From 08/2009

2GR-FXE ENGINE MECHANICAL: ENGINE UNIT: REMOVAL

1. INSTALL ENGINE ON ENGINE STAND

(a) Install the engine onto an engine stand with the bolts.

2. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts and 2 engine hangers.

Text in Illustration

3. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Removal

4. REMOVE THROTTLE BODY BRACKET

(a) Remove the bolt and throttle body bracket.

5. REMOVE NO. 2 EGR PIPE Removal

6. REMOVE EGR COOLER ASSEMBLY Removal

7. REMOVE NO. 1 EGR COOLER BRACKET

(a) Remove the 3 bolts and No. 1 EGR cooler bracket.

8. REMOVE EGR DELIVERY CHAMBER Removal

9. REMOVE NO. 1 SURGE TANK STAY

(a) Remove the bolt and No. 1 surge tank stay.

10. REMOVE IGNITION COIL ASSEMBLY Removal

11. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

12. REMOVE INTAKE MANIFOLD

(a) Uniformly loosen and remove the 6 bolts and 4 nuts.

(b) Remove the intake manifold and 2 gaskets.

13. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Uniformly loosen and remove the 6 nuts.

(b) Remove the exhaust manifold sub-assembly RH and gasket.

14. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Remove the bolt and No. 2 engine oil level dipstick guide.

15. REMOVE NO. 2 MANIFOLD STAY Removal

16. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Removal

17. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Uniformly loosen and remove the 6 nuts.

(b) Remove the exhaust manifold sub-assembly LH and gasket.

18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts and V-ribbed belt tensioner assembly.

19. REMOVE NO. 2 TIMING GEAR COVER

(a) Remove the 2 bolts and No. 2 timing gear cover.

20. REMOVE WATER PUMP PULLEY Removal

21. REMOVE RADIO SETTING CONDENSER

(a) Remove the 2 bolts and 2 radio setting condensers.

22. REMOVE NO. 1 VACUUM SWITCHING VALVE

(a) Remove the bolt and No. 1 vacuum switching valve.

23. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

24. REMOVE SENSOR WIRE

(a) Disconnect the 2 knock control sensor connectors and knock control sensor wire connector.

(b) Disconnect the 2 clamps and remove the knock control sensor wire from the engine assembly.

25. REMOVE KNOCK CONTROL SENSOR Removal

26. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Removal