Removal (from 12/2010)

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Fuel System: Precaution (from 12/2010)

2. REMOVE FRONT WHEELS

3. REMOVE ENGINE UNDER COVER RH

4. REMOVE ENGINE UNDER COVER LH

5. REMOVE FRONT FENDER APRON SEAL RH

6. DRAIN ENGINE OIL

7. DRAIN ENGINE COOLANT Service and Repair

8. DRAIN AUTOMATIC TRANSAXLE FLUID Removal (from 12/2010)

9. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH Removal

10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH Removal

11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

13. REMOVE COWL TOP PANEL OUTER Removal (from 12/2010)

14. REMOVE BATTERY

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

15. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 6 clips and intake duct seal.

16. REMOVE V-BANK COVER SUB-ASSEMBLY Removal (from 12/2010)

17. REMOVE V-RIBBED BELT Removal (from 12/2010)

18. REMOVE RADIATOR RESERVE TANK ASSEMBLY

19. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

20. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the 4 bolts and engine moving control rod.

21. REMOVE NO. 2 AIR CLEANER INLET

(a) Disconnect the clamp and 2 vacuum hoses.

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

22. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE Removal (from 12/2010)

23. REMOVE AIR CLEANER CASE

(a) Remove the air cleaner filter element from the air cleaner case.

(b) Disconnect the connector, vacuum hose, and hose clamp.

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

24. REMOVE NO. 1 AIR CLEANER INLET

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

25. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY

(a) Disconnect the wire harness clamp.

(b) Remove the clip, bolt and intake air resonator.

26. REMOVE NO. 1 FUEL VAPOR FEED HOSE

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

27. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Removal (from 12/2010)

28. SEPARATE FUEL TUBE SUB-ASSEMBLY

(a) Release the claw and remove the No. 1 fuel pipe clamp.

(b) Disconnect the connector from the tube while pinching parts A with your fingers as shown in the illustration.

NOTICE:
* 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, kink or twist the nylon tube.
* If the pipe and connector are stuck together, push and pull on the connector to release them.
* Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

29. REMOVE RADIATOR HOSE INLET

(a) Remove the clamp and disconnect the radiator hose inlet.

30. REMOVE RADIATOR HOSE OUTLET

(a) Remove the clamp and disconnect the radiator hose outlet.

31. DISCONNECT NO. 1 OIL COOLER INLET HOSE Removal

32. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE Removal

33. DISCONNECT HEATER WATER HOSE INLET A

(a) Disconnect the heater water hose inlet.

34. DISCONNECT HEATER WATER OUTLET HOSE A

(a) Disconnect the heater water outlet hose.

35. REMOVE ECM Removal (from 12/2010)

36. REMOVE STARTER ASSEMBLY Removal (from 12/2010)

37. REMOVE UPPER RELAY BLOCK COVER

38. 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, release the engine room junction block. Pull the engine room junction block upward.

(3) Disconnect the 2 engine wire connectors.

(b) Disconnect the engine wire connector and 3 clamps.

(c) Remove the 2 bolts and disconnect the 2 ground cables.

(d) Remove the bolt and disconnect the ground cable from the wire bracket.

(e) Disconnect the engine wire clamp.

(f) Remove the 2 bolts and ground cable from the cylinder head.

39. SEPARATE WIRE HARNESS Removal (from 12/2010)

40. DISCONNECT CONNECTOR Removal (from 12/2010)

41. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Removal (from 12/2010)

42. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Disconnect the No. 1 oil reservoir to pump hose.

43. DISCONNECT STEERING GEAR OUTLET RETURN TUBE

(a) Disconnect the steering gear outlet return tube.

44. REMOVE FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET Removal

45. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

46. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

47. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedures described for the LH side.

48. REMOVE FRONT AXLE SHAFT LH NUT Removal

49. REMOVE FRONT AXLE SHAFT RH NUT

HINT
Use the same procedures described for the LH side.

50. SEPARATE FRONT SPEED SENSOR LH Removal

51. SEPARATE FRONT SPEED SENSOR RH

HINT
Use the same procedures described for the LH side.

52. SEPARATE TIE ROD ASSEMBLY LH Removal

53. SEPARATE TIE ROD ASSEMBLY RH

HINT
Use the same procedures described for the LH side.

54. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Removal

55. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Use the same procedures described for the LH side.

56. SEPARATE FRONT AXLE ASSEMBLY LH Removal

57. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
Use the same procedures described for the LH side.

58. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

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

59. REMOVE FLYWHEEL HOUSING UNDER COVER Removal (from 12/2010)

60. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Removal (from 12/2010)

61. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

62. REMOVE GENERATOR ASSEMBLY Removal (from 12/2010)

63. SEPARATE COOLER COMPRESSOR ASSEMBLY

(a) Remove the 2 connector clamps.

(b) Remove the 4 bolts and separate the compressor.

HINT
Hang up the compressor and hoses instead of detaching them.

64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

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

(c) Remove the 4 bolts, 2 nuts, front suspension member brace rears RH and LH.

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

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

(e) 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 90119-A0117

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

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

65. REMOVE VANE PUMP ASSEMBLY

(a) Remove the pressure feed tube clamp bolt.

(b) Remove the 2 bolts and vane pump.

66. REMOVE FRONT FRAME ASSEMBLY

(a) Disconnect the connector and clamp.

(b) Disengage the 2 clamps.

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

67. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

68. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

69. REMOVE ENGINE WIRE

70. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Removal (from 12/2010)

71. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Removal (from 12/2010)

72. INSTALL ENGINE STAND

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

73. REMOVE IGNITION COIL ASSEMBLY

(a) Remove the 6 bolts and 6 ignition coils.

74. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

75. REMOVE INTAKE MANIFOLD

(a) Uniformly loosen and remove the 6 bolts and 4 nuts.

(b) Remove the intake manifold and 2 gaskets.

76. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Uniformly loosen and remove the 6 nuts.

(b) Remove the manifold and gasket.

77. REMOVE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

(a) Remove the oil level dipstick.

(b) Remove the 2 bolts, No. 1 oil level dipstick guide and No. 2 oil level dipstick guide.

(c) Remove the 2 O-rings from the oil level dipstick guides.

78. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and No. 2 manifold stay.

79. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

80. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Uniformly loosen and remove the 6 nuts.

(b) Remove the manifold and gasket.

81. REMOVE ENGINE MOUNTING BRACKET RH

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

82. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.

83. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 5 bolts and V-ribbed belt tensioner assembly.

84. REMOVE NO. 2 TIMING GEAR COVER

(a) Remove the 2 bolts and No. 2 timing gear cover.

85. 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.)

86. REMOVE WATER PUMP PULLEY Removal

87. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and front No. 1 engine mounting bracket LH.

88. REMOVE RADIO SETTING CONDENSER

(a) Remove the 2 bolts and 2 radio setting condensers.

89. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

(a) Remove the bolt and No. 1 vacuum switching valve.

90. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.

91. REMOVE KNOCK CONTROL SENSOR Removal (from 12/2010)

92. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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

93. REPLACE PARTIAL ENGINE ASSEMBLY