Removal

2GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 11 clips and intake duct seal.
2. REMOVE ENGINE ROOM SIDE COVER LH

(a) Remove the 5 clips and side cover.
3. REMOVE ENGINE ROOM SIDE COVER RH

(a) Remove the 2 clips and side cover.
4. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover.
NOTE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.

5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Removal
6. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
Service Precautions.

7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
9. REMOVE FRONT WHEEL
10. REMOVE ENGINE UNDER COVER
11. REMOVE NO. 2 ENGINE UNDER COVER
12. REMOVE ENGINE UNDER COVER REAR LH

(a) Remove the bolt and engine under cover LH.
13. REMOVE ENGINE UNDER COVER REAR RH
HINT:
Remove the RH side following the same procedures as with the LH side.

14. DRAIN ENGINE OIL Replacement
15. DRAIN ENGINE COOLANT Testing and Inspection
16. REMOVE FRONT EXHAUST PIPE ASSEMBLY
HINT:
Removal.

17. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING
HINT:
Removal.

18. REMOVE NO. 1 INLET AIR CLEANER

(a) Remove the bolt, clip and inlet air cleaner.
19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal
20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Remove the 2 bolts, clamp and air cleaner case.
21. DISCONNECT UNION TO CHECK VALVE HOSE
(a) Remove the clamp and disconnect the union to check valve hose.
22. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Remove the clamp and disconnect the No. 2 fuel vapor feed hose.
23. DISCONNECT INLET RADIATOR HOSE

(a) Remove the clamp and disconnect the inlet radiator hose.
24. DISCONNECT OUTLET RADIATOR HOSE
(a) Remove the clamp and disconnect the outlet radiator hose.
25. DISCONNECT RADIATOR RESERVOIR TANK HOSE
(a) Remove the clamp and disconnect the radiator reservoir tank hose.
26. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.
27. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.
28. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE Removal
29. REMOVE DISCHARGE HOSE SUB-ASSEMBLY Removal
30. REMOVE ECM COVER Removal
31. DISCONNECT ENGINE WIRE
(a) Disconnect the 6 ECM connectors.

(b) Using a screwdriver, disconnect the connector holder.
(c) Remove the engine room No. 1 relay block cover.

(d) Remove the nut and disconnect the wire from the engine room No. 1 junction block.
(e) Remove the nut and disconnect the battery positive (+) cable.
(f) Disconnect the connector and remove the 4 clamps from body.

(g) Remove the bolt, clamp and engine wire No. 3.
(h) Remove the bolt and disconnect the ground cable.
32. DISCONNECT FUEL MAIN TUBE
HINT:
Service Precautions.

33. DISCONNECT NO. 3 FUEL HOSE

(a) Remove the clamp and disconnect the No. 3 fuel hose.
34. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the fuel pipe clamp.

(b) Pinch and pull the fuel tube's connector to disconnect it from the fuel tube sub-assembly.
- Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel main pipe.
- Do not use any tools to separate the connector and pipe.
- Do not forcefully bend or twist the hose.
- Keep the connector and pipe free from foreign matter.
- If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
- Put the connector in a plastic bag to prevent damage and contamination.

35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR

(a) Remove the 4 bolts and suspension member protector.
36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY Removal
37. DISCONNECT HEIGHT CONTROL SENSOR LINK

(a) Remove the nut and disconnect the height control sensor link.
38. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH

(a) Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.
39. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH
HINT:
Remove the RH side following the same procedures as for the LH side.

40. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH

(a) Remove the 2 bolts from the front lower ball joint.
41. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH
HINT:
Remove the RH side following the same procedures as for the LH side.

42. DISCONNECT POWER STEERING LINK WIRE HARNESS

(a) Remove the bolt (A) to disconnect the earth wire from the bracket.
(b) Remove the 2 clamps to disconnect the wire harness from the bracket.
(c) Disconnect the 2 connectors (C) and (D) from the power steering link assembly.
(d) Release the lock of connector (E) and disconnect the connector from the power steering link assembly.
(e) Remove the bolt (B) and the power steering earth wire from the power steering link assembly.
43. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY Removal
44. REMOVE ENGINE AND TRANSMISSION ASSEMBLY
(a) Set the engine lifter.

