FixVault

Engine Unit: Removal

  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: Removing Battery Tray
    G02639164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE AIR CLEANER ASSEMBLY 
    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.
      Fig 2: Removing Air Cleaner Assembly
      G02639165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    5. Disconnect the connector.
    6. Disconnect the engine wire clamp.
    Fig 3: Removing Engine Room Junction/Box
    G02639166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Disconnecting Discharge And Liquid Tubes From Compressor
      G02639167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the suction hose, pressure feed tube and gasket from the PS vane pump.
      Fig 5: Disconnecting Suction Hose & Pressure Feed Tube From PS Vane Pump
      G02639168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the upper radiator hose.
    6. Disconnect the lower radiator hose.
    7. Disconnect the fuel tube connector (see SFI ).
    8. Disconnect the 2 heater hoses.
    9. Disconnect the connector from the fusible link block.
      Fig 6: Disconnecting Connector From Fusible Link Block
      G02639169Courtesy 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.
      Fig 7: Disconnecting Shift Control Cables From Transaxle
      G02639170Courtesy 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.
      Fig 8: Removing Starter
      G02639171Courtesy 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.
      Fig 9: Disconnecting Clutch Release Cylinder & Line From Transaxle (M/T)
      G02639172Courtesy 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.
      Fig 10: Disconnecting Shift Control Cable From Transaxle (A/T)
      G02639173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. A/T: DISCONNECT OIL COOLER HOSES 
    Fig 11: Disconnecting Oil Cooler Hoses
    G02639174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT GROUND CABLE FROM TRANSAXLE 
  19. 4WD: REMOVE PROPELLER SHAFT (See  PROPELLER SHAFT ASSEMBLY  ) 
  20. REMOVE FRONT DRIVE SHAFTS (See  REMOVAL  ) 
  21. REMOVE FRONT EXHAUST PIPE 

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

    Fig 12: Removing Front Exhaust Pipe
    G02639175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT STABILIZER BAR LINKS 

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

    Fig 13: Disconnecting Stabilizer Bar Links
    G02639176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT PS GEAR ASSEMBLY 

    Remove the 2 bolts of the PS gear assembly.

    Fig 14: Removing PS Gear Assembly
    G02639177Courtesy 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: Removing PS Gear Assembly
      G02639178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Attach the sling device to the engine hangers.
      Fig 16: Attaching Sling Device To Engine Hangers
      G02639179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 timing chain cover.
      Fig 17: Removing RH Engine Mounting Insulator
      G02639180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt holding the LH engine mounting insulator to the mounting bracket.
      Fig 18: Removing LH Engine Mounting Insulator To Mounting Bracket
      G02639181Courtesy 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 Front Suspension Crossmember
      G02639182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Lower the engine out of the vehicle slowly and carefully.
      NOTE: Make sure the engine is clear of all wiring, hoses and cables.
      Fig 20: Lowering Engine Out Of Vehicle
      G02639183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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 To Mounting Insulator
      G02639184Courtesy 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 To Mounting Insulator
      G02639185Courtesy 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: Removing Stiffener Plate (4WD)
    G02639186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. 2WD: REMOVE CENTER BEARING BRACKET 

    Remove the 3 bolts and bearing bracket.

    Fig 24: Removing Center Bearing Bracket (2WD)
    G02639187Courtesy 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.
      Fig 25: Removing Torque Converter Clutch Bolts
      G02639188Courtesy 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 Bolts Holding Transaxle To Engine
      G02639189Courtesy 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.
        Fig 27: Disconnecting Wiring Harness Connectors From Transaxle (M/T)
        G02639190Courtesy 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: Disconnecting Wiring Harness Connectors From Transaxle (A/T)
        G02639191Courtesy 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: Removing Upper Bolts Holding Transaxle To Engine
      G02639192Courtesy 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, DISC AND FLYWHEEL 
  33. A/T: REMOVE DRIVE PLATE 
  34. 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 Bolts
      G02639193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE PS VANE PUMP 
    1. Disconnect the oil pressure switch connector.
    2. Remove the 2 bolts and vane pump.
      Fig 31: Removing PS Vane Pump
      G02639194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE GENERATOR 
    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.
      Fig 32: Removing Generator
      G02639195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002