Removal

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal

2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

3. REMOVE BATTERY

(a) Disconnect the negative battery terminal.
(b) Disconnect the positive battery terminal.
(c) Loosen the nut, and remove the bolt and battery clamp.
(d) Remove the battery and battery tray.
4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
5. REMOVE FRONT WHEELS
6. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

(a) Remove the 8 bolts, 4 clips and No. 1 engine under cover assembly.
7. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 bolts, clip and front fender apron seal RH.
8. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 bolts, clip and front fender apron seal LH.
9. DRAIN ENGINE OIL Replacement

10. DRAIN ENGINE COOLANT Service and Repair

11. DRAIN AUTOMATIC TRANSAXLE FLUID

12. REMOVE FRONT WIPER ARM HEAD CAP

13. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

14. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

16. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

17. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER

(a) Remove the 2 bolts, 2 clips and No. 1 cowl top to cowl brace inner.
18. REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Remove the nut, and separate the fuel pump resistor.

(b) Remove the 2 clips, and separate the engine wire.

(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.

20. REMOVE NO. 2 AIR CLEANER INLET

(a) Disconnect the vacuum switching valve clamp.
(b) Disconnect the 2 vacuum hoses.
(c) Remove the 2 bolts and No. 2 air cleaner inlet.
21. REMOVE NO. 1 AIR CLEANER INLET

(a) Remove the bolt and No. 1 air cleaner inlet.
22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the vacuum switching valve connector.
(b) Disconnect the vacuum hose.
(c) Remove the 3 bolts and air cleaner case.
25. REMOVE AIR CLEANER BRACKET

(a) Remove the 2 bolts and air cleaner bracket.
26. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY

(a) Remove the clip, bolt and intake air resonator.
27. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove bolt, 2 nuts and No. 2 engine mounting stay RH.
28. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the 3 bolts and engine moving control rod.
29. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
30. DISCONNECT RADIATOR INLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect radiator inlet hose from the water outlet.
31. DISCONNECT RADIATOR OUTLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the radiator outlet hose from the water inlet.
32. DISCONNECT HEATER WATER OUTLET HOSE B

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect heater water inlet hose B from the water inlet.
33. DISCONNECT HEATER WATER INLET HOSE B

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect heater water outlet hose B from the water outlet.
34. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

(b) Disconnect the fuel tube from the fuel pipe while pinching part A with your fingers as shown in the illustration.
- Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
- Disconnect the connector by hand.
- Do not bend, fold or rotate the nylon tube.
- If the pipe and connector are stuck together, push and pull the connector until it becomes free.
- Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

35. DISCONNECT NO. 1 OIL COOLER INLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 1 oil cooler inlet hose from the No. 1 oil cooler inlet tube.
36. REMOVE NO. 1 OIL COOLER OUTLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 1 oil cooler outlet hose from the No. 1 oil cooler outlet tube.
37. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut from the control shaft lever.
(b) Disconnect the transmission control cable assembly from the control shaft lever.

(d) Disconnect the control cable from the control cable clamp.
38. DISCONNECT RETURN TUBE SUB-ASSEMBLY

(a) Using pliers, grip the claws of the 2 clips and slide the 2 clips to disconnect the 2 return tube sub-assemblies.
(b) Drain the power steering fluid.
NOTE: Take care not to damage the hose protector.

39. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 1 oil reservoir to pump hose from the oil reservoir tank.
40. DISCONNECT ENGINE WIRE

(a) Disconnect the engine wire from the engine room junction block.
(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, unlock the engine room junction block. Pull the engine room junction block upward.

(b) Remove the bolt and 2 clamps from the body.

(c) Remove the 2 bolts and 2 ground cables.
(d) Disconnect the engine wire from the ECM and passenger side junction block.
41. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the union to check valve hose.
42. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Remove the center exhaust pipe assembly Removal.
43. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 4WD)
(a) Remove the front exhaust pipe assembly Removal.
44. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2WD)
(a) Remove the front exhaust pipe assembly Removal.
45. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Removal

46. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH Removal

47. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

48. REMOVE FRONT AXLE HUB NUT LH Removal

49. REMOVE FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

50. DISCONNECT FRONT SPEED SENSOR LH Removal

51. DISCONNECT FRONT SPEED SENSOR RH
HINT: Use the same procedures described for the LH side.

52. DISCONNECT TIE ROD ASSEMBLY LH Removal

53. DISCONNECT TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

54. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM LH Removal

55. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.

56. SEPARATE FRONT AXLE ASSEMBLY LH Removal

57. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

58. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
59. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

60. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

61. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.

