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Engine Assembly: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM .

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. REMOVE FRONT WHEEL 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE ENGINE UNDER COVER RH 
  6. DRAIN ENGINE COOLANT  (See COOLANT )
  7. DRAIN ENGINE OIL  (See REPLACEMENT )
  8. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for C59.

  9. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

    See AUTOMATIC TRANSAXLE FLUID for U341E.

  10. REMOVE NO. 2 CYLINDER HEAD COVER 
    1. Hold the rear of the cover and raise it to disengage the 2 clips on the rear of the cover. Continue to raise the cover to disengage the 2 clips on the front of the cover to remove the cover.
    NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
    Fig 1: Identifying No. 2 Cylinder Head Cover
    G06008773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  12. REMOVE AIR CLEANER CASE 
    1. Separate the air cleaner filter element from the air cleaner.
    2. Disconnect the engine wire harness clamp from air cleaner case.
    3. Remove the 3 bolts and the air cleaner case.
  13. REMOVE BATTERY 
    1. Disconnect the battery cables.
    2. Remove the bolt and loosen the nut.
    3. Remove the battery.
    Fig 2: Locating Battery Bolts
    G06008774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE BATTERY CARRIER 
    1. Separate the 2 wire harness clamps from the battery carrier.
      Fig 3: Removing Battery Carrier
      G06008775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts.
    3. Separate the radiator pipe from the battery carrier.
    4. Remove the 4 bolts and battery carrier.
    Fig 4: Locating Battery Carrier Bolts
    G06008776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disengage the clamp*1.
    2. Disconnect the No. 1 radiator hose from the cylinder head with the clamp*2.
    Fig 5: Locating No. 1 Radiator Hose
    G06008777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Disconnect the No. 2 radiator hose from the water inlet hose.
    Fig 6: Locating No. 2 Radiator Hose
    G06008778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the 2 clips and disconnect the 2 cables from the transaxle.
    2. Remove the 2 clips and disconnect the 2 cables from the control cable bracket.
    Fig 7: Locating Transmission Control Cable Assembly Bolts
    G06008779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. Disconnect the control cable from the control cable support.
    2. Remove the nut and disconnect the control cable from the control shaft lever.
    3. Remove the clip and disconnect the control cable from the control cable bracket.
    4. Remove the bolt and disconnect the clamp of the control cable.
    Fig 8: Locating Transmission Control Cable Assembly (For Automatic Transaxle)
    G06008780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Disconnect the fuel vapor feed hose.
    Fig 9: Locating Fuel Vapor Feed Hose
    G06008781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose.
    Fig 10: Locating Union To Connector Tube Hose
    G06008782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT OIL COOLER HOSE (for Automatic Transaxle) 
    1. Disconnect the 2 oil cooler hoses from the oil cooler tube.
    Fig 11: Locating Oil Cooler Hoses To Oil Cooler Tube
    G06041461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose from the engine.
    Fig 12: Locating Outlet Heater Water Hose
    G06008784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose from the engine.
    Fig 13: Locating Inlet Heater Water Hose
    G06008785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Release the claw to remove the No. 1 fuel pipe clamp.
      Fig 14: Identifying No. 1 Fuel Pipe Clamp
      G05387476Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
    Fig 15: Pulling Fuel Tube Connector
    G04828757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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, kink or twist 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 to release them.
  25. REMOVE V-RIBBED BELT  (See REMOVAL )
  26. REMOVE GENERATOR ASSEMBLY  (See DISASSEMBLY )
  27. REMOVE FAN BELT ADJUSTING BAR 
    1. Remove the bolt and fan belt adjusting bar.
  28. SEPARATE COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System) 
    1. Disconnect the connector.
    2. Remove the 2 bolts and 2 nuts.
      Fig 16: Identifying Compressor With Pulley Assembly, Bolts And Nuts
      G06008788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a "TORX" socket wrench (E8), remove the 2 stud bolts and compressor with pulley assembly.

    HINT:

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

    Fig 17: Identifying Compressor
    G06008789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 
    1. Remove the 4 bolts and clutch tube bracket, and separate the clutch release cylinder assembly.
    Fig 18: Locating Cylinder Assembly Bolts
    G06008790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT WIRE HARNESS 
    1. Pull up the lever to disconnect the ECM connector and release the clamp.
      Fig 19: Identifying ECM Connector
      G05387316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts.
    3. Remove the 3 connectors and 2 clamps from the engine room junction block and disconnect the wire harness.
      Fig 20: Removing Engine Room Junction Block
      G06008792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and clamp (for Manual Transaxle).
      Fig 21: Locating Bolt And Clamp (For Manual Transaxle)
      G06008793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and clamp (for Automatic Transaxle).
      Fig 22: Locating Bolt And Clamp (For Automatic Transaxle)
      G06008794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.
  31. SECURE STEERING WHEEL  (See REMOVAL )
  32. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  33. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY  (See REMOVAL )
  34. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See REMOVAL )
  35. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  36. REMOVE FRONT AXLE SHAFT LH NUT  (See REMOVAL )
  37. REMOVE FRONT AXLE SHAFT RH NUT 

    HINT:

    Perform the same procedure for the LH side.

  38. DISCONNECT FRONT SPEED SENSOR LH  (See REMOVAL )
  39. DISCONNECT FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure for the LH side.

  40. SEPARATE TIE ROD END SUB-ASSEMBLY LH  (See REMOVAL )
  41. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  42. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  43. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  44. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH  (See REMOVAL )
  45. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  46. SEPARATE STEERING KNUCKLE WITH AXLE HUB LH 
    1. Put matchmarks on the drive shaft and axle hub.
      NOTE: Do not punch the marks.
      Fig 23: Putting Matchmarks On Drive Shaft And Axle Hub
      G06008387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a plastic-faced hammer, disconnect the front axle assembly LH.
    NOTE:
    • Be careful not to damage the boot and speed sensor rotor.
    • Do not excessively push out the drive shaft from the axle assembly.
  47. SEPARATE STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure for the LH side.

  48. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  49. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See REMOVAL )
  50. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH  (See DISASSEMBLY )
  51. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH  (See DISASSEMBLY )
  52. REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle)  (See REMOVAL )
  53. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)  (See REMOVAL )
  54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY  (See REMOVAL )
  55. REMOVE CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY  (See REMOVAL )
  56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      NOTE: Place the engine on wooden blocks or equivalent so that the engine is level.
    2. Remove the bolt and 2 nuts, and separate the engine mounting insulator RH.
      Fig 24: Locating Engine Mounting Insulator Bolt And Nuts
      G06008796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the through bolt and nut, and separate the engine mounting insulator LH.
    4. Carefully remove the engine with transaxle from the vehicle.
    Fig 25: Locating Engine Mounting Insulator Bolt And Nuts
    G06008797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the bolt, nut and front engine mounting insulator.
    Fig 26: Locating Front Engine Mounting Insulator Bolt And Nut
    G06008798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE REAR ENGINE MOUNTING INSULATOR 
    1. Remove the through bolt and rear engine mounting insulator.
    Fig 27: Locating Rear Engine Mounting Insulator
    G06008799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 4 bolts and engine mounting insulator LH.

    HINT:

    Perform this procedure only when replacement of the engine mounting insulator is necessary.

    Fig 28: Locating Engine Mounting Insulator Bolt
    G06008800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Disconnect the clamp, and release the relay block assembly.
      Fig 29: Identifying Relay Block Assembly And Clamp
      G06008801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and radiator reserve tank.
      Fig 30: Locating Radiator Reserve Tank Bolts
      G06008802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and engine mounting insulator RH.

    HINT:

    Perform this procedure only when replacement of the engine mounting insulator is necessary.

    Fig 31: Locating Engine Mounting Insulator RH
    G06008803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSTALL ENGINE HANGER 
    1. Remove the bolt and wire harness bracket.
      Fig 32: Locating Wire Harness Bracket Bolt
      G06008804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 engine hangers with the 2 bolts.

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

      Fig 33: Locating Engine Hangers Bolts
      G05401553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TORQUE SPECIFICATION

      Part Name Part No.
      No. 1 engine hanger 12281-37021
      No. 2 engine hanger 12282-37011
      Bolt 91552-81050
  62. REMOVE FLYWHEEL HOUSING SIDE COVER 
  63. REMOVE STARTER ASSEMBLY  (See DISASSEMBLY )
  64. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL for C59.

  65. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT:

    See REMOVAL for U341E.

  66. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  67. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  68. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  69. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  70. REMOVE ENGINE WIRE 
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