Removal

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

2. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

4. 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.

5. REMOVE FRONT WHEEL

6. REMOVE NO. 1 ENGINE UNDER COVER

7. REMOVE NO. 2 ENGINE UNDER COVER

8. SEPARATE FRONT FENDER LINER RH

9. REMOVE FRONT FENDER APRON RH

10. REMOVE FRONT FENDER APRON LH

11. REMOVE NO. 3 ENGINE UNDER COVER

12. DRAIN ENGINE OIL Replacement

13. DRAIN ENGINE COOLANT Service and Repair

14. DRAIN TRANSFER OIL (for AWD) Replacement

15. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD)

16. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) Replacement

17. REMOVE OUTER COWL TOP PANEL

HINT
Removal.

18. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 12 clips and cool air intake duct seal.

19. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Hold the front of the V-bank cover sub-assembly 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 V-bank cover sub-assembly.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.

20. REMOVE INLET NO. 2 AIR CLEANER

(a) Disconnect the wire harness clamp and vacuum hose clamp.

(b) Remove the 2 bolts and inlet No. 2 air cleaner.

21. REMOVE AIR CLEANER CAP WITH HOSE Removal

22. REMOVE AIR CLEANER CASE

(a) Remove the air cleaner filter element.

(b) Disconnect the hose and hose clamp.

(c) Remove the 3 bolts and air cleaner case.

23. REMOVE BATTERY

(a) Loosen the nut and separate the positive (+) battery terminal cable.

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

(c) Remove the battery, battery insulator and battery tray.

24. REMOVE INLET NO. 1 AIR CLEANER

(a) Disconnect the hose clamp.

(b) Remove the 2 bolts and inlet No. 1 air cleaner.

25. DISCONNECT INLET NO. 1 OIL COOLER HOSE

(a) Disconnect the oil inlet cooler hose from the radiator assembly.

26. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE

(a) Disconnect the outlet oil cooler hose from the radiator assembly.

27. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the clamp.

(b) Disconnect the No. 1 radiator hose.

28. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disconnect the No. 2 radiator hose.

29. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

30. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

31. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Disconnect the No. 1 fuel vapor feed hose.

32. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE

(a) Disconnect the union to check valve hose.

33. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the clip and nut, and separate the transmission control cable assembly from the transaxle.

34. DISCONNECT ENGINE WIRE

(a) Remove the engine room relay block cover.

(b) Disconnect the 2 connectors.

(c) Remove the nut.

(d) Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

(e) Disconnect the 2 clamps, remove the 2 bolts and disconnect the engine wire.

(f) Disconnect the clamp, remove the bolt and disconnect the engine wire.

(g) Pull up the lever to disconnect the ECM connector.

(h) Disconnect the engine wire from the positive (+) battery terminal assembly.

35. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

36. REMOVE ENGINE MOVING CONTROL ROD

(a) Loosen the bolt A.

(b) Remove the bolts except A and engine moving control rod with the engine moving control rod bracket.

(c) Remove the bolt A and engine moving control rod from the engine moving control rod bracket.

37. DISCONNECT COOLER REFRIGERANT DISCHARGE HOSE Removal

38. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Removal

39. DISCONNECT FUEL MAIN TUBE

(a) Disengage the claw and open the No. 1 EFI fuel pipe clamp cover.

(b) Pinch the fuel tube connector and then pull out the fuel main tube.

NOTICE:
* Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
* Do not use any tools to separate the pipe and connector.
* Do not forcefully bend or twist the nylon tube.
* Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
* Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
* If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.
40. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Removal

41. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

42. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) Removal

43. SECURE STEERING WHEEL Removal

44. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

45. REMOVE FRONT AXLE SHAFT NUT LH Removal

46. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

47. SEPARATE FRONT SPEED SENSOR LH Removal

48. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

49. SEPARATE TIE ROD ASSEMBLY LH Removal

50. SEPARATE TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

51. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

52. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

53. SEPARATE FRONT LOWER SUSPENSION ARM LH Removal

54. SEPARATE FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

55. REMOVE FRONT AXLE ASSEMBLY LH Removal

56. REMOVE FRONT AXLE ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

57. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

58. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Disassembly

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

60. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) Removal

61. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Remove the nut and No. 1 exhaust pipe support bracket.

62. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the 2 bolts and flywheel housing under cover.

63. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Remove the 6 drive plate and torque converter clutch setting bolts.

HINT
There will be one black colored bolt.

64. REMOVE FRONT FLOOR BRACE

(a) Remove the 4 nuts and front floor brace.

65. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
* Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
* Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed or removed from an engine stand.
(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.

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

(e) Install the No. 1 and No. 2 engine hangers with the 4 bolts.

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

Part No.:

(f) Attach the sling device to the engine hangers and chain block.

66. REMOVE NO. 1 FRONT STABILIZER BRACKET LH (for AWD) Removal

67. REMOVE NO. 1 FRONT STABILIZER BRACKET RH (for AWD)

HINT
Perform the same procedure as for the LH side.

68. REMOVE FRONT STABILIZER BAR (for AWD)

69. REMOVE STEERING LINK ASSEMBLY (for AWD) Removal

70. DISCONNECT FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Disconnect the 2 clamps with the engine wire.

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

(d) Remove the bolt and disconnect the front engine mounting insulator.

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

71. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Remove the 3 hole plugs.

(b) Remove the 3 nuts and front engine mounting insulator.

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

72. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the 3 hole plugs.

(b) Remove the 3 nuts and engine mounting insulator LH.

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

73. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Remove the 3 hole plugs.

(b) Remove the 3 nuts and engine mounting insulator RH.

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

74. REMOVE REAR ENGINE MOUNTING INSULATOR

(a) Remove the 2 hole plugs.

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

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

75. REMOVE V-RIBBED BELT Removal

76. REMOVE GENERATOR ASSEMBLY Removal

77. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Removal

78. REMOVE STARTER ASSEMBLY Removal

79. REMOVE ENGINE WIRE

80. REMOVE MANIFOLD STAY

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

81. REMOVE TRANSFER STIFFENER PLATE RH (for AWD)

(a) Remove the 4 bolts and transfer stiffener plate RH.

82. REMOVE FLEXIBLE HOSE BRACKET SUB-ASSEMBLY

83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)

84. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) Removal

85. REMOVE ENGINE MOUNTING BRACKET RH

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

86. REMOVE REAR ENGINE MOUNTING BRACKET (for 2WD)

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

87. REMOVE REAR ENGINE MOUNTING BRACKET (for AWD)

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

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