Complete replacement of the 2.5L I4 long block assembly, including removal of transmission, front subframe, and all engine accessories, followed by installation of new long block and reassembly.

Warnings

Tools required

Parts

• Long block assembly (2AR-FE) × 1 — Use OEM specification
• Engine oil filter × 1 — 04152-YZZA1
• Oil drain plug crush washer × 1 — 90430-12031
• Timing cover gasket × 1 — Use OEM specification
• Valve cover gasket with grommets × 1 — Use OEM specification
• Intake manifold gasket × 1 — Use OEM specification
• Exhaust manifold gasket × 1 — Use OEM specification
• Water pump gasket/O-ring set × 1 — Use OEM specification
• Thermostat with gasket × 1 — Use OEM specification
• Front engine mount × 1 — 12361-0H100
• Rear engine mount × 1 — 12371-0H120
• Right side engine mount × 1 — 12305-0H100
• Transmission-to-engine gasket × 1 — Use OEM specification
• Coolant hoses (upper and lower radiator) × 1 — Use OEM specification
• Accessory drive belt × 1 — Use OEM specification

Fluids

• Toyota Genuine 0W-20 engine oil — 5 qt
• Toyota Super Long Life Coolant (Pink) — 10 qt
• Toyota WS ATF — 10 qt

Preparation

1. Park vehicle on level concrete surface in well-ventilated area with adequate overhead clearance for engine hoist
2. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
3. Remove engine cover and perform thorough photographic documentation of engine bay
4. Drain engine oil completely, remove oil filter, and install drain plug with new crush washer
5. Drain engine coolant from radiator drain cock and engine block drain plugs into suitable container
6. Relieve fuel system pressure by removing fuel pump relay and cranking engine until it fails to start
7. Raise vehicle on lift or jack stands at all four corners, ensuring stability before working underneath
8. Remove front wheels and lower engine splash shields/under covers
9. Tag and label all electrical connectors, vacuum lines, and coolant hoses with location information

Procedure

1. 1

   Remove hood and air intake system
   With assistant, mark hood hinge positions with paint pen, then remove four hood bolts and carefully lift hood away. Remove engine air intake assembly including air filter box, mass airflow sensor, and intake ducting from throttle body to air box. Disconnect MAF sensor electrical connector before removal.
2. 2

   Disconnect all electrical connections and sensors
   Systematically disconnect all engine electrical connectors including: alternator, starter motor, all ignition coils, throttle position sensor, coolant temperature sensors, oil pressure sensor, camshaft/crankshaft position sensors, knock sensors, injector harness connectors, and all oxygen sensors. Release main engine harness from all mounting clips and position harness away from engine for later removal with engine.
3. 3

   Remove fuel system and throttle components
   Using fuel line disconnect tools, separate fuel feed and return lines at engine-side quick connectors. Plug open lines to prevent contamination. Remove throttle body assembly after disconnecting coolant bypass hoses. Cap or plug all open coolant passages.
   ⚠️Fuel system operates at high pressure. Ensure pressure is fully relieved and have fire extinguisher accessible. Work in well-ventilated area away from ignition sources.
4. 4

   Disconnect cooling system
   Disconnect upper and lower radiator hoses from engine. Remove heater inlet and outlet hoses at firewall connections. Disconnect all coolant bypass hoses to throttle body and intake manifold. On vehicles with engine oil cooler, disconnect coolant lines from oil cooler assembly. Cap all open coolant passages to prevent contamination during engine removal.
5. 5

   Remove accessory drive components
   Remove serpentine accessory belt. Unbolt and remove alternator completely. Remove air conditioning compressor mounting bolts but leave refrigerant lines connected; secure compressor to chassis with wire or bungee cords in position where hoses are not stressed. Remove power steering pump (if equipped with hydraulic system) and secure aside. On electric power steering models, no pump removal is necessary.
6. 6

   Disconnect exhaust system
   From underneath vehicle, spray exhaust manifold nuts and flange bolts with penetrating oil and allow to soak. Remove three-way catalytic converter/front exhaust pipe from exhaust manifold by removing manifold nuts and flange bolts at downstream connection. Support exhaust with jack or wire to prevent damage to hangers.
   ⚠Exhaust fasteners are prone to seizing. If studs break, they must be extracted before new engine installation. Apply penetrating oil and allow extended soak time.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
7. 7

   Separate transmission from engine
   Support transmission securely with transmission jack. Remove all transmission-to-engine bellhousing bolts, noting different lengths and positions. On automatic transmission models, access torque converter bolts through starter motor opening or inspection cover and remove all torque converter-to-flywheel bolts while rotating crankshaft. Carefully separate transmission from engine by prying at designated pry points, ensuring torque converter remains with transmission. Lower transmission on jack and move aside.
   ⚠Transmission weighs approximately 150 lbs. Ensure transmission jack is properly positioned and stable. Do not allow transmission to hang on input shaft.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
8. 8

   Remove engine mounting brackets and supports
   Remove right-side engine mount through-bolt and mount assembly from chassis. Remove front engine mount through-bolt and mount bracket from engine. Remove rear engine mount through-bolt. Support engine weight with engine hoist before removing final mounting points. Attach hoist chains to factory lifting eyes on engine using proper grade hooks and chain.
   ⚠️Engine must be fully supported by hoist before removing final mount. Ensure hoist is positioned with proper balance and all chains are secure.
   Torque spec

   Mounting Bolts47 Nm (35 lb-ft)
9. 9

   Extract engine from vehicle
   With engine fully supported by hoist and all connections verified disconnected, slowly raise engine while tilting slightly toward firewall to clear transmission mount area. Continue raising and angling engine forward to clear radiator support and front body structure. Have assistant guide engine and monitor clearances. Once clear of engine bay, lower engine onto engine stand or suitable work surface. Inspect engine bay for any remaining components that should have been removed.
10. 10

