Removal

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

3. REMOVE COOL AIR INTAKE DUCT SEAL Removal

4. REMOVE BATTERY

(a) Loosen the nut, and disconnect the negative battery terminal.

CAUTION:
Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

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

(b) Remove the nut, and separate the positive battery terminal cable.

(c) Loosen the nut, and remove the bolt and battery clamp.

(d) Remove the battery and battery tray.

5. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

6. REMOVE FRONT WHEELS

7. REMOVE ENGINE UNDER COVER ASSEMBLY

(a) Remove the 2 bolts and engine under cover assembly RR.

(b) Remove the 2 bolts, 2 screws, 5 clips and engine under cover assembly.

8. REMOVE NO. 1 ENGINE UNDER COVER

(a) Remove the 6 bolts, 2 clips and No. 1 engine under cover.

9. REMOVE NO. 2 ENGINE UNDER COVER

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

10. REMOVE FLOOR UNDER COVER LH Removal

11. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY LH Removal

12. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY RH Removal

13. REMOVE FRONT FENDER LINER LH Removal

14. REMOVE FRONT FENDER LINER RH Removal

15. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 bolts, clip and front fender apron seal LH.

16. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 bolts, clip and front fender apron seal RH.

17. DRAIN ENGINE OIL Replacement

18. DRAIN ENGINE COOLANT Service and Repair

19. DRAIN AUTOMATIC TRANSAXLE FLUID Removal

20. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

21. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

22. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

23. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

24. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) Remove the 4 clips, and separate the engine wire.

(b) Remove the 8 bolts, 6 nuts and front outer cowl top panel sub-assembly.

25. 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 V-bank cover sub-assembly. Continue rising the V-bank cover sub-assembly to disengage the clip on the rear of the V-bank cover sub-assembly and remove the cover.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

26. REMOVE NO. 2 AIR CLEANER INLET Removal

27. REMOVE NO. 1 AIR CLEANER INLET Removal

28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

(a) Remove the air cleaner filter element sub-assembly.

30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal

31. REMOVE AIR CLEANER BRACKET

(a) Remove the 2 bolts and air cleaner bracket.

32. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

(a) Disconnect the level warning switch connector.

(b) Remove the bolt, and separate the brake master cylinder reservoir assembly.

33. REMOVE RESERVOIR BRACKET

(a) Remove the 2 bolts and reservoir bracket.

34. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

35. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the 3 bolts and engine moving control rod.

36. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Slide the clamp and disconnect the No. 1 fuel vapor feed hose.

37. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the clamp.

(b) Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 1 radiator hose from the water outlet.

38. DISCONNECT NO. 2 RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 2 radiator hose from the water inlet.

39. DISCONNECT HEATER WATER HOSE OUTLET B

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect heater water outlet hose B from the water inlet.

40. DISCONNECT HEATER WATER HOSE INLET B

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect heater water inlet hose B from the water outlet.

41. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

(b) Disconnect the fuel tube from the fuel pipe pinching part A with your fingers as shown in the illustration.

NOTICE:
* Check for dirt and foreign objects 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.

42. DISCONNECT OIL COOLER INLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the No. 2 oil cooler hose.

43. DISCONNECT OIL COOLER OUTLET HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler outlet hose.

44. 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.

(c) Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.

(d) Disconnect the transmission control cable assembly from the control cable clamp.

45. DISCONNECT ENGINE WIRE

(a) Disconnect the engine wire from the engine room relay block.

(1) Remove the No. 1 relay block cover.

(2) Remove the nut.

(3) Disconnect the engine wire connector from the engine room relay block.

(4) Unlock the engine wire. Pull the engine room wire.

(b) Disconnect the engine wire clamp.

(d) Disconnect the heated oxygen sensor connector and clamp.

(e) Remove the 2 bolts, clip and 2 ground cables.

(f) Disconnect the 3 ECM connectors, 2 junction block connectors and clamp.

(g) Remove the 2 nuts and clamp, and separate the engine wire from the body.

