Removal

1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

(a) Remove the 4 bolts.

(b) Unhook the engine under cover from the frame as shown in the illustration.

Text in Illustration

4. REMOVE REAR ENGINE UNDER COVER ASSEMBLY

(a) Remove the 4 bolts and rear engine under cover.

5. DRAIN ENGINE COOLANT Service and Repair

6. DRAIN ENGINE OIL Replacement

7. REMOVE HOOD SUPPORT Removal

8. REMOVE HOOD SUB-ASSEMBLY

(a) Disconnect the windshield washer hose.

(b) Remove the 4 bolts, then remove the hood.

9. REMOVE RADIATOR ASSEMBLY

(a) Remove the radiator assembly Removal.

10. REMOVE V-BANK COVER Removal

11. REMOVE AIR CLEANER CAP AND HOSE Removal

12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

13. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal

14. REMOVE INTAKE AIR SURGE TANK Removal

15. REMOVE GENERATOR ASSEMBLY

(a) Remove the generator assembly Removal.

16. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY

(a) Remove the exhaust manifold sub-assembly Removal.

17. REMOVE STARTER ASSEMBLY

(a) Remove the starter assembly Removal.

18. SEPARATE COOLER COMPRESSOR ASSEMBLY

HINT
It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

(a) Disconnect the cooler compressor connector.

(b) Remove the bolt and separate the suction hose.

(d) Using a E8 "TORX" socket wrench, remove the stud bolt and separate the cooler compressor assembly.

19. SEPARATE VANE PUMP ASSEMBLY

(a) Disconnect the 2 clamps and vane pump connector.

(b) Remove the 2 bolts and separate the vane pump.

20. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

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

(b) Disconnect the No. 1 fuel pipe Service Precautions.

21. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY

(a) Remove the No. 2 fuel pipe clamp.

(b) Disconnect the No. 2 fuel pipe Service Precautions.

22. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

23. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

24. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

(a) Remove the manual transmission unit assembly Removal.

25. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

(a) Remove the automatic transmission assembly Removal or ).

26. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission) Removal

27. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission) Removal

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

(a) Using SST, hold the crankshaft.

SST : 09213-54015

91651-60855

SST : 09330-00021

(b) Remove the 8 bolts and flywheel.

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

(a) Using SST, hold the crankshaft.

SST : 09213-54015

91651-60855

SST : 09330-00021

(b) Remove the 8 bolts, rear drive plate spacer, drive plate and ring gear and front drive plate spacer.

30. DISCONNECT ENGINE WIRE (for 2WD)

(a) Remove the glove compartment door Removal.

(b) Disconnect the 6 connectors from the ECM.

(c) Disconnect the 3 connectors and the clamp from the air conditioning unit.

(d) Disengage the grommet from the wire harness support.

(e) Disengage the 4 claws to remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

(f) Disconnect the connector.

(g) Remove the bolt and separate the ground wire from the body.

31. DISCONNECT ENGINE WIRE (for 4WD)

(a) Remove the glove compartment door Removal.

(b) Disconnect the connector from the four wheel drive control ECU.

(c) Disconnect the 6 connectors from the ECM.

(d) Disconnect the 3 connectors and the clamp from the air conditioning unit.

(e) Disengage the grommet from the wire harness support.

(f) Disengage the 4 claws to remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

(g) Disconnect the connector.

(h) Remove the bolt and separate the ground wire from the body.

32. DISCONNECT ENGINE WIRE (for Automatic Transmission 4WD)

(a) Disconnect the front differential connector and clamp.

(b) Disconnect the harness clamp.

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

(b) Remove the bolt and separate the fuel pipe clamp.

Text in Illustration

HINT

Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

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

(e) Remove the 6 nuts and 4 bolts from the 2 front engine mounting insulators.

(f) Lift the engine out of the vehicle carefully.

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

(g) Remove the 2 front engine mounting insulators.

(h) Place the engine onto a work bench.

34. REMOVE ENGINE WIRE

(a) Remove the bolt and separate the ground wire from the bank 1 cylinder head cover.

(b) Remove the 2 bolts and separate the ground wire from the bank 1 camshaft housing.