Toyota Camry 1983-1996 Repair Guide

Engine

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REMOVAL & INSTALLATION



In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:



If you have to drain any of the fluids, use a suitable container.
 
Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
 
Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
 
After unbolting the transmission or transaxle, always make sure it is properly supported.
 
If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
 
When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
 
Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
 
After the engine is clear of the compartment, place it on an engine stand or workbench.
 
After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this guide.
 

Diesel Engines
  1. Disconnect and remove the battery. Drain the coolant from the radiator and engine drain cocks. Matchmark and remove the hood.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the relay block bracket and position the assembly out of the way without disconnecting any electrical harness. Remove the cruise control actuator.
  2.  
  3. If the vehicle is not equipped with cruise control, disconnect the accelerator cable at the injection pump. Disconnect the throttle cable at the injection pump. Remove the air cleaner assembly with the air cleaner hose.
  4.  
  5. Disconnect and remove the heater hoses. Remove the radiator.
  6.  
  7. Disconnect, plug and label the fuel inlet and outlet hoses, the vacuum pump vacuum hoses, the pressure hose for the turbocharger warning switch, the idle up vacuum hoses and the HAC vacuum hose.
  8.  
  9. Disconnect and label all electrical wires, vacuum hoses and cables from their various engine parts.
  10.  
  11. Disconnect the speedometer cable. Remove the transaxle case protection shield. Disconnect the transaxle control cable at the swivel and bracket and lift it out.
  12.  
  13. Remove the windshield washer and radiator reservoir tanks.
  14.  
  15. Unbolt the power steering pump, remove the drive belt and then position the pump out of the way with the hoses still connected. Support the pump with a piece of string or wire. Unbolt and position the air condition compressor on the radiator support. Support the compressor with a piece of string or wire.
  16.  
  17. Raise and support the vehicle safely. Drain the engine oil. Drain the transaxle fluid.
  18.  
  19. Unbolt both halfshafts. Unbolt the left side steering knuckle for halfshaft removal.
  20.  
  21. Disconnect the exhaust pipe at the turbocharger elbow manifold.
  22.  
  23. Remove the rear engine insulator. Lower the vehicle and remove the front engine mount bolts.
  24.  
  25. Attach an engine lifting hoist to the lifting brackets. Take up the weight of the engine with the hoist and then remove the right and left engine mounts.
  26.  
  27. Slowly and carefully, remove the engine/transaxle assembly from the vehicle. Be careful to avoid striking the crankshaft pulley or the transaxle against any part of the body.
  28.  

To install:
  1. Slowly and carefully, lower the engine/transaxle assembly into the engine compartment and align each mounting with its bracket. Temporarily install the transaxle case and mounting through bolts. Remove the lifting hoist from the engine.
  2.  
  3. Raise and safely support the vehicle. Install the engine rear mounting insulator.
  4.  
  5. Connect the exhaust pipe to the exhaust elbow using a new gasket. Connect the left steering knuckle to the ball joint. Tighten the bolts to 65 ft. lbs. (88 Nm).
  6.  
  7. Connect both front driveshafts. Tighten the nuts to 27 ft. lbs. (36 Nm). Depress the brake pedal as each nut is tightened. Lower the vehicle.
  8.  
  9. Install all other components previously removed. Route, connect and clamp all the electrical wires to their various engine parts. Connect all the vacuum hoses. adjust the tension of all drive belts.
  10.  
  11. Fill the radiator with coolant to the proper level. Fill the transaxle with ATF. Install a new oil filter and replace the engine oil.
  12.  
  13. Start the engine and check for leaks of any kind. Correct all leaks as necessary.
  14.  
  15. Adjust the engine idle and maximum idle speeds.
  16.  
  17. Install and adjust the hood.
  18.  
  19. Perform a road test. Recheck the coolant and engine oil levels.
  20.  

