ENGINE ASSEMBLY REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note


    • After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE BATTERY HOLD DOWN CLAMP


    1. A01DQNI

      Remove the nut and disconnect the engine wire.

    2. Remove the 2 nuts and battery hold down clamp.

  3. REMOVE BATTERY

  4. REMOVE BATTERY TRAY

  5. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. A01DNPL

      Remove the 8 bolts and hood.

      Note

      If the hood support is detached from the ball joint, it become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

  6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  7. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  8. REMOVE FRONT BUMPER COVER LOWER


    1. Remove the clip, 5 bolts and front bumper cover lower.

  9. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts.

    2. A01DQWQ

      Unhook the engine under cover from the vehicle body as shown in the illustration.

  10. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  11. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


    1. Remove the 4 bolts and rear engine under cover.

  12. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      A01DQCVE01
      Text in Illustration
      *1 Radiator Cap *2 Radiator Reservoir
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. Drain the coolant by removing the radiator cap.

    3. Loosen the cylinder block drain cock plug.

    4. Loosen the cylinder block drain cock plug and drain the coolant from the engine.

      Note

      If coolant is not drained from the radiator drain cock plug, cylinder block drain cock plugs and radiator reservoir, clogging in the radiator or coolant leakage from the seal of the water pump may result.

  13. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug and gasket, and then drain the oil into a container.

    3. Clean the drain plug and install it with a new gasket.

      Torque:
      35 N*m  { 352 kgf*cm, 25 ft.*lbf }

  14. REMOVE FRONT FENDER APRON SEAL RH


    1. Remove the 4 clips and fender apron seal.

  15. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL RH


    1. Remove the 5 clips and frame seal.

  16. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 5 clips and fender apron seal.

  17. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL LH


    1. Remove the 5 clips and frame seal.

  18. REMOVE RESONATOR WITH AIR CLEANER CAP SUB-ASSEMBLY


    1. A01DTKZ

      Disconnect the sensor connector.

    2. Detach the wire harness clamp.

    3. Loosen the hose clamp and remove the resonator with air cleaner cap.

    4. A01DNS4

      Detach the 4 hook clamps, and then remove the air cleaner cap and resonator with air cleaner cap.

  19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  20. REMOVE AIR CLEANER CASE ASSEMBLY


    1. A01DM2P

      Remove the 3 bolts and air cleaner case.

  21. REMOVE FRONT BUMPER COVER


    1. A01DPU0

      Remove the 2 screws.

      Tech Tips

      Use the same procedure for the screws on the other side.

    2. A01DT5KE01
      Text in Illustration
      *1 Screw
      *2 Bolt A
      *3 Bolt B

      Remove the 2 screws.

    3. Remove the 2 bolts labeled A and 2 bolts labeled B.

    4. A01DM67E01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the front bumper cover.

    5. Remove the 4 clips.

    6. Detach the 16 claws and remove the front bumper cover.

      Note

      Do not hold the middle of the front bumper cover, as it may become reformed.

    7. w/ TOYOTA Parking Assist-sensor System, w/ Fog Light:

      Disconnect the 3 connectors.

    8. w/ TOYOTA Parking Assist-sensor System, w/o Fog Light:

      Disconnect the connector.

    9. w/o TOYOTA Parking Assist-sensor System, w/ Fog Light:

      Disconnect the 2 connectors.

    10. w/ Headlight Cleaner System:

      Disconnect the No. 1 headlight cleaner hose.

  22. REMOVE FRONT UPPER BUMPER RETAINER


    1. A01DP8A

      Remove the 3 bolts and front bumper upper retainer.

  23. REMOVE RADIATOR SIDE DEFLECTOR LH


    1. A01DNFT

      Using a clip remover, detach the 3 claws and remove the clip. Then move the radiator side deflector LH so that the radiator can be removed in the step below.

  24. REMOVE RADIATOR SIDE DEFLECTOR RH


    1. A01DQIE

      Using a clip remover, detach the 3 claws and remove the clip. Then move the radiator side deflector RH so that the radiator can be removed in the step below.

  25. REMOVE NO. 1 RADIATOR HOSE


    1. A01DMPR

      Detach the clamp and remove the No. 1 radiator hose.

    2. A01DNNF

      Remove the 2 nuts and hose clamp.

  26. REMOVE NO. 2 RADIATOR HOSE

    A01DPK1

  27. REMOVE FAN SHROUD


    1. A01DP8Q

      Loosen the 4 nuts holding the fluid coupling fan.

    2. Remove the vane pump V belt and the fan and generator V belt Click here.

    3. A01DPJX

      Remove the 2 bolts holding the fan shroud.

    4. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    5. Remove the fan pulley from the water pump.

  28. REMOVE RADIATOR ASSEMBLY


    1. A01DTP6

      Remove the 4 bolts and radiator assembly from the radiator support.

  29. REMOVE INTAKE PIPE ASSEMBLY


    1. A01DQT4E01

      Loosen the hose clamp and remove the 2 bolts and intake pipe.

  30. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. A01DR3K

      Remove the 4 bolts and idle pulley bracket.

    2. A01DPU5

      Disconnect the connector.

