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Engine Unit: Removal

  1. Remove Battery And Tray. 
  2. Remove Hood. 
  3. Remove Engine Under Covers. 
  4. Drain Engine Coolant. 
  5. Drain Engine Oil. 
  6. Drain Transaxle Oil. 
  7. Disconnect Accelerator Cable. 
  8. Remove Washer Tank. 
  9. With Cruise Control System:  Disconnect cruise control actuator from body.
    1. Disconnect the actuator connector.
    2. Disconnect the wire clamp from the actuator bracket.
    3. Remove the 3 bolts, and disconnect the actuator from the body.
    Fig 1: Locating Cruise Control Actuator Mounting Bolts
    G01082502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Remove Air Cleaner Cap. 
    1. Disconnect the MAF meter connector.
      Fig 2: Locating MAF Meter Connectors
      G01082503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the VSV connector for canister closed valve.
    3. Disconnect the air hose from air cleaner cap.
    4. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case.
    5. Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body.
    6. Remove the air cleaner cap and air cleaner hose assembly.
  11. Remove Air Cleaner Case. 
    1. Remove the air filter.
    2. Disconnect the engine wire from the clamp on the air cleaner case.
    3. Remove the bolt holding VSV bracket to the air cleaner case.
    4. Remove the 3 bolts and air cleaner case.
      Fig 3: Locating Air Cleaner Case Bolts
      G01082504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    12. NOTE: Letters for steps a through d are called out in figure. See Fig 4.
  12. Disconnect Tube, Hoses And Connectors. 
    1. Remove the fuel tube clamp.
      Fig 4: Locating Step 12 Components
      G01082505Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuse tube from fuel pipe on vehicle side.
    3. Disconnect the heater hose from water bypass pipe.
    4. Disconnect the brake booster vacuum hose from pipe.
    5. Disconnect the heater hose from water hose union on cylinder head.
    6. Disconnect the DLC1.
  13. Remove  Generator And Drive Belt  .
  14. Remove  Radiator Assembly  .
  15. With A/C:  disconnect A/C compressor from engine:
    1. Disconnect the A/C compressor connector.
      2. NOTE: Suspend the A/C compressor securely.
      Fig 5: Locating A/C Compressor Mounting Bolts
      G01082506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a torx socket (T40), remove the 3 bolts, and disconnect the A/C compressor from the engine.
  16. M/T: Disconnect Clutch Release Cylinder From Transaxle. 
    1. Remove the bolt, and disconnect the bracket from the transaxle.
      Fig 6: Locating clutch release cylinder bracket, clamp & mounting bolt
      G01082507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clamp bolt, and disconnect the tube from the transaxle.
    3. Remove the 2 bolts, and disconnect the release cylinder from the transaxle.
  17. Disconnect Transaxle Control Cable(s) From Transaxle.  .
    Fig 7: Locating Control Cable Bracket Mounting Bolts
    G01082508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. Disconnect Engine Wire From Engine Compartment Relay Box. 
    1. Remove the 2 bolts and disconnect the relay box.
    2. Disconnect the 3 connectors.
    3. Disconnect the negative cable from the 2 clamps on the engine wire.
    4. Disconnect the positive cable from the engine wire.
      Fig 8: Locating Engine Compartment Relay Box
      G01082509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt, and disconnect the ground cable from the transaxle.
      Fig 9: Locating Ground Cable
      G01082510Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Disconnect Engine Wire From Cabin. 
    1. Remove the Finish Lower Center Panel .
    2. Remove the 3 bolts and disconnect the ECM.
    3. Disconnect the 3 (M/T and 3 A/T) or 4 (4 A/T) ECM connectors.
      Fig 10: Locating Engine Wire Connectors From Cabin
      G01082511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the 5 cowl wire connectors from connectors on bracket.
    5. Disconnect the heated oxygen sensor (Bank 1 sensor 2) connector.
    6. Pull out the engine wire from the cabin.
      Fig 11: Locating Engine Wire From Cabin
      G01082512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Disconnect PS Pump From Engine. 
    1. Disconnect the PS oil pressure switch connector.
    2. Using SST, remove the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000).
    3. Remove the PS pump pulley.
      Fig 12: Removing Power Steering Pump Pulley
      G01082513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. NOTE: Put aside the pump and suspend it to the cowl with a string.
      Fig 13: Locating Power Steering Pump Through Bolts
      G01082514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.
  21. Remove Front Exhaust Pipe. 
    1. Remove the bolt and pipe clamp, and disconnect the center exhaust pipe from the front exhaust pipe.
      Fig 14: Locating Center Exhaust Pipe Mounting Bolt
      G01082515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts holding the front pipe to the exhaust manifold.
    3. Remove the front exhaust pipe and 2 gaskets.
  22. Remove  Drive Shafts  . 
    Fig 15: Locating Front Pipe To Exhaust Manifold Mounting Bolts
    G01082516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. Remove The 2 Bolts, Nut And Drive Shaft Heat Insulator. 
    Fig 16: Locating Drive Shaft Heat Insulator Mounting Bolts
    G01082517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. Remove Front Engine Mounting Bracket. 
    1. Remove the through bolt and nut holding the front mounting insulator to the mounting bracket.
    2. Remove the 2 bolt and front engine mounting bracket.
      Fig 17: Locating Front Engine Mounting Bracket Mounting Bolt
      G01082518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. Remove Rear Mounting Bracket. 
    1. Remove the through bolt holding the rear mounting insulator to the mounting bracket.
      Fig 18: Locating Rear Mounting Bracket Through & Mounting Bolts
      G01082519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 (M/T and 4 A/T) or 2 (3 A/T) bolts and rear engine mounting bracket.
  26. Attach Engine Sling Device To Engine Hangers. 