Gasoline Engines
2-WHEEL DRIVE
  1. Drain the engine coolant from the radiator and engine drain cocks.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the hood. Disconnect and remove the battery, on some models it may be necessary to remove the battery tray also. On vehicles equipped with an automatic transaxle, disconnect the throttle cable and bracket from the throttle body.
  2.  


CAUTION
Some models covered by this guidemay be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Chassis Electrical .

  1. Disconnect and label all cables, electrical wires and vacuum lines attached to various engine parts.
  2.  
  3. Remove the cruise control actuator and bracket. Disconnect the radiator and heater hoses. Disconnect the automatic transaxle cooler lines. Remove the radiator. On some models it may be necessary to remove the washer fluid reservoir.
  4.  
  5. Remove the air cleaner assembly and air flow meter. Disconnect all wiring and linkage at the transaxle.
  6.  
  7. Pull out the fuel injection system wiring harness. Secure the assembly to the right side of fender apron.
  8.  
  9. Disconnect and plug the fuel lines at the fuel filter and return pipes. Unbolt the air conditioning compressor and position it out of the way. DO NOT disconnect any refrigerant lines.
  10.  
  11. Disconnect the speedometer cable at the transaxle. Remove the clutch release cylinder without disconnecting the fluid line.
  12.  
  13. Disconnect any engine wiring attached to the cabin of the vehicle.
  14.  
  15. Raise and support the vehicle safely. Drain the engine oil. Remove the engine under covers.
  16.  
  17. Remove the suspension lower crossmember. Drain the transaxle fluid. Wrap both driveshaft boots with shop towels an unbolt both halfshafts.
  18.  
  19. Unbolt the power steering pump (leaving the hoses connected) and position it out of the way. Disconnect the exhaust pipe from the manifold. Disconnect the front, rear and center engine mounts at the frame member. On some models a center crossmember may need to be removed also.
  20.  
  21. Attach an engine hoist chain to the lifting eyes and connect a suitable engine lifting device to the hoist. Take up the engine weight with the crane and remove the right and left side engine mounts.
  22.  
  23. Carefully, raise and remove the engine and transaxle assembly from the vehicle. Clear the right side of the mounting while lowering the transaxle and clear the power steering gear while lowering the neutral start switch. Make sure that the engine clears all wiring hoses and cables.
  24.  
  25. Position the engine in a suitable engine holding stand and disconnect the lifting device and the chains.
  26.  

To install:
  1. Connect the engine hoist chains to the lifting eyes and connect the lifting device to the hoist. Remove the engine from the holding stand.
  2.  
  3. Carefully lower the engine and transaxle assembly into the engine compartment. Keep the engine level and align each mounting with its bracket. Temporarily install engine mounting through their nuts and bolts. Remove the lifting device and chain hoist from the engine.
  4.  
  5. Raise the vehicle and support safely. Install the front and rear mounting insulators onto the frame member. Tighten the bolts to specifications. Refer to the Torque Specification chart in this section.
  6.  
  7. Install all other components previously removed. Route, connect and clamp all the electrical wires to their various engine parts. Connect all the vacuum hoses. adjust the tension of all drive belts.
  8.  
  9. Fill the radiator with coolant to the proper level. Fill the transaxle with ATF. Install a new oil filter and replace the engine oil.
  10.  
  11. Start the engine and check for leaks of any kind. Correct all leaks as necessary.
  12.  
  13. Adjust the engine idle and maximum idle speeds.
  14.  
  15. Install and adjust the hood.
  16.  
  17. Perform a road test. Recheck the coolant and engine oil levels.
  18.  

