Removal

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions.

2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER ASSEMBLY (w/ Engine Under Cover Assembly)
6. REMOVE NO. 1 ENGINE UNDER COVER
7. REMOVE NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover)
8. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
9. REMOVE FRONT FENDER APRON SEAL RH
10. DRAIN ENGINE OIL Replacement

11. DRAIN ENGINE COOLANT Testing and Inspection

12. DRAIN AUTOMATIC TRANSAXLE FLUID Removal

13. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
.
14. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY Removal

15. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 4 clips and intake duct seal.
16. REMOVE ENGINE ROOM COVER SIDE

(a) Remove the 4 clips and engine room cover side.
17. 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.

18. REMOVE V-RIBBED BELT Removal

19. REMOVE NO. 2 AIR CLEANER INLET

(a) Remove the 2 bolts, 2 clamps and No. 2 air cleaner inlet.
20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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

(a) Remove the bolt and No. 1 air cleaner inlet.
23. REMOVE BATTERY
(a) Loosen the bolt and nut, and remove the battery clamp.
(b) Remove the battery and battery tray.
24. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY

(a) Remove the clip, bolt and intake air resonator.
25. REMOVE AIR CLEANER BRACKET

(a) Remove the 2 bolts and air cleaner bracket.
26. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

(a) Remove the 3 bolts and engine moving control rod.
28. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
29. DISCONNECT UNION TO CHECK VALVE HOSE
(a) Remove the clamp and disconnect the union to check valve hose.
30. REMOVE RADIATOR HOSE INLET

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

(a) Remove the clamp and disconnect the radiator hose outlet.
32. DISCONNECT OIL COOLER INLET HOSE

(a) Remove the clamp and disconnect the oil cooler inlet hose.
33. DISCONNECT OIL COOLER OUTLET HOSE
(a) Remove the clamp and disconnect the oil cooler outlet hose.
34. DISCONNECT HEATER INLET WATER HOSE

(a) Disconnect the heater inlet water hose.
35. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose.
36. REMOVE JUNCTION BLOCK COVER
37. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

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, unlock the engine room J/B. Pull the engine room J/B upward.

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

(c) Remove the bolt and ground cable.
(d) Remove the 2 nuts and engine wire from the body.
(e) Disconnect the engine wire from the ECM and passenger side J/B.
39. 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.

(d) Disconnect the control cable from the control cable clamp.
40. 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.

41. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Disconnect the No. 1 oil reservoir to pump hose.
42. DISCONNECT RETURN TUBE SUB-ASSEMBLY

(a) Disconnect the return tube sub-assembly.
NOTE: Take care not to damage the hose protector.

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

44. REMOVE OXYGEN SENSOR Removal

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

46. REMOVE EXHAUST PIPE ASSEMBLY FRONT Removal

47. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH Removal

48. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

49. REMOVE FRONT AXLE HUB NUT LH Removal

50. REMOVE FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

51. DISCONNECT FRONT SPEED SENSOR LH Removal

52. DISCONNECT FRONT SPEED SENSOR RH
HINT: Use the same procedures described for the LH side.

53. DISCONNECT TIE ROD ASSEMBLY LH Removal

54. DISCONNECT TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

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

56. SEPARATE FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.

57. SEPARATE FRONT AXLE ASSEMBLY LH Removal

58. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

59. DISCONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

60. DISCONNECT HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT LH (w/ Air Suspension)

(a) Remove the nut and disconnect the height control sensor.
61. DISCONNECT HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT RH (w/ Air Suspension)
HINT: Use the same procedures described for the LH side.

62. REMOVE GENERATOR ASSEMBLY

63. 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.

64. 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.

(c) Remove the 6 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.

65. REMOVE VANE PUMP ASSEMBLY
(a) Disconnect the power steering oil pressure switch connector.
(b) Remove the 3 pressure feed tube clamp bolts.

(c) Loosen the bolt A.
(d) Remove the bolt B and vane pump.
66. REMOVE FRONT STABILIZER BAR (for 4WD)

67. REMOVE POWER STEERING LINK (for 4WD)

68. 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.
69. REMOVE FRONT FRAME ASSEMBLY

(a) Disconnect the connector and clamp.

(b) Disconnect the 2 clamps.

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

(e) Remove the 2 bolts and separate the engine mounting insulator RR.
70. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

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

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

73. REMOVE ENGINE WIRE
74. REMOVE STARTER ASSEMBLY

75. REMOVE ENGINE MOUNTING BRACKET FRONT Removal

76. REMOVE MANIFOLD STAY
(a) Remove the bolt, nut, and manifold stay.
77. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
Removal.

78. REMOVE TRANSFER STIFFENER PLATE RH (for 4WD) Removal

79. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD)
Removal.

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

81. SECURE ENGINE
(a) Secure the engine onto an engine stand with the bolts.
82. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Remove the 2 bolts and exhaust pipe support bracket.
83. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Disconnect the 2 water by-pass hoses from the throttle with motor body assembly.
(b) Disconnect the vapor feed hose.
(c) Disconnect the throttle with motor body assembly connector and clamp.
(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.
(h) Remove the 2 nuts and intake air surge tank.
(i) Remove the gasket from the intake air surge tank.
84. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 ignition coils.
85. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove the bolt and No. 2 engine mounting stay RH.
86. REMOVE INTAKE MANIFOLD

(a) Uniformly loosen and remove the 6 bolts and 4 nuts.
(b) Remove the intake manifold and 2 gaskets.
87. 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.
88. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY

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

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

(a) Remove the 3 bolts and No. 2 insulator.
91. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

(a) Remove the 3 bolts and engine mounting bracket RH.
93. REMOVE ENGINE MOUNTING BRACKET RR

(a) Remove the 3 bolts and engine mounting bracket RR.
94. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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

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

(a) Remove the bolt, plate and No. 2 idler pulley sub-assembly.
97. REMOVE WATER PUMP PULLEY Removal

98. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH

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

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

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

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
102. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY (w/ Oil Cooler)

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
103. REMOVE KNOCK CONTROL SENSOR Removal

104. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

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