    Remove the 2 nuts, 2 clips and No. 2 cylinder head cover.

  27. Remove Engine And Transaxle Assembly From Vehicle. 
    1. Install the 2 engine hangers in the correct direction.
      Fig 19: Installing Engine Hangers
      G01082520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Engine hanger part No.:

      1. Front: 12281-20021.
      2. Rear: 12281-15040.
      3. Bolt part No.: 91512-B1016 2 pieces.
      4. Torque: 38 N.m (388 kgf.cm, 28 ft.lbf)  .

      2. WARNING: Do not attempt to hang the engine by hooking the chain to any other part.
    2. Attach the engine sling device to the engine hangers.
    3. M/T: Remove the 2 bolts and LH mounting stay.
      Fig 20: Locating Left Side Engine Mount Through & Mounting Bolts
      G01082521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the through bolt and nut holding the LH mounting insulator to the mounting bracket.
    5. Remove the 4 bolts and LH engine mounting insulator.
    6. Disconnect the ground strap from the body.
    7. Remove the bolt and 2 nuts, and disconnect the RH engine mounting bracket from the RH engine mounting insulator.
      Fig 21: Locating Right Side Crounding Strap, Engine Mount Mounting Bolts & Nuts
      G01082522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt holding the A/C piping clamp from the RH engine mounting insulator.
    9. Remove the 3 bolts and RH engine mounting insulator.
      Fig 22: Locating Right Side A/C Clamp, Engine Mount Through & Mounting Bolts
      G01082523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      10. CAUTION: Make sure the engine is clear of steering gear assembly all wiring, hoses and cables.
      Fig 23: Removing Engine From Engine Compartment
      G01082524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Lift the engine out of the vehicle slowly and carefully.
    11. Place the engine and transaxle assembly onto the stand.
  28. Separate Engine And Transaxle. 
    1. For M/T: See  Separate Engine And Transaxle  .
    2. For (AT (A131L): See  Separate Engine And Transaxle  .
    3. For (A/T (A245E): See  Separate Engine And Transaxle  .
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