Removal
1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair
2. DISCHARGE FUEL SYSTEM PRESSURE Removal
3. 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.
4. REMOVE HOOD SUB-ASSEMBLY
(a) Disconnect the washer nozzle hose.
Remove the 8 bolts and hood.
NOTICE:
If the hood support is detached from the ball joint, it become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.
5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
(a) Remove the cowl top ventilator louver Removal.
6. REMOVE FRONT BUMPER COVER LOWER
(a) Remove the clip, 5 bolts and front bumper cover lower.
7. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
(a) Remove the 4 bolts.
Unhook the engine under cover from the vehicle body as shown in the illustration.
8. REMOVE TRANSMISSION UNDER COVER
(a) Remove the 2 bolts and transmission under cover.
9. REMOVE REAR ENGINE UNDER COVER ASSEMBLY
(a) Remove the 4 bolts and rear engine under cover.
10. REMOVE FRONT FENDER APRON SEAL LH
(a) Remove the 5 clips and front fender apron seal.
11. REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the 5 clips and front fender apron seal.
12. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL LH
(a) Remove the 5 clips and No. 1 front fender apron to frame seal.
13. REMOVE NO. 1 FRONT FENDER APRON TO FRAME SEAL RH
(a) Remove the 5 clips and No. 1 front fender apron to frame seal.
14. REMOVE UPPER RADIATOR SUPPORT SEAL
(a) Remove the 13 clips and upper radiator support seal.
15. DRAIN ENGINE OIL Replacement
16. DRAIN ENGINE COOLANT Service and Repair
17. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL
18. REMOVE BATTERY HOLD DOWN CLAMP Removal
19. REMOVE BATTERY
20. REMOVE BATTERY TRAY
21. REMOVE V-BANK COVER Removal
22. REMOVE FRONT BUMPER COVER
(a) Remove the front bumper cover Removal.
23. REMOVE AIR CLEANER CAP AND HOSE Removal
24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a) Remove the air cleaner filter element.
Detach the wire harness clamp.
(b) Remove the 3 bolts and air cleaner case.
25. REMOVE UPPER FRONT BUMPER RETAINER Removal
26. REMOVE RADIATOR SIDE DEFLECTOR RH Removal
27. REMOVE RADIATOR SIDE DEFLECTOR LH Removal
28. REMOVE NO. 1 RADIATOR HOSE Removal
29. REMOVE NO. 2 RADIATOR HOSE Removal
30. REMOVE RADIATOR RESERVOIR Removal
31. DISCONNECT OIL COOLER TUBE Removal
32. REMOVE FAN SHROUD Removal
33. REMOVE RADIATOR ASSEMBLY Removal
34. REMOVE INTAKE AIR SURGE TANK Removal
35. REMOVE FAN AND GENERATOR V BELT Removal
36. DISCONNECT VANE PUMP ASSEMBLY Removal
37. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY Removal
38. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Removal
39. REMOVE COOLER COMPRESSOR ASSEMBLY Removal
40. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Remove the front exhaust pipe Removal.
41. REMOVE MANIFOLD STAY Removal
42. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal
43. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal
44. REMOVE NO. 2 MANIFOLD STAY Removal
45. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Removal
46. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Removal
47. REMOVE WIRING HARNESS CLAMP BRACKET Removal
48. REMOVE GENERATOR ASSEMBLY Removal
49. REMOVE STARTER COVER Removal
50. REMOVE STARTER ASSEMBLY Removal
51. REMOVE FLYWHEEL HOUSING SIDE COVER Removal
52. DISCONNECT ENGINE WIRE
Remove the bolt and disconnect the connector.
for 4WD:
Disconnect the connector and detach the clamp.
(a) Remove the lower instrument panel Removal.
(b) Disconnect the ECM connector.
Detach the clamp and disconnect the 6 connectors.
Detach the grommet from the wire harness support.
Detach 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.
53. DISCONNECT HEATER WATER HOSE ASSEMBLY
Disconnect the 2 hoses and heater water hose.
54. DISCONNECT NO. 1 AND NO. 2 FUEL PIPES
Remove the fuel pipe clamp from the fuel tube connector.
(a) Disconnect the No. 1 and No. 2 fuel pipes Service Precautions.
55. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) Removal
56. REMOVE PROPELLER SHAFT ASSEMBLY (for 2WD) Removal
57. REMOVE PROPELLER SHAFT ASSEMBLY (for 4WD) Removal
58. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(a) for 2WD:
Remove the automatic transmission from the vehicle .
(b) for 4WD:
Remove the automatic transmission from the vehicle Removal.
59. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for 2WD)
60. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for 4WD) Removal
61. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
Remove the bolt and disconnect the suction hose.
62. DISCONNECT OIL COOLER TUBE SUB-ASSEMBLY
(a) Remove the bolt and disconnect the oil cooler tube.
Text in Illustration
63. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft.
SST : 09213-54015
91651-60855
SST : 09330-00021
(a) Remove the 8 bolts, rear spacer, drive plate and front spacer.
64. REMOVE ENGINE ASSEMBLY
(a) Install 2 engine hangers with 4 bolts as shown in the illustration.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
Text in Illustration
HINT
(b) Attach an engine sling device and hang the engine with a chain block.
(c) Remove the 6 nuts from the front engine mounting insulator LH and RH.
(d) Lift the engine out of the vehicle carefully.
NOTICE:
Make sure the engine is clear of all wiring and hoses.
(e) Remove the front engine mounting insulator LH and RH.
(f) Place the engine onto a work bench.
65. INSTALL ENGINE STAND
(a) Install the engine onto an engine stand with bolts.