(b) Remove the 4 bolts, then separate the engine rear mounting member.

(c) Remove the 12 bolts shown in the illustration.
(d) Operate the engine lifter, then slowly remove the engine from the vehicle.
NOTE:
Make sure that the engine is clear of all wiring and hoses.

45. INSTALL ENGINE HANGERS

(a) Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts as shown in the illustration.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)

(b) Attach an engine sling device and hang the engine with a chain block.
46. REMOVE STARTER ASSEMBLY Removal
47. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
HINT:
Removal.

48. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY

(a) Remove the oil level gauge.
(b) Remove the bolt, then remove the No. 2 oil dipstick guide.
(c) Remove the O-ring from the No. 2 oil dipstick guide.

(d) Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.
(e) Remove the O-ring from the No. 1 oil dipstick guide.
49. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 6 nuts, exhaust manifold and gasket.
50. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage:
0.7 mm (0.028 in.)
HINT:
The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).
If the warpage is greater than the maximum, replace the manifold.
51. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 6 nuts, exhaust manifold and gasket.
52. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Using SST, hold the crankshaft.
SST: 09213-70011
09213-70020
SST: 09330-00021

(b) Remove the 8 bolts, front spacer, drive plate and rear spacer.
54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.
55. FIX ENGINE ON ENGINE STAND
(a) Fix the engine onto a engine stand with the bolts.
56. REMOVE V-RIBBED BELT Removal
57. REMOVE NO. 2 ENGINE COVER

(a) Remove the 3 clips and clamp, then remove the No. 2 engine cover.
58. REMOVE NO. 1 ENGINE COVER

(a) Remove the 3 clips, then remove the No. 1 engine cover.
59. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the bolt, plate and idler pulley.
60. REMOVE GENERATOR ASSEMBLY Removal
61. REMOVE COOLER COMPRESSOR ASSEMBLY Removal
62. REMOVE ENGINE MOUNTING BRACKET LH

(a) Disconnect the 2 clamps.
(b) Remove the 4 bolts and mounting bracket.
63. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 4 bolts and mounting bracket.
64. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.
65. REMOVE WATER PUMP PULLEY Removal
66. REMOVE ENGINE WIRE
(a) Remove the engine wire from the engine.
67. REMOVE INJECTOR DRIVER

(a) Remove the bolt, 2 nuts and injector driver.
68. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
HINT:
Removal

69. INSPECT INTAKE AIR SURGE TANK ASSEMBLY

(a) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage:
2.5 mm (0.098 in.)
If the warpage is greater than the maximum, replace the surge tank.
70. REMOVE NO. 2 SURGE TANK STAY
(a) Remove the bolt and No. 2 surge tank stay.
71. REMOVE WATER HOSE JOINT

(a) Remove the bolt, and disconnect 2 hoses and water hose joint.
72. REMOVE INTAKE MANIFOLD Removal
73. INSPECT INTAKE MANIFOLD

(a) Surge tank side:
(1) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the maximum, replace the intake manifold.
(b) Cylinder head side:
(1) Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the maximum, replace the intake manifold.
74. REMOVE FUEL TUBE SUB-ASSEMBLY

(a) Remove the 2 bolts and fuel tube sub-assembly.
75. REMOVE FUEL PUMP
HINT:
Removal.

76. REMOVE FUEL INJECTOR ASSEMBLY
HINT:
Removal.

77. REMOVE KNOCK SENSOR Removal
78. REMOVE RADIO SETTING CONDENSER

(a) Remove the 2 bolts and 2 radio setting condensers.
79. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY

(a) Remove the bolt and V-bank cover bracket.
80. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 ignition coils.
81. REMOVE ENGINE OIL LEVEL SENSOR

(a) Remove the 4 bolts, then remove the oil level sensor and gasket.
82. REMOVE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the oil pressure switch.
83. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the temperature sensor.