Part 1

2GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal

2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

5. DRAIN ENGINE OIL Replacement

6. REMOVE ENGINE UNDER COVER (for 2WD)

7. REMOVE ENGINE UNDER COVER (for 4WD)

8. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD)

(a) Remove the 4 screws, 2 grommets, 2 spacers and under cover.

9. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET (for 2WD)

Remove the 2 bolts and bracket.

10. REMOVE REAR ENGINE UNDER COVER RH (for 2WD)

(a) Remove the bolt and under cover.

11. REMOVE REAR ENGINE UNDER COVER LH (for 2WD)

(a) Remove the bolt and under cover.

12. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER (for 2WD)

(a) Remove the 4 bolts and protector.

13. DRAIN ENGINE COOLANT Service and Repair

14. DRAIN FRONT DIFFERENTIAL OIL (for 4WD)

15. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 7 clips and intake duct seal.

16. REMOVE ENGINE ROOM SIDE COVER RH

Remove the 2 clips and side cover.

17. REMOVE ENGINE ROOM SIDE COVER LH

Remove the 3 clips and side cover.

18. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Hold the front of the V-bank cover and raise it to disengage the 3 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.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.

19. REMOVE NO. 1 AIR CLEANER INLET

(a) Remove the bolt and air cleaner inlet.

20. DISCONNECT NO. 2 VENTILATION HOSE Removal

21. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal

22. REMOVE AIR CLEANER CASE

(a) Remove the 3 bolts, clamp and case.

23. DISCONNECT PURGE LINE HOSE

(a) Remove the clamp and disconnect the feed hose.

24. DISCONNECT NO. 1 RADIATOR HOSE

25. DISCONNECT NO. 2 RADIATOR HOSE

26. DISCONNECT RADIATOR RESERVOIR HOSE

27. DISCONNECT HEATER WATER INLET HOSE A

28. DISCONNECT HEATER WATER OUTLET HOSE A

29. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Disconnect the fuel tube LH and RH side Service Precautions.

30. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY

(a) Disconnect the fuel hose from the pipe.

31. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Disconnect the union to check valve hose from the intake air surge tank.

32. DISCONNECT ENGINE WIRE

(a) for RH Side:

(1) Remove the nut and battery positive (+) cable, and disconnect the clamp from the battery (see illustration (A)).

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

(3) Remove the nut and detach the 2 claws, and remove the wire harness from the No. 1 relay block (see illustration (B)).

(4) Remove the nut and No. 2 ground cable (see illustration (C)).

(5) Detach the 3 claws and remove the wire harness from the wire harness cover (see illustration (C)).

(6) Disconnect the clamp and connector, and remove the 2 bolts and No. 4 relay block (see illustration (D)).

(b) for LH Side:

(1) Remove the bolt and No. 2 ground cable (see illustration (E)).

(2) Remove the 3 bolts and ECM box cover.

(3) Using a screw driver, detach the 2 claws as shown in the illustration (F).

HINT
Tape the screwdriver tip before use.

(4) Disconnect the 2 connector holders and connectors (see illustration (F)).

(5) Disconnect the ECM's harness from the clamp (see illustration (F)).

(c) for Engine Bank 1 Side:

(1) Disconnect the clamp, and remove the bolt and ground cable (see illustration (G)).

(d) for Power Steering Link Side (for 2WD):

(1) Remove the bolt (A) and (B), and disconnect the ground cable.

(2) Disconnect the 2 connectors (C).

(3) Release the lock of connector (D), and then disconnect the connector.

(4) Detach the 2 clamps (E).

(e) for Power Steering Link side (for 4WD):

(1) Remove the bolt (A) and (B), and disconnect the ground cable.

(2) Disconnect the 2 connectors (C).

(3) Release the lock of connector (E), and then disconnect the connector.

(4) Detach the 2 clamps (F).

(5) Remove the bolt (G) and disconnect the wire harness bracket.

(f) for Automatic Transmission Side:

Remove the nut and disconnect the ground cable from the RH side.

33. REMOVE FRONT FLOOR COVER CENTER LH (for 4WD) Removal

34. REMOVE FRONT FLOOR BRACE CENTER Removal

35. REMOVE HEATED OXYGEN SENSOR

(a) Remove the sensor Removal.

36. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

37. REMOVE FRONT FLOOR NO. 1 HEAT INSULATOR Removal

38. REMOVE AIR GUIDE PLATE OUTSIDE RH Removal

39. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 2WD) Removal

40. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) Removal

41. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

42. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (for 2WD) Removal

43. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (for 2WD) Removal

44. REMOVE COOLER COMPRESSOR ASSEMBLY (for 2WD) Removal

45. REMOVE OIL FILTER BRACKET (for 4WD) Removal

46. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD) Removal

47. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE (for 4WD) Removal

48. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (for 4WD) Removal

49. REMOVE COOLER COMPRESSOR ASSEMBLY (for 4WD) Removal

50. REMOVE GENERATOR WITH CLUTCH PULLEY Removal

51. REMOVE FRONT WHEELS

52. REMOVE FRONT AXLE HUB NUT LH (for 4WD)

Using SST and hammer, release the staked part of the front axle hub nut.

SST : 09930-00010

53. REMOVE FRONT AXLE HUB NUT RH (for 4WD)

HINT
Perform the same procedure as for the LH side.

54. REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY (for 2WD)

(a) for Interior Side:

Fix the steering wheel in place with the seat belt in order to prevent rotation.

HINT
This operation helps prevent damage to the spiral cable.

(b) for Exterior Side:

Loosen the bolt (A) and remove the bolt (B).

(1) Put matchmarks on the steering sliding yoke and No. 2 steering intermediate shaft.

(2) Remove the sliding yoke from the No. 2 steering intermediate shaft.

55. REMOVE INSTRUMENT PANEL NO. 1 UNDER COVER SUB-ASSEMBLY (for 4WD) Removal

56. REMOVE NO. 1 AIR DUCT (for 4WD)

57. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)

(a) for Interior Side:

Fix the steering wheel in place with the seat belt in order to prevent rotation.

HINT
This operation helps prevent damage to the spiral cable.

Remove the bolt and steering column hole cover's clamp.

Put matchmarks on the No. 2 steering intermediate shaft and steering column.

(b) for Exterior Side:

Remove the bolt and slide the No. 2 steering intermediate shaft.

Put matchmarks on the No. 2 steering intermediate shaft and power steering link.

(1) Remove the No. 2 steering intermediate shaft.

58. SEPARATE HEIGHT CONTROL SENSOR LINK LH (for 2WD)

(a) Remove the nut and disconnect the height control sensor link.

59. SEPARATE HEIGHT CONTROL SENSOR LINK RH (for 2WD)

HINT
Perform the same procedure as for the LH side.

60. SEPARATE HEIGHT CONTROL SENSOR LINK LH (for 4WD)

Remove the bolt and disconnect the height control sensor link.

61. SEPARATE HEIGHT CONTROL SENSOR LINK RH (for 4WD)

HINT
Perform the same procedure as for the LH side.

62. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY (for 2WD)

Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.

NOTICE:
Do not remove the nut.

63. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT
Perform the same procedure as for the LH side.

64. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)

Remove the bolt, and separate the front shock absorber and bracket lower.

65. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT
Perform the same procedure as for the LH side.

66. SEPARATE FRONT SPEED SENSOR LH (for 4WD) Removal

67. SEPARATE FRONT SPEED SENSOR RH (for 4WD)

HINT
Perform the same procedure as for the LH side.

68. SEPARATE TIE ROD ASSEMBLY LH (for 2WD) Removal

69. SEPARATE TIE ROD ASSEMBLY RH (for 2WD)

HINT
Perform the same procedure as for the LH side.