Removal

4GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 11 clips and cool air intake duct seal.

2. REMOVE ENGINE ROOM SIDE COVER LH

(a) Remove the 4 clips, grommet and engine room side cover LH.

Text in Illustration

3. REMOVE ENGINE ROOM SIDE COVER

(a) Remove the clip, grommet and engine room side cover.

Text in Illustration

4. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Raise the V-bank cover sub-assembly to disengage the clip on the rear of the cover. Raise the V-bank cover sub-assembly 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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

6. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

8. 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.

9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

10. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission) Removal

11. REMOVE REAR CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) Removal

12. REMOVE FRONT CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) Removal

13. REMOVE FRONT ASH RECEPTACLE ASSEMBLY (for Manual Transmission) Removal

14. REMOVE CONSOLE BOX REGISTER ASSEMBLY (for Manual Transmission) Removal

15. REMOVE CONSOLE BOX (for Manual Transmission) Removal

16. REMOVE NO. 2 CONSOLE BOX DUCT (for Manual Transmission) Removal

17. REMOVE NO. 1 SHIFT AND SELECT LEVER BOOT (for Manual Transmission) Removal

18. REMOVE SHIFT LEVER CAP (for Manual Transmission) Removal

19. REMOVE FRONT WHEEL

20. REMOVE ENGINE UNDER COVER

21. REMOVE FRONT FLOOR COVER LH

(a) Remove the 12 grommets and front floor cover LH.

22. REMOVE FRONT FLOOR COVER RH

(a) Remove the 12 grommets and front floor cover RH.

23. REMOVE NO. 2 FLOOR UNDER COVER

(a) Remove the 4 clips and No. 2 floor under cover.

24. REMOVE NO. 1 FLOOR UNDER COVER

(a) Remove the 4 clips and No. 1 floor under cover.

25. REMOVE NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY LH

(a) Remove the 3 bolts and No. 1 body mounting bracket sub-assembly LH.

26. REMOVE NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY RH

(a) Remove the 3 bolts and No. 1 body mounting bracket sub-assembly RH.

27. REMOVE NO. 2 ENGINE UNDER COVER

(a) Remove the 4 screws and No. 2 engine under cover.

28. REMOVE REAR ENGINE UNDER COVER LH

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

29. REMOVE REAR ENGINE UNDER COVER RH

HINT
Perform the same procedure as for the LH side.

30. DRAIN ENGINE OIL Replacement

31. DRAIN ENGINE COOLANT Service and Repair

32. REMOVE REAR BODY SUPPORT BRACKET Removal

33. REMOVE FRONT CENTER FLOOR BRACE Removal

34. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

35. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Manual Transmission) Removal

36. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Automatic Transmission) Removal

37. REMOVE INLET NO. 1 AIR CLEANER

(a) Remove the bolt, clip and inlet No. 1 air cleaner.

38. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal

39. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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

40. DISCONNECT UNION TO CHECK VALVE HOSE

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

41. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

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

42. DISCONNECT NO. 1 RADIATOR HOSE

(a) Remove the clamp and disconnect the mo. 1 radiator hose.

43. DISCONNECT NO. 2 RADIATOR HOSE

(a) Remove the clamp and disconnect the No. 2 radiator hose.

44. DISCONNECT RADIATOR RESERVOIR TANK HOSE

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

45. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

46. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

47. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE Removal

48. REMOVE DISCHARGE HOSE SUB-ASSEMBLY Removal

49. REMOVE ECM COVER

(a) Remove the 3 bolts and engine room ECU cover.

50. DISCONNECT ENGINE WIRE

(a) Disconnect the 5 connectors.

(b) Disconnect the connector clamp.

(d) Disconnect the 4 ECM connectors.

(e) Remove the bolt and disconnect the ground cable.

(f) Remove the nut and disconnect the wire from the engine room No. 1 junction block.

(g) Remove the nut and disconnect the battery positive (+) cable.

(h) Disconnect the connector and 4 clamps from the body.

(i) Remove the bolt and disconnect the ground cable from the cylinder head cover sub-assembly LH.

(j) Remove the bolt, clamp and No. 3 engine wire.

51. DISCONNECT FUEL MAIN TUBE

(a) Observe the following precautions when disconnecting the fuel tube connector:

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

(2) Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.

(3) Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.

(4) Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean the dirt away if necessary.

(5) Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.

