Engine Unit: Removal

WARNING: This page is about a different car, the 2004 Toyota MR2, 2003 Toyota MR2, and 2002 Toyota MR2. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE ENGINE HOOD .
REMOVE REAR SUSPENSION UPPER BRACE .
REMOVE ENGINE UNDER COVERS .
SMT: REDUCE ACCUMULATOR PRESSURE .
DRAIN ENGINE COOLANT .
DRAIN ENGINE OIL .
DRAIN TRANSAXLE OIL .
REMOVE BATTERY BRACKET .
1. Remove the battery and tray.
2. Disconnect the battery wire from the battery bracket.
3. Remove the 3 bolts and battery bracket.
  
  Fig 1: Removing Battery Tray
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE INTAKE AIR HOSE AND AIR CLEANER CAP ASSEMBLY
1. Disconnect the MAF meter connector, VSV connector for EVAP and VSV connector for CCV.
2. Disconnect the 4 vacuum hoses.
3. Disconnect the 2 clamps and air cleaner cap.
4. Loosen the hose clamp, and remove the intake air hose and air cleaner cap assembly from the throttle body.
5. Remove the air filter.
6. Remove the 2 bolts and air cleaner lower case.
DISCONNECT ACCELERATOR CABLE
REMOVE REAR BUMPER COVER . See Figure.

Fig 3: Removing Air Intake Assembly
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE FRONT EXHAUST PIPE
1. Disconnect the heated oxygen sensor (bank 1 sensor 2) connector.
2. Remove the 2 bolts, 2 springs and 3 nuts.
3. Disconnect the ring, and remove the front exhaust pipe and 3 gaskets.
  
  Fig 4: Removing Front Exhaust Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT A/C COMPRESSOR
1. Remove the drive belt.
2. Disconnect the A/C compressor connector.
3. Remove the 3 bolts, and disconnect the A/C compressor.
4. Suspend the A/C compressor securely.
DISCONNECT ENGINE WIRE
1. Disconnect the engine wire from the luggage compartment.
  1. Remove the luggage compartment box. See Figure.
  2. Disconnect the 2 ECM connectors.
    
    Fig 6: Disconnecting ECM Connectors
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Disconnect the 4 junction connectors.
  4. Disconnect the grommet, and pull out the engine wire.
  5. SMT:
    Disconnect the transmission control ECU connector.
    
    Fig 7: Disconnecting Transmission Control ECU Connector
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the engine wire from the J/B No. 1.
  1. Remove the relay box cover.
  2. Remove the nut, and disconnect the engine wire.
    
    Fig 8: Disconnecting Engine Wire From Junction Box No. 1
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the 2 bolts, and disconnect the 2 ground wires.
  
  Fig 9: Disconnecting 2 Ground Wires From Engine Compartment
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Separate the positive (+) battery wires.
  1. Remove the terminal cover.
  2. Remove the nut and terminal, and separate the battery wires.
  3. Disconnect the battery wire from the vehicle.
    
    Fig 10: Separating Positive Battery Wires
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Disconnect the 3 wire brackets and heated oxygen sensor (bank 1 sensor 2) wire from the vehicle.
  
  Fig 11: Disconnecting 3 Wire Brackets
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISCONNECT WATER HOSES

Fig 12: Disconnecting Hoses
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the 2 radiator hoses and 2 heater hoses.
SMT: DISCONNECT HPU CONNECTOR AND SMT SYSTEM HOSES . See HYDRAULIC POWER UNIT .
DISCONNECT FUEL TUBE
Remove the fuel pipe clamp, and disconnect the fuel tube from the fuel pipe.

Fig 13: Disconnecting Fuel Tube
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
M/T: DISCONNECT CLUTCH HOSE . See REMOVAL & INSTALLATION .
M/T: DISCONNECT TRANSAXLE CONTROL CABLES . See REMOVAL & INSTALLATION .
REMOVE DRIVE SHAFTS . See REMOVAL .
SET ENGINE JACK
Remove the 2 clips, 2 nuts and No. 2 cylinder head cover, and set a engine jack.

Fig 14: Setting Up Jack To Support Engine
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE: Using chain, hold the engine tightly.
DISCONNECT ENGINE MOUNTING
1. Remove the through bolt and nut holding the LH engine mounting insulator to the mounting bracket.
  
  Fig 15: Removing Through Bolt & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 bolts, 3 nuts and RH engine mounting insulator.
  
  Fig 16: Removing Engine Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the through bolt and nut holding the front engine mounting insulator to the mounting bracket.
  
  Fig 17: Removing Through Bolt & Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE SUSPENSION MEMBER
1. Remove the 2 bolts, and disconnect the ABS wire.
2. M/T:
  Remove the 4 bolts, and disconnect the suspension member.
  
  Fig 18: Removing Suspension Member
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. SMT:
  Remove the 4 bolts, and disconnect the suspension member and HPU assembly.
4. Remove the through bolt, nut and suspension member.
REMOVE ENGINE AND TRANSAXLE ASSEMBLY
1. Lower the engine out of vehicle slowly and carefully.
  
  Fig 19: Using Jack To Lower Engine Out Of Vehicle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Make sure the engine is clear of all wiring, hoses and cables.
2. Using a engine sliding device, and place the engine and transaxle assembly onto the stand.
SEPARATE ENGINE AND TRANSAXLE . See REMOVAL & INSTALLATION .
1. Remove the starter. See REMOVAL & INSTALLATION .
2. Remove the 6 bolts, and separate the engine and transaxle.
REMOVE CLUTCH DISC . See CLUTCH ASSEMBLY .
REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.