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Engine Assembly: Removal

WARNING: This page is about a different variant/trim than selected.
  1. DISCHARGE FUEL SYSTEM PRESSURE  (See FUEL SYSTEM )
  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  4. REMOVE FRONT WHEELS 
  5. REMOVE ENGINE UNDER COVER LH 
  6. REMOVE ENGINE UNDER COVER RH 
  7. DRAIN ENGINE COOLANT  (See COOLANT )
  8. DRAIN AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) 

    HINT:

  9. DRAIN MANUAL TRANSAXLE OIL (for Manual Transaxle) 

    HINT:

    See MANUAL TRANSAXLE OIL for E351.

  10. DRAIN TRANSFER OIL (for 4WD)  (See REPLACEMENT )
  11. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Remove the 2 nuts and No. 1 engine cover sub-assembly.
    Fig 1: Locating No. 1 Engine Cover Sub-Assembly And Nuts
    G06008364Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. SEPARATE RADIATOR RESERVE TANK ASSEMBLY 
    1. Remove the 3 bolts and separate the radiator reserve tank assembly.
      Fig 2: Locating Radiator Reserve Tank Assembly And Bolts
      G06008427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See REMOVAL )
  14. REMOVE AIR CLEANER CASE 
    1. Remove the air cleaner filter element.
    2. Disconnect the clamp of the engine wire.
    3. Remove the 3 bolts and air cleaner case.
    Fig 3: Locating Air Cleaner Case And Bolts
    G06008426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE BATTERY 
    1. Remove the bolt, nut and battery clamp.
      Fig 4: Locating Battery Clamp And Bolt With Nut
      G06008425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the battery and battery insulator.
  16. REMOVE BATTERY CARRIER 
    1. Remove the battery tray.
    2. Separate the 2 wire harness clamps from the battery carrier.
    3. Remove the 4 bolts and battery carrier.
    Fig 5: Identifying Wire Harness Clamps And Battery Carrier Bolts
    G06008368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. SEPARATE WIRE HARNESS 
    1. Disconnect the 3 connectors from the engine room relay block.
    2. Remove the 2 nuts and disconnect the wire harnesses from the engine room relay block.
    3. Using a screwdriver, unlock the 2 claws.
    4. Pull the engine room relay block upward.
      Fig 6: Pulling Engine Room Relay Block Upward
      G06008369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Pull up the lever and disconnect the ECM connector.
    6. Disconnect the clamp.
      Fig 7: Disconnecting ECM Connector
      G05387316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the bolt and disconnect the ground cable and clamp (for Manual Transaxle).
      Fig 8: Locating Ground Cable And Clamp (Manual Transaxle)
      G06008371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt and disconnect the ground cable and clamp (for Automatic Transaxle).
  18. REMOVE THROTTLE BODY ASSEMBLY  (See REMOVAL )
  19. REMOVE V-RIBBED BELT  (See REMOVAL  )
  20. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  21. SEPARATE COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and 2 nuts.
      Fig 9: Locating Ground Cable And Clamp (Automatic Transaxle)
      G06008421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 10: Identifying Compressor 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 11: Identifying Compressor Stud Bolts
      G06008789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Disconnect the No. 2 radiator hose from the water inlet.
    Fig 12: Locating No. 2 Radiator Hose Clamp
    G06008375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disconnect the No. 1 radiator hose from the cylinder head.
    Fig 13: Locating No. 1 Radiator Hose Clamp
    G06008418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT OIL COOLER HOSE (for Automatic Transaxle) 
    1. Disconnect the 2 oil cooler hoses.
    Fig 14: Locating Oil Cooler Hose Clamp (Automatic Transaxle)
    G06041049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT BREATHER HOSE (for Automatic Transaxle) 
    1. Disconnect the breather hose.
    Fig 15: Locating Breather Hose Clamp (Automatic Transaxle)
    G06041050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
    Fig 16: Locating Outlet Heater Water Hose
    G06008379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
    Fig 17: Locating Inlet Heater Water Hose Clamp
    G06008414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE FUEL TUBE SUB-ASSEMBLY 
    1. Release the claw and remove the No. 1 fuel pipe clamp.
      Fig 18: Identifying No. 1 Fuel Pipe Clamp
      G06008381Courtesy 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 or 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 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.
        Fig 19: Pulling Fuel Tube Connector Out Of Pipe
        G04828757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT UNION TO CONNECTOR TUBE HOSE 
    1. Disconnect the union to connector tube hose.
      Fig 20: Locating Connector Tube Hose
      G06008383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL for E351.

  31. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle) 
    1. U250E Automatic Transaxle:
      1. Remove the nut and disconnect the control cable assembly from the control shaft lever.
      2. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.
        Fig 21: Locating Transmission Control Cable Assembly And Nut (Automatic Transaxle)
        G06011483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the control cable assembly from the control cable bracket.
      Fig 22: Locating Control Cable Bracket
      G06008385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. U140F Automatic Transaxle:
      1. Remove the nut and disconnect the control cable assembly from the control shaft lever.
      2. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.
        Fig 23: Locating Control Cable Assembly Nuts
        G06041058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Disconnect the control cable assembly from the control cable bracket.
      Fig 24: Locating Control Cable Bracket
      G06041059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) 
    1. Remove the 2 clips and disconnect the 2 transmission control cables from the control cable bracket*1.
    2. Remove the 2 clips and disconnect the 2 transmission control cables from the transaxle*2.
      Fig 25: Identifying Control Cable Bracket
      G06008411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. SECURE STEERING WHEEL  (See REMOVAL )
  34. REMOVE COLUMN HOLE COVER SILENCER SHEET  (See REMOVAL )
  35. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    HINT:

  36. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY  (See REMOVAL )
  37. REMOVE CENTER EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  38. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  39. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)  (See REMOVAL )
  40. REMOVE FRONT AXLE SHAFT LH NUT  (See REMOVAL )
  41. REMOVE FRONT AXLE SHAFT RH NUT 

    HINT:

    Perform the same procedure for the LH side.

  42. SEPARATE FRONT SPEED SENSOR LH  (See REMOVAL )
  43. SEPARATE FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure for the LH side.

  44. SEPARATE TIE ROD END SUB-ASSEMBLY LH 

    HINT:

  45. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

  46. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  47. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure for the LH side.

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

    HINT:

    Perform the same procedure for the LH side.

  50. SEPARATE STEERING KNUCKLE WITH AXLE HUB LH 
    1. Put matchmarks on the drive shaft and axle hub.
      NOTE: Do not punch the marks.
    2. Using a plastic-faced hammer, disconnect the front axle assembly LH.
      NOTE:
      • Be careful not to damage the boot or speed sensor rotor.
      • Do not excessively push out the drive shaft from the axle assembly.
        Fig 26: Putting Matchmarks On Drive Shaft And Axle Hub
        G06008387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. SEPARATE STEERING KNUCKLE WITH AXLE HUB RH 

    HINT:

    Perform the same procedure for the LH side.

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  53. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH  (See REMOVAL )
  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)  (See REMOVAL )
  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)  (See REMOVAL )
  56. SEPARATE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) 

    HINT:

  57. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    HINT:

  58. REMOVE CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY 

    HINT:

  59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
      NOTE: Place the engine on wooden blocks or equivalent so that the engine is level.
      Fig 27: Identifying Engine Assembly With Transaxle On Engine Lifter
      G06041062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and 2 nuts, and separate the engine mounting insulator RH.
      Fig 28: Locating Engine Mounting Insulator RH Bolt And Nuts
      G06008389Courtesy 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 29: Locating Engine Mounting Insulator LH Bolt And Nuts
      G06008390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSTALL ENGINE HANGERS 
    1. Install the No. 1 and No. 2 engine hangers with new bolts as shown in the illustration.

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

      TORQUE SPECIFICATION

      Item Part No.
      No. 1 engine hanger 12281-28010
      No. 2 engine hanger 12282-28010
      Bolt 91512-B1020 or 91552-81020
      Fig 30: Identifying No. 1 And No. 2 Engine Hangers With Bolts
      G05387100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an engine sling device and a chain block, suspend the engine assembly with transaxle.
      Fig 31: Lifting Engine Assembly
      G06008392Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the through bolt and nut, and separate the front engine mounting insulator.
    Fig 32: Locating Front Engine Mounting Insulator Bolt And Nut
    G06008393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE REAR ENGINE MOUNTING INSULATOR (for 2WD) 
    1. Remove the through bolt and separate the rear engine mounting insulator.
    Fig 33: Locating Rear Engine Mounting Insulator And Bolt (2WD)
    G06008394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. REMOVE REAR ENGINE MOUNTING INSULATOR (for 4WD) 
    1. Remove the through bolt and separate the rear engine mounting insulator.
    Fig 34: Locating Rear Engine Mounting Insulator Bolt (4WD)
    G06041069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 4 bolts and engine mounting insulator LH.
    Fig 35: Locating Engine Mounting Insulator LH And Bolts
    G06008395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 
    1. Remove the 3 bolts and engine mounting insulator sub-assembly RH.
    Fig 36: Locating Engine Mounting Insulator Sub-Assembly RH And Bolts
    G06008396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. REMOVE DRIVE SHAFT BEARING BRACKET (for 2WD) 
    1. Remove the 3 bolts and bracket.
      Fig 37: Locating Drive Shaft Bearing Bracket And Bolts (2WD)
      G06008398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE STARTER ASSEMBLY (for Automatic Transaxle)  (See DISASSEMBLY )
  68. REMOVE STARTER ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  69. REMOVE MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL for E351.

  70. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle) 

    HINT:

  71. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVALINSPECTION for E351.

  72. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transaxle) 

    HINT:

    See REMOVAL for E351.

  73. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)  (See REMOVAL )
  74. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)  (See REMOVAL )
  75. REMOVE ENGINE WIRE 
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