From 08/2009

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PRECAUTION (w/ Air Suspension)

NOTICE:
Be sure to read Precaution thoroughly before servicing Air Suspension System.

2. PRECAUTION (w/ Navigation System for HDD)

NOTICE:
After the engine switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal Navigation System (for HDD).

3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

4. REMOVE ENGINE ROOM SIDE COVER Removal

5. REMOVE ENGINE ROOM SIDE COVER LH Removal

6. REMOVE COOL AIR INTAKE DUCT SEAL Removal

7. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

8. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.)

9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

10. REMOVE FRONT WHEEL

11. REMOVE NO. 1 ENGINE UNDER COVER

12. REMOVE NO. 2 ENGINE UNDER COVER

13. REMOVE FRONT FLOOR COVER LH Removal

14. REMOVE FRONT FENDER LINER LH

15. REMOVE FRONT FENDER LINER RH

16. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 bolts, clip and front fender apron seal LH.

17. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 bolts, clip and front fender apron seal RH.

18. DRAIN ENGINE OIL Replacement

19. DRAIN ENGINE COOLANT Service and Repair

20. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) Replacement

21. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) Replacement

22. DRAIN TRANSFER OIL (for AWD) Replacement

23. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH Removal

24. REMOVE FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH Removal

25. REMOVE FRONT FENDER TO COWL SIDE SEAL LH Removal

26. REMOVE FRONT FENDER TO COWL SIDE SEAL RH Removal

27. REMOVE FRONT WIPER ARM HEAD CAP Removal

28. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

29. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

30. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

31. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

32. REMOVE FRONT SHOCK ABSORBER CAP (w/ Air Suspension) Removal

33. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY Removal

34. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

NOTICE:
Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

35. REMOVE NO. 2 AIR CLEANER INLET

(a) Disconnect the 2 vacuum hose clamps from the No. 2 air cleaner inlet.

(b) Remove the 2 bolts and No. 2 air cleaner inlet.

36. REMOVE NO. 1 AIR CLEANER INLET

(a) Disconnect the vacuum hose clamp from the No. 1 air cleaner inlet.

(b) Remove the bolt and No. 1 air cleaner inlet.

37. REMOVE BATTERY

(a) Disconnect the positive (+) cable from the positive (+) battery terminal.

(b) Loosen the nut, and remove the bolt from the battery clamp.

(c) Remove the battery and battery tray.

38. REMOVE AIR CLEANER ASSEMBLY Removal

39. REMOVE AIR CLEANER BRACKET

(a) Disconnect the engine wire clamp.

(b) Remove the 2 bolts and air cleaner bracket.

40. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

(a) Disconnect the connector from the brake master cylinder reservoir sub-assembly.

(b) Remove the bolt and separate the radiator reservoir tank assembly from the reservoir bracket.

41. REMOVE RESERVOIR BRACKET

(a) Remove the 2 bolts and reservoir bracket.

42. REMOVE NO. 1 RELAY BLOCK COVER

(a) Remove the No. 1 relay block cover.

43. DISCONNECT ENGINE WIRE

(a) Remove the 2 bolts and separate the 2 earth wires.

(b) Disconnect the 2 wire clamps.

(d) Remove the nut.

(e) Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

(f) Pull up the lever to disconnect the ECM connector.

(g) Disconnect the 2 wire clamps.

44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut from the control shaft lever.

(b) Using a screwdriver, disengage the 4 claws and disconnect the control cable with clip from the control cable bracket.

(c) Remove the clip.

45. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Disconnect the No. 1 fuel vapor feed hose.

46. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the No. 1 radiator hose.

(b) Separate the No. 1 radiator hose from the radiator pipe clamp.

47. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disconnect the No. 2 radiator hose.

48. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

49. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

50. DISCONNECT FUEL MAIN TUBE

(a) Remove the No. 1 fuel pipe clamp.

(b) Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.

NOTICE:
* Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not forcefully bend or twist the nylon tube.
* Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
* If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
51. DISCONNECT NO. 1 INLET OIL COOLER HOSE

(a) Disconnect the No. 1 inlet oil cooler hose.

52. DISCONNECT NO. 1 OUTLET OIL COOLER HOSE

(a) Disconnect the No. 1 outlet oil cooler hose.

53. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Disconnect the union to check valve hose.

54. SEPARATE NO. 2 EARTH WIRE

(a) Remove the 2 bolts and separate the No. 2 earth wire clamps.

55. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

56. REMOVE ENGINE MOVING CONTROL ROD BRACKET

(a) Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.

57. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the bolt and engine moving control rod from the engine moving control rod bracket.

HINT
Perform this procedure only when replacement of the engine moving control rod is necessary.

58. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

(a) Remove the nut and disconnect the discharge hose sub-assembly.

NOTICE:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

59. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the nut and disconnect the suction hose sub-assembly.

NOTICE:
Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

60. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Removal

61. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

62. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Remove the 2 nuts and No. 1 exhaust pipe support bracket.

63. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) Removal

64. SECURE STEERING WHEEL Removal

65. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

66. SEPARATE HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension)

(a) Remove the nut and separate the height control sensor link sub-assembly from the lower suspension arm.

67. REMOVE FRONT AXLE SHAFT NUT LH Removal

68. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

69. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

70. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

71. SEPARATE FRONT SPEED SENSOR LH Removal

72. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

73. SEPARATE TIE ROD ASSEMBLY LH Removal

74. SEPARATE TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

75. SEPARATE FRONT LOWER SUSPENSION ARM LH Removal

76. SEPARATE FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

77. SEPARATE FRONT DRIVE SHAFT ASSEMBLY Removal

78. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

79. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING Disassembly

80. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

81. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the 2 bolts and flywheel housing under cover.

82. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Remove the 6 drive plate and torque converter clutch setting bolts.

HINT
There will be one black colored bolt.

83. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
* Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
* Do not perform any procedure 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.
(b) Remove the 6 bolts, 2 nuts and frame side rail plates RH and LH.

Text in Illustration

(d) Operate the engine lifter, then remove the engine assembly from the vehicle.

NOTICE:
* Make sure that the engine is clear of all wiring and hoses.
* While lowering the engine from the vehicle, do not allow it to contact the vehicle.
(e) Install the No. 1 and No. 2 engine hangers with the 4 bolts.

Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

Part No.

(f) Attach the sling device to the engine hangers and chain block.

84. REMOVE NO. 2 EARTH WIRE

(a) Remove the bolt and No. 2 earth wire from the engine assembly.

85. REMOVE V-RIBBED BELT Removal

86. REMOVE GENERATOR ASSEMBLY Removal

87. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Removal

88. REMOVE STARTER ASSEMBLY Removal

89. REMOVE RADIATOR PIPE CLAMP

(a) Separate the breather plug hose and sensor wire from the radiator pipe clamp.

(b) Remove the bolt and radiator pipe clamp.

90. REMOVE ENGINE WIRE

(a) Remove the engine wire from the engine with transaxle.

91. REMOVE NO. 1 FRONT STABILIZER BRACKET LH (for AWD) Removal

92. REMOVE NO. 1 FRONT STABILIZER BRACKET RH (for AWD)

HINT
Perform the same procedure as for the LH side.

93. REMOVE FRONT STABILIZER BAR (for AWD)

94. REMOVE STEERING LINK ASSEMBLY (for AWD) Removal

95. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the nut and separate the engine mounting insulator LH.

(b) Disconnect the wire clamp and connector.

(d) Remove the nut and separate the engine mounting insulator RH.

(e) Remove the 2 bolts and separate the rear engine mounting insulator assembly.

NOTICE:
Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.

(f) Remove the front frame assembly.

96. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the 2 hole plugs.

(b) Remove the 3 nuts and front engine mounting insulator.

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

97. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the 2 hole plugs.

(b) Remove the 3 nuts and engine mounting insulator LH.

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

98. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Remove the 2 hole plugs.

(b) Remove the 3 nuts and engine mounting insulator RH.

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

99. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Remove the 2 hole plugs.

(b) Remove the 2 nuts and rear engine mounting insulator assembly.

NOTICE:
Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.

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

100. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut and manifold stay.

101. REMOVE TRANSFER STIFFENER PLATE RH (for AWD)

(a) Remove the 4 bolts and transfer stiffener plate RH.

102. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) Removal

103. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) Removal

104. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts and engine mounting bracket RH.

105. REMOVE REAR ENGINE MOUNTING BRACKET (for 2WD)

(a) Remove the 3 bolts and rear engine mounting bracket.

106. REMOVE REAR ENGINE MOUNTING BRACKET (for AWD)

(a) Remove the 3 bolts and rear engine mounting bracket.

107. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Removal