Text in Illustration

52. DISCONNECT NO. 3 FUEL HOSE

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

53. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR

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

54. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY Removal

55. DISCONNECT HEIGHT CONTROL SENSOR LINK (w/ HID Headlight System)

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

56. SEPARATE 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 LH.

NOTICE:
Support the steering knuckle using a rubber attachment or other similar object to prevent excessive force from being applied to the flexible hose.

57. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

58. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

(a) Remove the 2 bolts and separate the front lower ball joint assembly LH.

59. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

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

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

Text in Illustration

61. 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.

62. REMOVE FRONT NO. 6 FLOOR HEAT INSULATOR (for Manual Transmission) Removal

63. SEPARATE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transmission) Removal

64. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission) Removal

65. DISCONNECT GROUND CABLE (for Manual Transmission) Removal

66. DISCONNECT WIRE HARNESS (for Manual Transmission) Removal

67. REMOVE NO. 1 CLUTCH HOUSING COVER (for Manual Transmission) Removal

68. REMOVE NO. 2 CLUTCH HOUSING COVER (for Manual Transmission) Removal

69. SEPARATE CLUTCH COVER ASSEMBLY (for Manual Transmission) Removal

70. SEPARATE FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (for Manual Transmission) Removal

71. REMOVE FLOOR SHIFT LEVER ASSEMBLY (for Manual Transmission) Removal

72. SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for Automatic Transmission)

(a) Separate the floor shift gear shifting rod sub-assembly for A960E Removal.

73. SEPARATE WIRE HARNESS (for Automatic Transmission)

(a) Disconnect the park / neutral position switch connector, transmission wire connector and 2 transmission revolution sensor connectors.

Text in Illustration

HINT
Disengage the claw, press down the lever, and then disconnect the transmission wire connector.

(b) Remove the 2 bolts and separate the wire harness clamps from the automatic transmission assembly.

Text in Illustration

74. DISCONNECT WATER BY-PASS HOSE (for Automatic Transmission)

(a) Remove the bolt and water by-pass hose clamp.

Text in Illustration

(b) Disconnect the 2 water by-pass hoses from the transmission oil cooler.

NOTICE:
Use a container to catch any coolant which flows out of the water by-pass hoses.

75. REMOVE ENGINE AND TRANSMISSION ASSEMBLY

(a) Set the engine lifter.

(b) for Manual Transmission:

(1) Remove the 4 bolts, 4 nuts and rear engine mounting member.

Text in Illustration

(2) Remove the 4 bolts, 4 nuts and rear engine mounting member.

Text in Illustration

(d) Remove the 12 bolts and 2 nuts, then remove the engine and transmission assembly.

Text in Illustration

(e) 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.

(f) Install the No. 1 and No. 2 engine hangers with the 4 bolts.

Text in Illustration

Torque : 33 Nm (336 kgf-cm, 24 ft-lbf)

Part No.

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

76. 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.

(c) Remove the O-ring from the No. 2 engine oil level dipstick guide.

77. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Disconnect the clamp from the engine oil level dipstick guide.

(b) Remove the bolt and engine oil level dipstick guide.

(c) Remove the O-ring from the engine oil level dipstick guide.

78. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH

(a) Remove the 2 clips and engine under cover sub-assembly LH from the front suspension crossmember assembly.

79. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH

(a) Remove the 2 clips and engine under cover sub-assembly RH from the front suspension crossmember assembly.

80. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 6 nuts and exhaust manifold sub-assembly LH.

Text in Illustration

(c) Remove the exhaust manifold gasket LH.

81. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 6 nuts and exhaust manifold sub-assembly RH.

Text in Illustration

(c) Remove the exhaust manifold gasket.

82. REMOVE STARTER ASSEMBLY Removal

83. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission) Removal

84. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for Manual Transmission)

(a) Remove the 4 bolts and rear No. 1 engine mounting insulator from the manual transmission assembly.

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

85. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) Removal

86. REMOVE FLYWHEEL HOUSING SIDE COVER (for Automatic Transmission)

(a) Remove the flywheel housing side cover for A960E Removal.

87. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

(a) Remove the drive plate and torque converter clutch setting bolt for A960E Removal.

88. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

(a) Remove the automatic transmission assembly for A960E Removal.

89. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for Automatic Transmission)

(a) Remove the 4 bolts and rear No. 1 engine mounting insulator from the automatic transmission assembly.

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

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

91. SEPARATE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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

92. REMOVE FRONT ENGINE MOUNTING INSULATOR LH

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

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

93. REMOVE FRONT ENGINE MOUNTING INSULATOR RH

(a) Remove the nut and front engine mounting insulator RH.

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

94. INSTALL ENGINE ON ENGINE STAND

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