    Transfer components from old engine to new long block
    Remove and transfer all necessary components from old engine to new long block: alternator bracket, accessory drive pulleys, water pump (if not included), thermostat housing, intake manifold, exhaust manifold, ignition coils and spark plugs, all sensors (coolant temp, oil pressure, knock, cam/crank position), engine harness brackets, dipstick tube, and any other external components not included with long block. Clean all mounting surfaces thoroughly and use new gaskets for all components.
    ℹ️Verify what components are included with your specific long block. Some include timing components and oil pump, others may require transfer of additional internal components.
    Torque spec

    Intake Manifold Bolts25 Nm (18 lb-ft)

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)

    Gasket Surface Bolts20 Nm (15 lb-ft)
11. 11

    Install flywheel or flexplate
    If flywheel/flexplate was removed or not included with long block, install it now. Clean flywheel and crankshaft flange thoroughly with brake cleaner. Apply thread locker to flywheel bolts. Position flywheel with alignment dowel pins, install bolts, and torque in star pattern sequence to specification. If bolts are TTY type, follow torque-plus-angle procedure per manufacturer specifications.
    ⚠Flywheel must be locked from rotation during torque procedure. Use flywheel holding tool or have assistant apply brake pedal with transmission in gear.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)
12. 12

    Install new engine into vehicle
    With all necessary components transferred to new long block, attach engine hoist to factory lifting eyes. Carefully guide engine into engine bay, angling front downward to clear radiator support. Lower slowly while aligning with transmission bellhousing. Once engine is in approximate position, align engine with transmission input shaft (or torque converter pilot) and transmission mounting surface. Install one or two transmission-to-engine bolts finger-tight to hold alignment before releasing hoist tension.
    ⚠Do not force engine to mate with transmission. If resistance is felt, remove and verify torque converter is fully seated in transmission pump, clutch disc is properly aligned (manual), and input shaft is centered.
13. 13

    Install engine mounts and torque transmission bolts
    Install new engine mount assemblies at all three mounting positions (front, rear, right side) with through-bolts finger-tight. Install all remaining transmission-to-engine bellhousing bolts in correct positions. Torque all transmission-to-engine bolts to specification in cross-pattern sequence. On automatic transmission, rotate crankshaft to access and install all torque converter-to-flywheel bolts through starter opening. Torque engine mount through-bolts to specification once engine weight is resting on mounts.
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Mounting Bolts47 Nm (35 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
14. 14

    Reconnect exhaust system
    Install new exhaust manifold gasket. Position front exhaust pipe/catalytic converter to exhaust manifold flange. Apply anti-seize compound to exhaust manifold stud threads. Install manifold nuts and torque to specification working from center outward (hot-to-cold pattern). Install downstream exhaust flange bolts and torque to specification. Verify exhaust system has proper clearance and is not contacting chassis or suspension components.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
15. 15

    Install accessory components and reconnect systems
    Install air conditioning compressor to mounting bracket and torque bolts to specification. Install alternator and torque mounting bolts. Install new accessory drive belt per routing diagram on fan shroud. Reconnect all electrical connectors using photographs and labels as reference: alternator, starter, ignition coils, all sensors, injector harness, and main engine harness. Reconnect fuel lines using new O-rings or clips as required. Reconnect all coolant hoses and secure with new clamps. Install throttle body with new gasket.
    Torque spec

    Mounting Bolts47 Nm (35 lb-ft)

    Electrical Connector Bolts7 Nm (5 lb-ft)

    Gasket Bolts20 Nm (15 lb-ft)
16. 16

    Complete final assembly and prepare for startup
    Install new oil filter and verify oil drain plug is tight with new crush washer. Fill engine with 5 quarts of Toyota Genuine 0W-20 engine oil. Fill cooling system with proper mixture of Toyota Super Long Life Coolant (approximately 10 quarts total capacity). Install engine under covers and splash shields. Install front wheels and torque lug nuts to specification. Install air intake system and reconnect MAF sensor. Install hood with assistant, aligning to marked positions. Reconnect battery negative terminal.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Double-check that all electrical connectors are fully seated and locked with retaining clips engaged
2. Verify all coolant hoses are properly secured with clamps and no hoses are kinked or improperly routed
3. Confirm all ground straps are reinstalled to proper locations on engine block and chassis
4. Verify no tools or rags remain in engine bay before attempting to start engine
5. Check that transmission fluid level is correct and top off if needed after engine removal process
6. Ensure all exhaust connections are tight and exhaust system has proper clearance throughout suspension travel

Verification

• Prime oil system by removing fuel pump relay and cranking engine for 10-15 seconds in multiple intervals until oil pressure gauge shows pressure
• Perform initial startup and verify oil pressure within first few seconds; shut down immediately if no oil pressure is observed
• Allow engine to reach operating temperature while monitoring for coolant leaks, oil leaks, and unusual noises
• Verify cooling fans cycle on and off properly and engine temperature remains in normal range
• Check for exhaust leaks by listening and visual inspection of all exhaust connections while engine is running
• After initial warm-up and cool-down cycle, recheck all fluid levels and top off as necessary
• Perform test drive to verify proper engine performance, transmission shifting, and absence of vibrations or unusual sounds
• After test drive, re-inspect all connections for leaks and verify no warning lights are illuminated on instrument cluster
• Recheck engine oil level after vehicle sits overnight and top off to proper level on dipstick
• Monitor engine oil level and coolant level daily for first week of operation to detect any consumption or leaks

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