Removal
1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
Service Precautions
2. REMOVE BATTERY
3. DRAIN ENGINE COOLANT Service and Repair
4. DRAIN ENGINE OIL Removal
5. REMOVE HOOD SUB-ASSEMBLY
(a) Disconnect the windshield washer hose.
(b) Separate the 2 hood supports.
(c) Remove the 4 bolts, then remove the hood.
6. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH Removal
7. REMOVE FAN SHROUD Removal
8. REMOVE RADIATOR ASSEMBLY Removal
9. REMOVE V-BANK COVER Removal
10. REMOVE AIR CLEANER ASSEMBLY Removal
11. REMOVE AIR PUMP ASSEMBLY (w/ Secondary Air Injection System)
Removal
12. REMOVE NO. 2 AIR CLEANER HOSE (w/ Secondary Air Injection System)
(a) Remove the 2 bolts, then remove the No. 2 air cleaner hose.
13. REMOVE AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)
Removal
14. REMOVE AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)
(a) Remove the bolt.
(b) Disconnect the 2 wire harness clamps.
(c) Remove the bolt then, remove the air tube assembly.
15. REMOVE TRANSMISSION ASSEMBLY
HINT
Refer to the table below when removing transmission.
16. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)
17. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)
18. REMOVE FAN PULLEY
19. REMOVE VANE PUMP ASSEMBLY Removal
20. REMOVE GENERATOR ASSEMBLY Removal
21. SEPARATE COOLER COMPRESSOR ASSEMBLY Removal
22. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Removal
23. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Removal
24. DISCONNECT HEATER WATER INLET HOSE
25. DISCONNECT HEATER WATER OUTLET HOSE
26. REMOVE INTAKE AIR SURGE TANK Removal
27. SEPARATE ENGINE WIRE
(a) Remove the glove compartment door.
(b) Remove the instrument panel finish panel sub-assembly lower RH.
(c) Disconnect the 7 connectors from the ECM.
(d) Disconnect the connector from four wheel drive ECU (4WD only).
(e) Disengage the wire harness clamp.
(f) Pull the wire harness into the engine room.
(g) Disconnect the front differential connector (4WD only).
(h) Disconnect the 3 connectors from the engine room relay block.
(i) Remove the nut, then separate the engine wire from the engine room relay block.
28. SEPARATE NO. 2 ENGINE WIRE
(a) Disconnect the ground cable from the cylinder block.
29. REMOVE ENGINE ASSEMBLY
(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Text in Illustration
HINT
Torque : 33 Nm (336 kgf-cm, 24 ft-lbf)
(b) Attach the engine sling device and hang the engine with the chain block.
(c) Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets.
(d) Lift the engine out of the vehicle carefully.
NOTICE:
Make sure that the engine is clear of all wiring and hoses.
(e) Place the engine onto a working bench.
30. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) Removal
31. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) Removal
32. REMOVE HEATER WATER INLET HOSE
33. REMOVE HEATER WATER OUTLET HOSE
34. REMOVE VENTILATION HOSE
35. REMOVE NO. 2 VENTILATION HOSE
36. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Remove the 6 nuts, exhaust manifold and gasket.
37. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Remove the 6 nuts, exhaust manifold and gasket.
38. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Remove the 4 bolts, then remove the engine mounting bracket RH.
39. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Remove the 3 bolts, then remove the engine mounting bracket LH.
40. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the 2 bolts, then remove the 2 idler pulleys.
41. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, then remove the idler pulley.
42. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal
43. REMOVE WATER INLET Removal
44. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
(a) Remove the 3 bolts and 2 nuts, then remove the oil filter bracket and gasket.
45. REMOVE INTAKE MANIFOLD
46. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
47. REMOVE WATER BY-PASS JOINT REAR
48. REMOVE OIL FILTER CAP SUB-ASSEMBLY
49. REMOVE OIL FILLER CAP HOUSING
(a) Remove the 2 nuts, oil filler cap housing and gasket.
50. REMOVE IGNITION COIL ASSEMBLY Removal
51. REMOVE SPARK PLUG
52. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY