure as above on the opposite side.

  44. SEPARATE TIE ROD END SUB-ASSEMBLY LH 
    1. Separate the tie rod end sub-assembly LH (See REMOVAL ).

      SST 09628-62011 

  45. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    SST 09628-62011 

    HINT:

    Perform the same procedure as above on the opposite side.

  46. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH 
    1. Separate the front suspension arm sub-assembly lower No. 1 LH (See REMOVAL ).
  47. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  48. SEPARATE FRONT AXLE ASSEMBLY LH 
    1. Separate the front axle assembly LH (See REMOVAL ).
  49. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  50. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator RH.
      Fig 10: Removing Engine Mounting Insulator RH
      G05192770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and nut, then separate the engine mounting insulator LH.
      Fig 11: Removing Engine Mounting Insulator LH With Bolt And Nut
      G05192949Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 6 bolts as shown in the illustration.
    5. Carefully remove the engine with transaxle from the engine compartment.
      Fig 12: Removing Suspension Crossmember With Bolts
      G05192950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the engine hanger (12281-22021) with the bolt (91512-B1016 or 90080-10161).

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

    7. Install the engine hanger (12281-15050) with the bolt (91512-B1016 or 90080-10161).

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

      HINT:

      Securely install the front engine hanger (12281-22021) and the rear engine hanger (12281-15050) onto the engine assembly.

      Fig 13: Installing Engine Hanger With Bolt
      G05192951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Attach the engine sling and hang the engine with the chain block.
  51. SEPARATE VANE PUMP ASSEMBLY 
    1. Separate the vane pump assembly (See REMOVAL ).
  52. REMOVE FRONT SUSPENSION CROSSMEMBER W/ CENTER MEMBER 
    1. Remove the through bolt and nut, then separate the engine mounting insulator FR from the engine mounting bracket FR.
      Fig 14: Removing Bolt Securing Engine Mounting Insulator FR, From Engine Mounting Bracket FR
      G05192952Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the through bolt, then separate the engine mounting insulator RR from the engine mounting bracket RR.
    3. Separate the engine and transaxle assembly from the suspension crossmember and the engine mounting member.
    Fig 15: Removing Bolt Securing Engine Mounting Insulator RR, From Engine Mounting Bracket RR
    G05192953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE STARTER ASSEMBLY 
    1. Remove the starter assembly (See REMOVAL ).
  54. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the manual transaxle assembly (See REMOVAL ).
  55. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Remove the automatic transaxle assembly (See REMOVAL ).
  56. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) 
    1. Remove the clutch cover assembly (See REMOVAL ).
  57. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 
    1. Remove the clutch disc assembly (See REMOVAL ).
  58. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Remove the flywheel sub-assembly (See REMOVAL  ).

      SST 09960-10010 (09962-01000, 09963-01000) 

  59. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Remove the drive plate & ring gear sub-assembly (See REMOVAL  ).

      SST 09960-10010 (09962-01000, 09963-01000) 

  60. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the ignition coil assembly (See REMOVAL  ).
  61. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Remove the fuel delivery pipe sub-assembly (See REMOVAL ).
  62. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY 
  63. REMOVE INTAKE MANIFOLD 
    1. Remove the intake manifold (See FUEL SYSTEM ).
  64. REMOVE OIL LEVEL GAGE GUIDE 
    1. Disconnect the crankshaft position sensor clamp.
    2. Remove the bolt, then remove the oil level gage guide.
      Fig 16: Removing Oil Level Gage Guide With Bolt
      G05192954Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE WATER bypass PIPE NO.1 
    1. Disconnect the knock sensor clamp.
    2. Remove the 2 bolts and 2 nuts, then remove the water bypass pipe No. 1.
      3. Fig 17: Removing Water bypass Pipe No.1 - 2WD
      G05192955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the gasket from the cylinder block.
  66. REMOVE WATER INLET 
    1. Remove the water inlet (See REMOVAL ).
  67. REMOVE THERMOSTAT 
  68. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Remove the engine oil pressure switch assembly (See LUBRICATION SYSTEM ).
  69. REMOVE CAMSHAFT POSITION SENSOR 
    1. Remove the bolt, then remove the camshaft position sensor.
      Fig 18: Removing Camshaft Position Sensor With Bolt
      G05192956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. REMOVE CRANKSHAFT POSITION SENSOR 
    1. Remove the 2 bolts, then remove the crankshaft position sensor.
      Fig 19: Removing Crankshaft Position Sensor With Bolts
      G05192957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE KNOCK SENSOR 
    1. Remove the nut, then remove the knock sensor.
      2. Fig 20: Locating Knock Sensor
      G05233211Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the V-ribbed belt tensioner assembly (See REMOVAL  ).
  73. REMOVE MANIFOLD STAY 
    1. Remove the 3 bolts and manifold stay.
      Fig 21: Locating Manifold Stay And Bolts
      G05233212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Disconnect the air fuel ratio sensor connector [A].
    2. Remove the 4 bolts [B], then remove the exhaust manifold heat insulator.
      Fig 22: Removing Exhaust Manifold Heat Insulator No.1 - 2WD
      G05192960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE EXHAUST MANIFOLD 
    1. Remove the 5 nuts, then remove the exhaust manifold.
    2. Remove the gasket from the cylinder head.
      Fig 23: Removing Gasket And Exhaust Manifold With Nuts
      G05192961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using SST, remove the engine coolant temperature sensor.

      SST 09817-33190 

      Fig 24: Removing Engine Coolant Temperature Sensor Using SST
      G05192962Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE RADIO SETTING CONDENSER 
    1. Remove the bolt, then remove the condenser.
      2. Fig 25: Removing Condenser With Bolt
      G05192963Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE WATER bypass HOSE NO.2 
  79. REMOVE RADIATOR HOSE INLET 
  80. REMOVE HEATER INLET WATER HOSE 
  81. REPLACE PARTIAL ENGINE ASSEMBLY 
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