ALL-TRAC 4-WHEEL DRIVE
  1. Disconnect the negative battery cable and drain the engine coolant. Remove the hood.
  2.  
  3. Disconnect the accelerator cable from the throttle body. Remove the radiator.
  4.  
  5. Disconnect the heater hoses.
  6.  
  7. Disconnect the inlet hose at the fuel filter. Disconnect the return hose at the fuel return pipe.
  8.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect and remove the cruise control actuator.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the clutch slave cylinder and hose bracket without disconnecting the hose. Position the assembly out of the way. Disconnect the speedometer cable and the transaxle control cables.
  6.  
  7. Disconnect and remove the air conditioning compressor with the refrigerant lines still attached; position it out of the way. DO NOT disconnect the refrigerant lines.
  8.  
  9. Disconnect and label all wires, connectors and vacuum lines from their various engine parts.
  10.  
  11. Raise the front of the vehicle so that there is sufficient clearance to lower the engine. Drain the engine oil and remove the engine undercovers.
  12.  
  13. Remove the lower suspension crossmember and the halfshafts. Disconnect and remove the propeller shaft. Cover the drive boots with shop towels.
  14.  
  15. Remove the power steering pump with the hydraulic lines still attached and place it against the cowl. Secure the pump with a piece of string or wire. Remove the front exhaust pipe.
  16.  
  17. Remove the engine mounting center member and the stabilizer bar. Lower the vehicle.
  18.  
  19. Unplug the TCCS (Toyota Computer Control System) and ECU (Electronic Control Unit) connectors and pull them out through the firewall. Remove the power steering pump reservoir tank mounting bolts.
  20.  
  21. Attach an engine lifting device to the engine lift brackets. Remove the right side engine mount stay and then remove the insulator and bracket. Remove the left side engine mount insulator and bracket.
  22.  
  23. Lower the engine and transaxle as an assembly from the engine compartment. Be careful not to hit the power steering gear housing or the neutral safety switch.
  24.  
  25. Place the engine in a suitable engine holding stand.
  26.  

To install:
  1. Remove the engine from the holding stand. Carefully raise the engine into the engine compartment being careful not to strike the power steering gear housing or the neutral start switch.
  2.  
  3. Keep the engine level and align each mounting with the bracket. Install the left and right mounting insulators and temporarily install the through bolts. Tighten the left mount bolts to 38 ft. lbs. (52 Nm), the thru-bolt to 64 ft. lbs. (87 Nm) and right mounting bracket bolts to 64 ft. lbs. (87 Nm), the nuts to 38 ft. lbs. (52 Nm) and the right mounting stay bolt and nut to 54 ft. lbs. (73 Nm). Remove the lifting device from the engine.
  4.  
  5. Install the power steering pump reservoir mounting bolts. Engage the TCCS and ECU connectors. Raise the vehicle and support safely.
  6.  
  7. Install the stabilizer bar. Install the engine mounting center member and tighten the member body bolts to 29 ft. lbs. (39 Nm) and all other member bolts to 38 ft. lbs. (52 Nm).
  8.  
  9. Install the front exhaust pipe and tighten the bolts to 46 ft. lbs. (62 Nm). Attach the power steering pump to the bracket. Install the propeller shaft and connect the front driveshafts. Install the suspension lower crossmember. Tighten the member body bolts to 153 ft. lbs. (207 Nm) and all other member bolts to 29 ft. lbs. (39 Nm).
  10.  
  11. Install the engine covers and lower the vehicle. Connect all electrical wires, connectors and vacuum hoses. Install the air conditioning compressor and the drive belt.
  12.  
  13. Connect the transaxle control and speedometer cables. Install the clutch release cylinder and release bracket.
  14.  
  15. Install the air cleaner, air cleaner hose and flow meter assembly. Install the cruise control actuator.
  16.  
  17. Unplug and connect the fuel hoses. Connect the heater water hoses.
  18.  
  19. Install the radiator. Install the accelerator cable and adjust it. Install the battery.
  20.  
  21. Fill the engine with coolant to the proper level. Install a new oil filter and replace the engine oil. Start the engine and check for leaks of any kind. Correct all leaks as necessary.
  22.  
  23. Adjust the power steering pump and the alternator drive belt tension. Adjust the ignition timing and the valve clearance.
  24.  
  25. Install the hood and check the toe-in.
  26.  
  27. Perform a road test. Recheck the coolant and engine oil levels.
  28.  

 
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