(b) Remove the 6 bolts, 2 nuts, and frame side rail plates RH and LH.

(c) Remove the 6 bolts, 2 nuts, and front suspension member brace rear RH and LH.
(d) Operate the engine lifter, then remove the engine assembly from the vehicle.
NOTE: Make sure that the engine is clear of all wiring and hoses.

62. REMOVE V-RIBBED BELT Removal

63. REMOVE VANE PUMP ASSEMBLY
(a) Disconnect the power steering oil pressure switch connector.

(b) Remove the 2 nuts.

(c) Loosen the bolt A.
(d) Remove the bolt B.
(e) Remove the bolt A and vane pump assembly.
64. REMOVE FRONT STABILIZER BAR (for 4WD)

65. REMOVE POWER STEERING LINK
(a) Remove the 2 bolts and power steering link with vane pump.
66. INSTALL ENGINE HANGERS

(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part No.:
No. 1 Engine hanger 12281-31120
No. 2 Engine hanger 12282-31100
Bolts 91671-10825
Torque: 33 Nm (337 kgf-cm, 24 ft-lbf)
(b) Attach the engine sling device and hang the engine with the chain block.
67. REMOVE FRONT FRAME ASSEMBLY

(a) Disconnect the active mount VSV connector and harness clamp.

(b) Remove the 2 nuts and disconnect the engine mounting insulators RH and LH.

(d) Remove the 2 bolts and separate the engine mounting insulator RR (for 4WD).
68. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

69. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Removal

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

71. REMOVE ENGINE WIRE
72. REMOVE STARTER ASSEMBLY

73. REMOVE ENGINE FRONT MOUNTING BRACKET

74. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut, and manifold stay.
75. REMOVE TRANSFER STIFFENER PLATE RH Removal

76. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) .

77. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD) Removal
78. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Removal

79. SECURE ENGINE
(a) Secure the engine onto an engine stand with the bolts.

(b) Remove the engine hangers.
80. REMOVE VENTILATION HOSE

(a) Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the ventilation hose.
81. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Disconnect the 2 water by-pass hoses from the throttle with motor body assembly (*1).
(b) Disconnect the vapor feed hose (*2).
(c) Disconnect the throttle with motor body assembly connector and clamp (*3).
(d) Disconnect the No. 1 ventilation hose.

(e) Disconnect the connector.
(f) Remove the 4 bolts, No. 1 surge tank stay and throttle body bracket.

(g) Using a 5 mm socket hexagon wrench, remove the 4 bolts.
(h) Remove the 2 nuts and intake air surge tank (*4).
(i) Remove the gasket from the intake air surge tank (*5).
82. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 ignition coils.
83. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the bolt and No. 2 engine mounting stay RH.
84. REMOVE INTAKE MANIFOLD

(a) Uniformly loosen and remove the 6 bolts and 4 nuts.
(b) Remove the intake manifold and 2 gaskets.
85. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the A/F sensor connector clamp.

(b) Uniformly loosen and remove the 6 nuts.
(c) Remove the manifold and gasket.
86. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY

(a) Remove the oil level gauge.
(b) Remove the 2 bolts, No. 1 and No. 2 oil level gauge guides.
(c) Remove the O-rings from the oil level gauge guide.
87. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and No. 2 manifold stay.
88. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 3 bolts and No. 2 insulator.
89. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Uniformly loosen and remove the 6 nuts.
(b) Remove the manifold and gasket.
90. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the engine mounting bracket and 3 bolts.
91. REMOVE DRIVE SHAFT BEARING BRACKET (for 2WD)

(a) Remove the 3 bolts and drive shaft bearing bracket.
92. REMOVE ENGINE MOUNTING BRACKET RR (for 4WD)

(a) Remove the 3 bolts and engine mounting bracket RR.
93. REMOVE GENERATOR ASSEMBLY

94. REMOVE COOLER COMPRESSOR ASSEMBLY
95. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts and V-ribbed belt tensioner assembly.
96. REMOVE NO. 2 TIMING GEAR COVER

(a) Remove the 2 bolts and No. 2 timing gear cover.
97. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Remove the bolt, plate and No. 2 idler pulley sub-assembly.
98. REMOVE WATER PUMP PULLEY Removal

99. REMOVE NO. 1 ENGINE FRONT MOUNTING BRACKET LH

(a) Remove the 6 bolts and No. 1 engine front mounting bracket LH.
100. REMOVE RADIO SETTING CONDENSER

(a) Remove the 2 bolts and 2 radio setting condensers.
101. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

(a) Remove the bolt and No. 1 vacuum switching valve.
102. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
103. REMOVE KNOCK CONTROL SENSOR Removal

104. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket.