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Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    (See PRECAUTION )

  2. REMOVE BATTERY 
    1. Disconnect the cable from the battery terminal.
    2. Loosen the nut and remove the battery clamp.
    3. Remove the battery.
  3. REMOVE BATTERY TRAY 
  4. REMOVE FRONT WHEELS 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE ENGINE UNDER COVER RH 
  7. DRAIN ENGINE COOLANT  (See REPLACEMENT )
  8. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) 
  9. DRAIN AUTOMATIC TRANSAXLE OIL (for Automatic Transaxle) 
  10. REMOVE FRONT WIPER ARM HEAD CAP  (See REMOVAL )
  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  13. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  14. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  15. REMOVE COWL TOP VENTILATOR LOUVER LH  (See REMOVAL )
  16. REMOVE FRONT WIPER MOTOR AND LINK  (See REMOVAL )
  17. REMOVE FRONT AIR SHUTTER SEAL RH 
    1. Disengage the 2 claws and remove the front air shutter seal RH.
      Fig 1: Identifying Claws Locations
      G05399083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE OUTER COWL TOP PANEL 
    1. Disengage the wire harness clamp.
      Fig 2: Locating Wire Harness Clamp
      G05399084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 9 bolts and remove the outer cowl top panel.
      Fig 3: Locating Bolts And Outer Cowl Top Panel
      G05399085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE AIR CLEANER ASSEMBLY 
    1. Separate the intake air flow meter connector and 2 wire harness clamps.
      2. Fig 4: Locating Clamps
      G05399086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the ventilation hose from the air cleaner hose.
    3. Unfasten the 2 clamps.
    4. Remove the air cleaner cap sub-assembly with air cleaner hose.
    5. Remove the air cleaner element.
    6. Separate the wire harness clamp from the air cleaner case.
      7. Fig 5: Identifying Bolts And Air Cleaner Case With Air Cleaner Inlet
      G04828735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts and remove the air cleaner case with air cleaner inlet.
  20. REMOVE AIR CLEANER BRACKET 
    1. Separate the wire harness clamp from the air cleaner bracket.
      2. Fig 6: Locating Bolts And Air Cleaner Bracket
      G04828736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and remove the air cleaner bracket.
  21. REMOVE BATTERY CARRIER 
    1. Separate the wire harness clamp from the battery carrier.
      2. Fig 7: Locating Bolts And Battery Carrier
      G05399089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and remove the battery carrier.
  22. REMOVE NO. 2 CYLINDER HEAD COVER  (See REMOVAL )
  23. REMOVE FAN AND GENERATOR V BELT  (See REMOVAL  )
  24. REMOVE NO. 2 RADIATOR HOSE 
    1. Loosen the 2 clips and remove the No. 2 radiator hose.
      2. Fig 8: Locating Clips And No. 2 Radiator Hose
      G05399090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE FRONT BUMPER COVER  (See REMOVAL )
  26. DISCONNECT NO. 1 RADIATOR HOSE  (See REMOVAL )
  27. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transaxle)  (See REMOVAL )
  28. DISCONNECT NO. 2 OIL COOLER INLET HOSE (for Automatic Transaxle)  (See REMOVAL )
  29. REMOVE HOOD LOCK ASSEMBLY  (See REMOVAL )
  30. REMOVE NO. 1 COOLER COVER  (See REMOVAL )
  31. REMOVE UPPER RADIATOR SUPPORT ABSORBER  (See DISASSEMBLY )
  32. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY  (See REMOVAL )
  33. REMOVE RADIATOR ASSEMBLY  (See REMOVAL )
  34. SEPARATE WITH PULLEY COMPRESSOR ASSEMBLY  (See REMOVAL )
  35. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
      Fig 9: Locating Nut And Transmission Control Cable Assembly
      G04831146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the 2 clips and the washers, and disconnect the 2 cables from the transaxle.
      2. Fig 10: Locating Clips And Cables
      G04831643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 clips and disconnect the 2 cables from the control cable bracket.
  37. SEPARATE UNION TO CHECK VALVE HOSE 
    1. Loosen the clip and separate the union to check valve hose.
      Fig 11: Locating Clip And Check Valve Hose
      G05399093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. SEPARATE NO. 1 FUEL VAPOR FEED HOSE 
    1. Separate the No. 1 fuel vapor feed hose from the vacuum switching valve assembly.
      Fig 12: Locating No. 1 Fuel Vapor Feed Hose
      G05399094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT ENGINE WIRE 
    1. Remove the bolt and wire harness clamp and separate the transaxle earth wire (for Automatic Transaxle).
      Fig 13: Locating Bolt And Wire Harness Clamp
      G05399095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and 2 wire harness clamp and separate the transaxle earth wire (for Manual Transaxle).
      Fig 14: Locating Bolt And Wire Harness Clamp
      G05399096Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 2 connectors.
      Fig 15: Locating Connectors
      G05399097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Pull up the lever and disconnect the connector from the engine control computer.
    5. Separate the 2 wire harness clamps.
      Fig 16: Locating Wire Harness Clamps
      G05399098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 connectors and clamp from the engine room junction block and disconnect the 2 wire harness clamps.
      7. Fig 17: Locating Connectors And Clamp
      G05399099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disconnect all wire harnesses and connectors.
      NOTE: Make sure that no wire harness is connected between the body and engine.
  40. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) 
    1. Disconnect heater water outlet hose A from the heater unit.
      Fig 18: Locating Heater Water Outlet Hose
      G05399100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. DISCONNECT HEATER WATER INLET HOSE A 
    1. Disconnect heater water inlet hose A from the heater unit.
      Fig 19: Locating Heater Water Inlet Hose
      G05399101Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
      Fig 20: Locating No. 1 Fuel Pipe Clamp
      G05399102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
      NOTE:
      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.
      • Perform this work by hand. Do not use any tools.
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull them to release them.
        Fig 21: Identifying Fuel Tube Connector
        G05399103Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Remove the 4 bolts, then separate the clutch release cylinder.

      HINT:

      Suspend the clutch release cylinder with a piece of rope so as not to overload the clutch pipe.

      Fig 22: Locating Bolts
      G04831658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  45. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY  (See REMOVAL )
  46. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See REMOVAL )
  47. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  48. REMOVE CONSOLE PANEL UPPER  (See REMOVAL )
  49. REMOVE CONSOLE BOX REAR COVER  (See REMOVAL )
  50. REMOVE CONSOLE BOX CARPET  (See REMOVAL )
  51. REMOVE REAR CONSOLE BOX ASSEMBLY  (See REMOVAL )
  52. REMOVE FRONT CONSOLE BOX  (See REMOVAL )
  53. REMOVE FRONT FLOOR BRACE CENTER  (See REMOVAL )
  54. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    1. Disconnect the heated oxygen sensor connector.
      2. Fig 23: Locating Heated Oxygen Sensor Connector
      G05398807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the grommet and pull the sensor connector out of the cabin through the floor panel.
    3. Remove the 2 bolts and 2 springs and separate the front exhaust pipe assembly from the exhaust tail pipe assembly.
      Fig 24: Locating Bolts And Springs
      G05399106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and 2 springs and separate the front exhaust pipe assembly from the exhaust manifold.
      5. Fig 25: Locating Bolts And Springs
      G05399107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 3 exhaust pipe supports and remove the front exhaust pipe assembly.
  55. REMOVE FRONT AXLE SHAFT LH NUT  (See REMOVAL )
  56. REMOVE FRONT AXLE SHAFT RH NUT 

    HINT:

    The removal procedure for the RH side is the same as that for the LH side.

  57. SEPARATE SPEED SENSOR FRONT LH  (See REMOVAL )
  58. SEPARATE SPEED SENSOR FRONT RH 

    HINT:

    The separation procedure for the RH side is the same as that for the LH side.

