Removal

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
HINT: Service Precautions.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
NOTE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE FRONT FENDER APRON SEAL RH
8. DRAIN ENGINE OIL Replacement
9. DRAIN ENGINE COOLANT Testing and Inspection
10. DRAIN AUTOMATIC TRANSAXLE FLUID Removal
11. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 7 clips and intake duct seal.
12. REMOVE ENGINE ROOM SIDE COVER LH
(a) Remove the hood hinge cover LH.

(b) Remove the 6 clips and engine room side cover LH.
13. REMOVE ENGINE ROOM SIDE COVER RH
(a) Remove the hood hinge cover RH.

(b) Remove the 5 clips and engine room side cover RH.
14. REMOVE V-BANK COVER SUB-ASSEMBLY

(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.

15. REMOVE V-RIBBED BELT Removal
16. REMOVE NO. 2 AIR CLEANER INLET

(a) Remove the 2 bolts, clamp and No. 2 air cleaner inlet.
17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal
18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the vacuum hose and hose clamp.
(b) Remove the 3 bolts and air cleaner case.
19. REMOVE NO. 1 AIR CLEANER INLET

(a) Remove the bolt and No. 1 air cleaner inlet.
20. REMOVE BATTERY

(a) Loosen the nut, and remove the bolt and battery clamp.
(b) Remove the battery and battery tray.
21. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY

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

(a) Remove the bolt, 2 nuts, and No. 2 engine mounting stay RH.
23. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Remove the 4 bolts and engine moving control rod.
24. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
25. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE

(a) Remove the clamp and disconnect the check valve to brake booster hose.
26. REMOVE RADIATOR HOSE INLET

(a) Remove the clamp and disconnect the radiator hose inlet.
27. REMOVE RADIATOR HOSE OUTLET

(a) Remove the clamp and disconnect the radiator hose outlet.
28. DISCONNECT NO. 1 OIL COOLER INLET HOSE

(a) Remove the clamp and disconnect the oil cooler inlet hose.
29. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE
(a) Remove the clamp and disconnect the oil cooler outlet hose.
30. DISCONNECT HEATER INLET WATER HOSE

(a) Disconnect the heater inlet water hose.
31. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose.
32. REMOVE ECM
HINT: Removal.

33. REMOVE RELAY BLOCK COVER UPPER
34. 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.
(3) Disconnect the engine wire connectors.

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

(a) Remove the clip and nut, and separate the cable from the transaxle.
36. SEPARATE FUEL TUBE SUB-ASSEMBLY

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

(b) Disconnect the connector from the tube 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.

37. DISCONNECT OIL RESERVOIR TO PUMP HOSE

(a) Disconnect the oil reservoir to pump hose.
38. DISCONNECT RETURN TUBE SUB-ASSEMBLY

(a) Disconnect the return tube sub-assembly.
39. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET Removal
40. REMOVE EXHAUST FRONT PIPE ASSEMBLY Removal
41. REMOVE FRONT AXLE HUB NUT LH Removal
42. REMOVE FRONT AXLE HUB NUT RH
HINT: Use the same procedure described for the LH side.

43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH Removal
44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

45. DISCONNECT FRONT SPEED SENSOR LH Removal
46. DISCONNECT FRONT SPEED SENSOR RH
HINT: Use the same procedure described for the LH side.

47. DISCONNECT TIE ROD ASSEMBLY LH Removal
48. DISCONNECT TIE ROD ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

49. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH Removal
50. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedure described for the LH side.

51. SEPARATE FRONT AXLE ASSEMBLY LH Removal
52. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

53. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Remove the 2 nuts and No. 1 exhaust pipe support bracket.
54. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Removal
55. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Removal
56. REMOVE GENERATOR ASSEMBLY Removal
57. SEPARATE COOLER COMPRESSOR ASSEMBLY
(a) Remove the 2 connector clamps.

(b) Remove the 4 bolts and separate the compressor.
HINT: Hang up the hoses instead of detaching them.

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

(b) Remove the 4 bolts, 2 nuts, and frame side rail plates RH and LH.
(c) Remove the 4 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.

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

(b) Remove pressure feed tube clamp bolt C.
(c) Loosen bolt A.
(d) Remove bolt B and the vane pump.
60. INSTALL ENGINE HANGER

(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.
61. REMOVE FRONT FRAME ASSEMBLY

(a) Disconnect the 2 connectors and 2 clamps.

(b) Disconnect the 2 clamps.

(d) Remove the 2 bolts and disconnect the engine mounting insulator FR and cable.
62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal
63. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal
64. REMOVE ENGINE WIRE
65. REMOVE STARTER ASSEMBLY Removal
66. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
HINT: Removal.

67. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Removal
68. SECURE ENGINE
(a) Secure the engine onto an engine stand with the bolts.
69. REMOVE INTAKE AIR SURGE TANK ASSEMBLY
HINT: Removal.

70. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 ignition coils.
71. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove the bolt and No. 2 engine mounting stay RH.
72. REMOVE INTAKE MANIFOLD

(a) Uniformly loosen and remove the 6 bolts and 4 nuts.
(b) Remove the intake manifold and 2 gaskets.
73. 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.
74. REMOVE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

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

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

(a) Remove the 3 bolts and No. 2 exhaust manifold heat insulator.
77. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

(a) Remove the 3 bolts and engine mounting bracket RH.
79. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.
80. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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

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

(a) Remove the bolt, 2 plates and No. 2 idler pulley sub-assembly.
HINT: Plate diameter:
Idler pulley cover plate: 33.6 mm (1.32 in.)
No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)

83. REMOVE WATER PUMP PULLEY Removal
84. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH

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

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

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

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
88. REMOVE KNOCK CONTROL SENSOR Removal
89. REMOVE ENGINE OIL LEVEL SENSOR

(a) Remove the 4 bolts, then remove the oil level sensor and gasket.
90. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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