Engine: Removal & Installation Toyota Paseo L40

Removal

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49065-S14688514072001011500000) under REMOVAL & INSTALLATION. Drain cooling system and engine oil. Remove hood, battery, coolant reservoir and radiator.
2. Remove air cleaner assembly with air intake connector and air cleaner bracket. Disconnect accelerator cable and throttle valve cable (A/T models) at throttle body.
3. Remove charcoal canister and drain canister. Drain canister is connected to charcoal canister with a hose and is located near charcoal canister.
4. Disconnect necessary electrical connections, coolant hoses, fuel lines and vacuum lines. Remove cruise control actuator (if equipped) from passenger's side front fender.
5. Remove retaining bolt and vacuum switching valve assembly, located on strut tower, near timing belt cover. Raise and support vehicle. Remove lower engine covers.
6. Disconnect necessary electrical connections, control cables and speedometer cable from transaxle. Disconnect oxygen sensor connector. Remove exhaust pipe-to-cylinder block support bracket bolts. Remove retaining nuts and separate exhaust pipe from exhaust manifold.
7. On M/T models, remove clutch release cylinder with hose attached and secure aside. On all models, remove the power steering pump and A/C compressor (if equipped) with hoses attached and secure aside. Remove power steering pump adjusting bracket and A/C compressor mounting bracket (if equipped).
8. On A/C equipped models without power steering, remove A/C idler pulley. On all models, remove front wheels. Drain transaxle fluid. Remove cotter pin and retainer from end of axle shaft. Apply brakes and remove axle shaft nut.
9. Remove nut and separate tie rod from steering knuckle. Remove ball joint-to-lower control arm bolts/nuts. Separate lower control arm from ball joint.
10. Cover axle shaft boot with shop towel. Using Puller (SST 09950-20017) attached to front hub, press axle shaft from hub assembly. Push hub assembly outward. Separate axle shaft from hub assembly.
11. Using hammer and brass drift, tap axle shaft from transaxle. (Scheme 10) Support engine with hoist. Remove through-bolt and rear (firewall side) engine mount bracket.
12. Remove through-bolt and right (timing belt side) engine mount. Remove left (transaxle side) engine mount bracket. Lift engine and transaxle from vehicle.

Scheme 10

Installation

1. Install engine and transaxle. Install right (timing belt side) engine mount and through-bolt. DO NOT tighten bolts/nuts at this time. NOTE: Ensure ground strap is connected to left (transaxle side) engine mount bracket.
2. Install left (transaxle side) engine mount bracket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000) . Install rear (firewall side) engine mount bracket and through-bolt. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000) .
3. With all other mount bolts tightened to specification, tighten right (timing belt side) engine mount bolts/nuts and through-bolt to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000) .
4. Install NEW snap ring on end of axle shaft. Coat lip of axle shaft seal with grease. Install axle shaft in transaxle with opening of snap ring facing downward.
5. Ensure axle shaft moves in and out .079-.120" (2.00-3.00 mm) after installation. Ensure axle shaft cannot be pulled from transaxle.
6. To install remaining components, reverse removal procedure. Install NEW exhaust pipe-to-exhaust manifold nuts. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49065-S17620278932001011500000) . Adjust fluid levels and control cables.

Scheme 11

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49065-S14688514072001011500000) under REMOVAL & INSTALLATION. Drain cooling system. Disconnect accelerator cable and throttle valve cable (A/T models) at throttle body.
2. Remove air cleaner assembly with air intake connector. Disconnect necessary electrical connections, coolant hoses, fuel lines, vacuum lines and PCV hose.
3. Remove A/C compressor and power steering pump (if equipped) with hoses attached and secure aside. Remove power steering pump bracket. On models equipped with A/C without power steering, remove A/C idler pulley.
4. On all models, remove distributor and spark plugs. Remove EGR pipe, EGR valve, EGR valve vacuum modulator, EGR temperature sensor (if equipped) and coolant housing. (Scheme 11) Raise and support vehicle. Remove right lower engine cover.
5. Disconnect oxygen sensor connector. Remove exhaust pipe-to-cylinder block support bracket bolts. Remove retaining nuts and separate exhaust pipe from exhaust manifold.
6. Remove exhaust manifold heat insulator. Remove retaining nuts, exhaust manifold and gasket. Remove air control valve and "O" ring from end of intake manifold and air pipe. (Scheme 11) CAUTION: DO NOT allow injectors to fall from delivery pipe when removing from intake manifold.
7. Remove throttle body and gasket from intake manifold (if necessary). Remove intake manifold braces. Disconnect fuel lines from delivery pipe and electrical connections from injectors. Remove retaining bolts, delivery pipe with injectors, spacers and insulators. (Scheme 11)
8. Remove air pipe. (Scheme 11) Remove retaining bolts/nuts, intake manifold and gasket. Remove retaining nuts, seal washers, valve cover and gasket.
9. Remove timing belt from camshaft sprocket and No. 2 idler pulley. See «TIMING BELT»(ref-49065-S31237295662001011500000) under REMOVAL & INSTALLATION. Remove camshafts. See CAMSHAFT under «REMOVAL & INSTALLATION»(ref-49065-S21547183592001011500000). CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage.
10. Loosen cylinder head bolts in sequence using several steps. (Scheme 12) Remove cylinder head bolts, cylinder head and cylinder head gasket.

Scheme 12