Removal

4GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: 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) Raise the V-bank cover to disengage the clip on the rear of the cover. Raise the cover again to disengage the 2 clips on the front 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.

5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

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 (for 2WD)

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

(a) Remove the bolt and engine under cover LH.

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

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. DRAIN FRONT DIFFERENTIAL OIL (for 4WD) Removal

17. REMOVE FRONT EXHAUST PIPE ASSEMBLY

HINT
Removal.

18. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

HINT
Removal.

19. REMOVE NO. 1 INLET AIR CLEANER

(a) Remove the bolt, clip and inlet air cleaner.

20. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Remove the 2 bolts, clamp and air cleaner case.

22. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Remove the clamp and disconnect the union to check valve hose.

23. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Remove the clamp and disconnect the No. 2 fuel vapor feed hose.

24. DISCONNECT INLET RADIATOR HOSE

(a) Remove the clamp and disconnect the inlet radiator hose.

25. DISCONNECT OUTLET RADIATOR HOSE

(a) Remove the clamp and disconnect the outlet radiator hose.

26. DISCONNECT RADIATOR RESERVOIR TANK HOSE

(a) Remove the clamp and disconnect the radiator reservoir tank hose.

27. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

28. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

29. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE Removal

30. REMOVE DISCHARGE HOSE SUB-ASSEMBLY Removal

31. REMOVE ECM COVER Removal

32. 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.

33. DISCONNECT FUEL MAIN TUBE

HINT
Service Precautions.

34. DISCONNECT NO. 3 FUEL HOSE

(a) Remove the clamp and disconnect the No. 3 fuel hose.

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

(a) Remove the 4 bolts and suspension member protector.

36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD) Removal

37. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) Removal

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

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

HINT
Remove the RH side following the same procedures as with the LH side.

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

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

HINT
Remove the RH side following the same procedures as with the LH side.

42. REMOVE TIE ROD ASSEMBLY LH (for 4WD) Removal

43. REMOVE TIE ROD ASSEMBLY RH (for 4WD)

HINT
Remove the RH side following the same procedures as with the LH side.

44. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 2WD)

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

45. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 4WD)

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

46. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)

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

47. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT
Remove the RH side following the same procedures as for the LH side.

48. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)

(a) Loosen the bolt and separate the lower part of the front shock absorber from the front absorber bracket lower.

49. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT
Remove the RH side following the same procedures as for the LH side.

50. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)

(a) Remove the 2 bolts from the front lower ball joint.

51. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)

HINT
Remove the RH side following the same procedures as for the LH side.

52. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)

(a) Remove the 2 bolts from the front lower ball joint.

53. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)

HINT
Remove the RH side following the same procedures as for the LH side.

54. SEPARATE FRONT AXLE ASSEMBLY LH (for 4WD) Removal

55. SEPARATE FRONT AXLE ASSEMBLY RH (for 4WD)

HINT
Remove the RH side following the same procedures as with the LH side.

56. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission)

(a) Remove the 2 bolts and exhaust pipe No. 1 support bracket sub-assembly.

57. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 2WD)

(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.

58. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 4WD)

(a) Remove the bolt (A) and the power steering earth wire from the power steering link assembly.

(b) Remove the bolt (B) to disconnect the earth wire from the bracket.

(c) Remove the 2 clamps to disconnect the wire harness from the front frame.

(d) Disconnect the 2 connectors (C) and (D) from the power steering link assembly.

(e) Release the lock of connector (E) and disconnect the connector from the power steering link assembly.

(f) Remove the bolt (F) to disconnect the bracket from the front frame.

59. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)

60. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD) Removal

61. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)

(a) Set the engine lifter.

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

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

NOTICE:
Make sure that the engine is clear of all wiring and hoses.

62. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 4WD)

(a) Set the engine lifter.

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

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

NOTICE:
Make sure that the engine is clear of all wiring and hoses.

63. 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)

Part No.:

(b) Attach an engine sling device and hang the engine with a chain block.

64. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) Removal

65. REMOVE STARTER ASSEMBLY Removal

66. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

HINT
.

67. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

HINT
* A960E .
* A760H Removal.

68. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD)

(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.

69. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD)

(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, then remove the No. 1 oil dipstick guide.

(e) Remove the O-ring from the No. 1 oil dipstick guide.

70. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 6 nuts, exhaust manifold and gasket.

71. 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.

72. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 6 nuts, exhaust manifold and gasket.

73. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

(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.

74. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD) Removal

75. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Removal

76. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

(a) Using SST, hold the crankshaft.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Remove the 8 bolts and the flywheel.

77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

(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.

78. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)

(a) Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.

79. REMOVE FRONT FRAME ASSEMBLY (for 4WD)

(a) Remove the 2 bolts, then separate the front frame assembly from the engine.

80. FIX ENGINE ON ENGINE STAND

(a) Fix the engine onto a engine stand with the bolts.

81. REMOVE V-RIBBED BELT Removal

82. REMOVE NO. 2 ENGINE COVER

(a) Remove the 3 clips and clamp, then remove the No. 2 engine cover.

83. REMOVE NO. 1 ENGINE COVER

(a) Remove the 3 clips, then remove the No. 1 engine cover.

84. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the bolt, plate and idler pulley.

85. REMOVE GENERATOR ASSEMBLY Removal

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

87. REMOVE OIL FILTER BRACKET (for 4WD) Disassembly

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

89. REMOVE ENGINE MOUNTING BRACKET LH

(a) Disconnect the 2 clamps.

(b) Remove the 4 bolts and mounting bracket.

90. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 4 bolts and mounting bracket.

91. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly. (2WD)

(b) Remove the 4 bolts, then remove the V-ribbed belt tensioner assembly. (4WD)

92. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD) Removal

93. REMOVE WATER PUMP PULLEY Removal

94. REMOVE ENGINE WIRE

(a) Remove the engine wire from the engine.

95. REMOVE INJECTOR DRIVER

(a) Remove the bolt, 2 nuts and injector driver.

96. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

HINT
Removal.

97. 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.

98. REMOVE NO. 2 SURGE TANK STAY

(a) Remove the bolt and No. 2 surge tank stay.

99. REMOVE WATER HOSE JOINT

(a) Remove the bolt, and disconnect 2 hoses and water hose joint.

100. REMOVE INTAKE MANIFOLD Removal

101. INSPECT INTAKE MANIFOLD

(a) Surge tank side:

(1) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

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 surface contacting the cylinder head for warpage.

Maximum warpage:

0.1 mm (0.003 in.)

If the warpage is greater than the maximum, replace the intake manifold.

102. REMOVE FUEL PUMP

HINT
Removal.

103. REMOVE FUEL INJECTOR ASSEMBLY

HINT
Removal.

104. REMOVE KNOCK SENSOR Removal

105. REMOVE WIRING HARNESS CLAMP BRACKET

(a) Remove the bolt and wiring harness clamp bracket.

106. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY

(a) Remove the bolt and V-bank cover bracket.

107. REMOVE IGNITION COIL ASSEMBLY

(a) Remove the 6 bolts and 6 ignition coils.

108. REMOVE ENGINE OIL LEVEL SENSOR

(a) Remove the 4 bolts, then remove the oil level sensor and gasket.

109. REMOVE OIL PRESSURE SWITCH ASSEMBLY

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

110. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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