ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedure Effect/Inoperative when not Performed Link
Disconnect cable from negative battery terminal Memorize steering angle neutral point Simple intelligent parking assist system*1

Click here

Toyota parking assist-sensor system (w/ Simple Intelligent Parking Assist System)*1
Initialize back door lock Power door lock control system

Click here


  • Replacement of engine assembly

  • Air leaks from intake system

  • Gas leaks from exhaust system

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

Replacement of CVT fluid ATF thermal degradation estimate reset The value of the Data List item "ATF thermal Degradation Estimate" is not estimated correctly

Click here

Front wheel alignment adjustment

Perform the following procedures in the order shown:


  1. Clear zero point calibration data and store system information

  2. Perform yaw rate and acceleration sensor zero point calibration and store system information

  • VSC disabled or malfunctions

  • DTCs are stored

  • Slip indicator light illuminates

  • ABS warning light illuminates

Click here

*1: When performing learning using the GTS.

Click here

CAUTION:


  • B008LWUC22
    *a Heavy object exceeding the capacity of the engine lifter

    Because the weight of the engine with transaxle assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the engine lifter could drop and components could fall down.


  • B008L3IC12
    *a High temperature areas

    Do not touch the engine or exhaust manifold converter sub-assembly when they are hot.

  • Touching the engine or exhaust manifold converter sub-assembly when they are hot could result in burns.


  • B008LF7

    Never perform work on fuel system components near any possible ignition sources.

  • Vaporized fuel could ignite, resulting in a serious accident.


  • B008LK1

    Do not perform work on fuel system components without first disconnecting the cable from the negative (-) battery terminal.

  • Sparks could cause vaporized fuel to ignite, resulting in a serious accident.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. REMOVE BATTERY

    Click here

  6. REMOVE FRONT WHEELS

    Click here

  7. REMOVE NO. 1 ENGINE UNDER COVER


    1. B008KJI

      Remove the 4 bolts, 4 screws, 4 clips and No. 1 engine under cover from the vehicle.

  8. REMOVE REAR ENGINE UNDER COVER LH


    1. B008MB2

      Remove the 6 clips and rear engine under cover LH from the vehicle.

  9. REMOVE REAR ENGINE UNDER COVER RH


    1. B008KJC

      Remove the 6 clips and rear engine under cover RH from the vehicle.

  10. DRAIN ENGINE OIL

    Click here

  11. DRAIN ENGINE COOLANT

    Click here

  12. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  13. REMOVE NO. 2 CYLINDER HEAD COVER

    Click here

  14. REMOVE ECM

    Click here

  15. DISCONNECT WIRE HARNESS


    1. B008L51

      Remove the 2 bolts to separate the engine wire from the vehicle.

    2. B008KKU

      Remove the bolt and nut to separate the engine wire from the battery clamp sub-assembly.

    3. B008KNM

      Remove the 3 nuts to separate the engine wire from the positive (+) battery terminal.

    4. B008KQJ

      Remove the bolt to separate the engine wire from the transaxle assembly.

  16. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. B008LZI

      Disengage the clamp to separate the engine wire from the battery clamp sub-assembly.

    2. Remove the 3 bolts and battery clamp sub-assembly from the vehicle.

  17. DISCONNECT NO. 1 RADIATOR HOSE

    B008M25

    1. Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  18. DISCONNECT NO. 2 RADIATOR HOSE

    B008LRK

    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

  19. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  20. DISCONNECT FUEL VAPOR FEED HOSE


    1. B008MEF

      Slide the clip and disconnect the fuel vapor feed hose from the purge valve (purge VSV).

  21. DISCONNECT UNION TO CONNECTOR TUBE HOSE

    B008L5W

    1. Slide the clip and disconnect the union to connector tube hose from the vacuum pump assembly.

  22. DISCONNECT OUTLET HEATER WATER HOSE


    1. B008LCS

      Disengage the clamp.

    2. Slide the clip and disconnect the outlet heater water hose from the No. 3 water by-pass hose.

  23. DISCONNECT INLET HEATER WATER HOSE


    1. B008K5T

      Slide the clip and disconnect the inlet heater water hose from the No. 1 water by-pass pipe.

  24. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B008MBI

      Disengage the claw and remove the No. 1 fuel pipe clamp.

    2. B008KFY

      Pinch the retainer as shown in the illustration, then pull the fuel tube connector off the fuel pipe.

      Note


      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them, as the fuel tube connector has O-rings that seal the fuel pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Protect the disconnected part by covering it with a plastic bag after disconnecting the fuel tube sub-assembly.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  25. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  27. SECURE STEERING WHEEL ASSEMBLY

    Click here

  28. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  29. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  30. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  31. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

    Click here

  33. REMOVE DRIVE SHAFT ASSEMBLY

    Click here

  34. REMOVE FLYWHEEL HOUSING UNDER COVER

    Click here

  35. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  36. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  37. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  38. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on an engine lifter.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle and front suspension crossmember sub-assembly level.

      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

    2. B008LF3

      Remove the 2 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    3. B008MCJ

      Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.

      Note

      While holding the nut in place, loosen the bolt.

    4. B008KKB

      Remove the 6 bolts to separate the front suspension crossmember sub-assembly from the vehicle.

    5. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

      Note


      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

  39. REMOVE WIRE HARNESS CLAMP BRACKET

    B008KGS

    1. Disengage the 5 clamps.

    2. Disconnect the air fuel ratio sensor connector.

    3. Remove the bolt and wire harness clamp bracket.

  40. INSTALL ENGINE HANGER


    1. B008KYEC04
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      B008MD9 Bolt

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-37070
      No. 2 Engine Hanger 12282-37060
      Bolt 91552-81050

    2. Attach an engine sling device and hang the engine assembly with transaxle with a chain block.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

  41. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B008M7I

      Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle.

  42. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.


    1. B008M3B

      Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle.

    2. B008LNG

      Remove the bolt, nut and disconnect the air conditioner tube and accessory assembly.

    3. Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle.

  43. REMOVE STARTER ASSEMBLY

    Click here

  44. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. B008LIN

      Remove the flywheel housing side cover from the cylinder block sub-assembly.

  45. REMOVE ENGINE WIRE


    1. Disconnect all the clamps and connectors and remove the engine wire from the engine assembly with transaxle.

  46. REMOVE NO. 3 WATER BY-PASS HOSE


    1. B008KRY

      Disengage the clamp.

    2. Slide the 2 clips and remove the No. 3 water by-pass hose from the cylinder head sub-assembly and oil cooler.

  47. REMOVE NO. 5 WATER BY-PASS HOSE


    1. B008LNN

      Disengage the 2 clamps.

    2. Slide the 2 clips and remove the No. 5 water by-pass hose from the No. 3 water by-pass pipe and oil cooler.

  48. REMOVE ENGINE ASSEMBLY

    Click here

  49. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  50. REMOVE FAN AND GENERATOR V BELT

    Click here

  51. REMOVE GENERATOR ASSEMBLY

    Click here

  52. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY

    Click here

  53. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

  54. REMOVE ENGINE HANGER


    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.