  59. SEPARATE TIE ROD END SUB-ASSEMBLY LH  (See REMOVAL )
  60. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    The separation procedure for the RH side is the same as that for the LH side.

  61. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  62. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    The separation procedure for the RH side is the same as that for the LH side.

  63. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY LH  (See REMOVAL )
  64. SEPARATE FRONT LOWER SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    The separation procedure for the RH side is the same as that for the LH side.

  65. SEPARATE FRONT AXLE ASSEMBLY LH  (See REMOVAL )
  66. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    The separation procedure for the RH side is the same as that for the LH side.

  67. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See DISASSEMBLY )
  68. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See DISASSEMBLY )
  69. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)  (See REMOVAL )
  70. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)  (See REMOVAL )
  71. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      Fig 26: Identifying Engine Lifter
      G05399108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove 2 bolts and remove the engine mounting stay RH.
      Fig 27: Locating Bolts And Engine Mounting Stay RH
      G05399109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and nut and remove the engine mounting insulator RH.
      NOTE: Be sure not to remove the other bolt A.
      Fig 28: Locating Bolts And Engine Mounting Insulator RH
      G05399110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the through bolt and nut and separate the transverse engine mounting insulator.
      Fig 29: Locating Through Bolt And Nut
      G05399111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 6 bolts and remove the engine assembly with transaxle and front suspension crossmember from the vehicle.
      Fig 30: Locating Bolts And Front Suspension Crossmember
      G05399112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR 
    1. Remove the 5 bolts and remove the transverse engine mounting insulator.
      2. Fig 31: Locating Bolts And Transverse Engine Mounting Insulator
      G05399113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Remove the bolt and remove the air fuel ratio sensor bracket.
    2. Install the engine hangers with the bolts, as shown in the illustration.

      Torque: 43 N*m (439 kgf*cm, 32 ft.*lbf) 

      Part No.: 12281-37020 (engine hanger No. 1) 

      12282-37010 (engine hanger No. 2) 

      91552-81050 (bolt) 

      Fig 32: Identifying Engine Hangers With Bolts
      G05401553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember.
    4. Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.
  74. REMOVE ENGINE MOVING CONTROL ROD COVER  (See REMOVAL )
  75. REMOVE ENGINE MOVING CONTROL ROD (for Automatic Transaxle)  (See REMOVAL )
  76. REMOVE ENGINE MOVING CONTROL ROD (for Manual Transaxle)  (See REMOVAL )
  77. REMOVE FLYWHEEL HOUSING SIDE COVER  (See REMOVAL )
  78. REMOVE STARTER ASSEMBLY  (See REMOVAL )
  79. REMOVE NO. 1 OIL COOLER INLET TUBE (for Automatic Transaxle)  (See REMOVAL )
  80. REMOVE NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transaxle)  (See REMOVAL )
  81. REMOVE NO. 2 OIL COOLER TUBE CLAMP (for Automatic Transaxle)  (See REMOVAL )
  82. REMOVE TRANSMISSION OIL LEVEL GAGE SUB-ASSEMBLY (for Automatic Transaxle) 
  83. SEPARATE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  84. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  85. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transaxle) 
    1. Remove the 2 bolts and the control cable bracket.
      2. Fig 33: Locating Bolts And Control Cable Bracket
      G04831660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  87. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  88. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 
  89. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) 
    1. Hold the crankshaft with SST.

      SST 09213-58013 (91651-60855), 09330-00021 

      Fig 34: Holding Crankshaft With SST
      G05399116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts and remove the rear spacer, drive plate and front spacer.
      Fig 35: Locating Bolts And Drive Plate
      G05399117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) 
    1. Hold the crankshaft with SST.

      SST 09213-58013 (91651-60855), 09330-00021 

      Fig 36: Holding Crankshaft With SST
      G05399116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts and remove the flywheel sub-assembly.
      Fig 37: Locating Bolts And Flywheel Sub-Assembly
      G05399119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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