46. 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.

47. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD) Removal

48. REMOVE TAIL EXHAUST PIPE ASSEMBLY Removal

49. REMOVE CENTER EXHAUST PIPE ASSEMBLY Removal

50. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Removal

51. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

52. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH Removal

53. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

54. REMOVE FRONT AXLE HUB NUT LH Removal

55. REMOVE FRONT AXLE HUB NUT RH

HINT
Use the same procedure described for the LH side.

56. DISCONNECT FRONT SPEED SENSOR LH Removal

57. DISCONNECT FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

58. DISCONNECT TIE ROD ASSEMBLY LH Removal

59. DISCONNECT TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

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

61. SEPARATE NO. 1 FRONT SUSPENSION LOWER ARM RH

HINT
Use the same procedure described for the LH side.

62. SEPARATE FRONT AXLE ASSEMBLY LH Removal

63. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

64. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

65. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY Removal

66. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Removal

67. 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.

(d) Operate the engine lifter, then remove the engine assembly from the vehicle.

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

68. REMOVE V-RIBBED BELT Removal

69. REMOVE FRONT STABILIZER BAR (for 4WD)

HINT
Removal.

70. REMOVE POWER STEERING LINK ASSEMBLY (for 4WD) Removal

71. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

(a) Disengage the clamp.

(b) Disconnect the connector.

(c) Disengage each clamp.

(d) Remove the 4 bolts and the compressor and magnetic clutch.

72. REMOVE VENTILATION HOSE

(a) Using pliers, grip the claws of the 2 clips and slide the 2 clips to remove the ventilation hose.

73. 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 (*4).

(h) Remove the 2 nuts and intake air surge tank (*5).

(i) Remove the gasket from the intake air surge tank.

74. REMOVE ENGINE WIRE

(a) Disconnect the oil pressure switch cover and clamp.

(b) Disconnect the oil pressure switch assembly connector.

(d) Disconnect the generator assembly connector and clamp.

(e) Remove the nut and separate the engine wire from the generator assembly.

(f) Disconnect the purge VSV connector, air fuel ratio sensor connector and 2 clamps.

(g) Remove the bolt.

(h) Disconnect the engine coolant temperature sensor connector, knock control sensor wire connector and 2 clamps.

(i) Disconnect the air fuel ratio sensor connector and clamp.

(j) Remove the bolt and 2 nuts.

(k) Disconnect the 2 clamps, radio setting condenser connector, 3 ignition coil assembly connectors, 2 camshaft timing oil control valve assembly connectors, 2 VVT sensor connectors and 3 injector assembly connectors, and separate the engine wire from the cylinder head cover sub-assembly RH.

(l) Remove the 3 bolts.

(m) Disconnect the 2 clamps, radio setting condenser connector, 3 ignition coil assembly connectors, 2 camshaft timing oil control valve assembly connectors, 2 VVT sensor connectors and 3 injector assembly connectors, and separate the engine wire from the engine assembly.

75. REMOVE STARTER ASSEMBLY Removal

76. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET

(a) Remove the 3 bolts and transverse engine mounting bracket.

77. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut, and manifold stay.

78. 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.

79. REMOVE FRONT FRAME ASSEMBLY

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

(b) Loosen the 3 nuts.

(d) Remove the 9 nuts.

(e) Remove the 2 bolts and separate the engine with transaxle from the front frame assembly.

80. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

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

81. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Remove the nut and transverse engine mounting insulator.

82. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Remove the nut and transverse engine mounting insulator.

83. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

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

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

86. REMOVE TRANSFER STIFFENER PLATE RH (for 4WD)

87. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) Removal

88. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD)

89. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Removal

90. SECURE ENGINE

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

(b) Remove the engine hangers.

91. REMOVE TRANSVERSE ENGINE MOUNTING INSULATOR

(a) Remove the 2 hole plugs.

(b) Remove the 2 nuts and transverse engine mounting insulator.