    3. Remove the 3 bolts and disconnect the cooler compressor.

      Tech Tips

      It is not necessary to completely remove the cooler compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  31. REMOVE GENERATOR ASSEMBLY


    1. A01DLZI

      Remove the terminal cap.

    2. Remove the nut and generator wire.

    3. Disconnect the generator connector.

    4. A01DQ8U

      Disconnect the vacuum pump hose.

    5. Remove the union bolt to disconnect the vacuum pump oil inlet hose and remove the 2 gaskets.

    6. Detach the vacuum pump oil inlet hose from the cord clip.

    7. Disconnect the vacuum pump oil outlet hose.

    8. A01DSBZ

      Remove the 2 bolts and generator.

  32. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY


    1. Remove the glove compartment door Click here.

  33. DISCONNECT ENGINE WIRE


    1. A01DO0M

      Remove the 3 bolts, detach the clamp and disconnect the engine wire.

    2. Remove the No. 1 relay block cover.

    3. A01DRJ6

      Remove the nut and detach the 2 claws.

    4. Disconnect the connector.

    5. Detach the 2 clamps and disconnect the engine wire.

    6. A01DS4E

      for LHD:

      Detach the 4 clamps.

    7. A01DOF2E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the grommet from the wire harness support.

    8. A01DQAWE02
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the 4 claws to remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

    9. A01DS2ME01
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the clamp and disconnect the 5 connectors as shown in the illustration.

  34. REMOVE WIRING HARNESS CLAMP BRACKET (for LHD)


    1. A01DPMA

      Remove the bolt and wiring harness clamp bracket.

  35. DISCONNECT HEATER WATER HOSE ASSEMBLY


    1. A01DMBJE01
      Text in Illustration
      *A for Rear Heater

      Remove the bolt and disconnect the heater water hoses.

  36. LOOSEN FUEL TANK CAP ASSEMBLY

  37. DRAIN FUEL


    1. A01DNOB

      Loosen the fuel filter drain plug and drain the fuel from the fuel filter.

  38. DISCONNECT FUEL HOSE


    1. A01DTLC

      Disconnect the 2 fuel hoses.

  39. DISCONNECT VANE PUMP ASSEMBLY


    1. A01DPARE02

      Using SST, hold the pulley and loosen the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the nut and vane pump pulley from the vane pump shaft.

    3. Remove the 2 bolts and nut and disconnect the vane pump.

      Tech Tips

      Disconnect the vane pump from the vehicle with the hoses connected, and hang it with a rope.

  40. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01DUMR

      Remove the 2 bolts and disconnect the release cylinder.

  41. REMOVE STARTER ASSEMBLY


    1. A01DPXX

      Disconnect the starter connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the starter wire.

    4. A01DSW2

      Remove the nut, 2 bolts and starter assembly.

  42. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DS3RE01

      Using SST, remove the oil filter.

      SST
      09228-44011

  43. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the bolt from the clamp.

    2. A01DQRD

      Remove the 2 bolts and No. 1 exhaust pipe support bracket.

    3. A01DNIM

      Remove the 3 nuts and front exhaust pipe.

    4. Remove the gasket.

  44. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. A01DTSDE07
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential.

    2. Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly.

    3. A01DNIAE10
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    4. Remove the 4 nuts, 4 washers and front propeller shaft assembly.

  45. REMOVE PROPELLER SHAFT ASSEMBLY


    1. A01DNVME01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    2. Remove the 4 nuts and 4 washers.

    3. A01DOUDE01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential flange.

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. Remove the propeller shaft.

  46. REMOVE MANUAL TRANSMISSION ASSEMBLY


    1. Remove the manual transmission Click here.

  47. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Note

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


    1. A01DPVM

      Remove the 4 bolts and rear engine mounting insulator from the transmission.

  48. REMOVE CLUTCH COVER ASSEMBLY


    1. A01DSECE01
      Text in Illustration
      *a Matchmark

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  49. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc, the pressure plate and the surface of the flywheel away from oil and foreign matter.

  50. REMOVE FLYWHEEL SUB-ASSEMBLY

    A01DQ4TE01

    1. Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

    2. Remove the 8 bolts and flywheel.

  51. REMOVE REAR END PLATE


    1. Remove the 2 bolts and rear end plate.

  52. REMOVE FLYWHEEL HOUSING DUST SEAL

  53. INSTALL ENGINE HANGER


    1. A01DQLWE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install an engine hanger to each location shown in the illustration.

      Tech Tips

      No. 1 Engine Hanger 12281-54080
      No. 2 Engine Hanger 12282-54070
      Bolt (No. 1 Engine Hanger) 90119-10736
      Bolt (No. 2 Engine Hanger) 91622-61022
      Torque:
      for No. 1 Engine Hanger
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }
      for No. 2 Engine Hanger
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

  54. REMOVE ENGINE ASSEMBLY


    1. Attach an engine sling device and hang the engine with a chain block.

    2. A01DTVLE01
      Text in Illustration
      *1 for RH Side
      *2 for LH Side

      Remove the 4 nuts and 4 bolts from the front engine mounting insulator LH and RH.

    3. Remove the engine by operating the engine sling device and chain block.

  55. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine to an engine stand with bolts.

    2. Remove engine hanger.

  56. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  57. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01DSYE

      Remove the 2 nuts and 2 front engine mounting insulators.