Removal

1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Service Precautions
2. REMOVE BATTERY
3. DRAIN ENGINE COOLANT Service and Repair
4. DRAIN ENGINE OIL Replacement
5. REMOVE HOOD SUPPORT Removal

6. REMOVE HOOD SUB-ASSEMBLY
(a) Disconnect the windshield washer hose.
(b) Remove the 4 bolts, then remove the hood.
7. REMOVE RADIATOR ASSEMBLY
Refer to the procedures up to " REMOVE RADIATOR ASSEMBLY" Removal.
8. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)
Refer to the procedures up to " REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY" .
9. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
Refer to the procedures up to " REMOVE AUTOMATIC TRANSMISSION ASSEMBLY" Removal or ).
10. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)
Refer to the procedures up to " REMOVE CLUTCH DISC ASSEMBLY" Removal.
11. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Remove the 8 bolts, then remove the flywheel and 2 spacers.
12. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Remove the 8 bolts, then remove the drive plate and 2 spacers.
13. REMOVE THROTTLE BODY BRACKET Removal
14. REMOVE OIL BAFFLE PLATE Removal
15. REMOVE NO. 1 SURGE TANK STAY Removal
16. REMOVE NO. 2 SURGE TANK STAY Removal
17. REMOVE INTAKE AIR SURGE TANK Removal
18. REMOVE GENERATOR ASSEMBLY Removal
19. SEPARATE COOLER COMPRESSOR ASSEMBLY Removal
20. REMOVE VANE PUMP ASSEMBLY Removal

21. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Remove the No. 2 fuel pipe clamp.
(b) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
NOTICE:
- Remove any dirt and foreign matter from the fuel tube connector before performing this work.
- Do not allow any scratches or foreign matter onto the parts when disconnecting, as the fuel tube connector has the O-rings that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.

22. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
(a) Remove the No. 2 fuel pipe clamp.
(b) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.
NOTICE:
- Remove any dirt and foreign matter from the fuel tube connector before performing this work.
- Do not allow any scratches or foreign matter onto the parts when disconnecting, as the fuel tube connector has the O-rings that seals the pipe.
- Perform this work by hand. Do not use any tools.
- Do not forcibly bend, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull to release them.

23. DISCONNECT HEATER INLET WATER HOSE
(a) Disconnect the heater inlet water hose shown in the illustration.

24. DISCONNECT HEATER WATER OUTLET HOSE
(a) Disconnect the heater outlet water hose shown in the illustration.
25. REMOVE NO. 2 ENGINE WIRE

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

(b) Remove the nut and separate the engine wire from the engine room relay block.

(d) Remove the bolt and separate the ground wire from the frame.
26. SEPARATE ENGINE WIRE
(a) Remove the glove compartment door Removal
(b) Disconnect the connector from the four wheel drive ECU (for Automatic Transmission 4WD).
(c) Disconnect the 3 connectors from the ECM.
(d) Disconnect the 2 connectors from the A/C unit.
(e) Pull the wire harness into the engine room.

(f) Remove the bolt and disengage the clamp, then separate the ground wire from the body.
(g) Disconnect the front differential connector (for Automatic Transmission 4WD).
27. REMOVE ENGINE ASSEMBLY

(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part No:
Engine hanger No. 1 12281-31070
Engine hanger No. 2 12282-31050
Bolt 90119-08177
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
(b) Attach the engine sling device and hang the engine with a 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.
NOTE: Make sure that the engine is clear of all wiring and hoses.

(e) Place the engine on a work bench.

28. REMOVE HEATER INLET WATER HOSE

29. REMOVE HEATER OUTLET WATER HOSE
(a) Disconnect and remove the heater outlet water hose with heater water outlet hose A.

30. REMOVE VENTILATION HOSE

31. REMOVE NO. 2 VENTILATION HOSE
32. REMOVE MANIFOLD STAY Removal
33. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal
34. REMOVE NO. 2 MANIFOLD STAY Removal
35. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Removal

36. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Remove the 4 bolts, then remove the engine mounting bracket RH.

37. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Remove the 3 bolts, then remove the engine mounting bracket LH.
38. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Removal
39. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Removal
40. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY Removal
41. REMOVE INTAKE MANIFOLD Removal
42. REMOVE IGNITION COIL ASSEMBLY Removal
43. REMOVE OIL FILLER CAP SUB-ASSEMBLY
44. REMOVE OIL FILLER CAP HOUSING
(a) Remove the 2 nuts, oil filler cap housing and gasket.
45. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
46. REMOVE ENGINE WIRE
(a) Remove the bolt and separate the ground wire from the bank 1 cylinder head.
(b) Remove the bolt and separate the ground wire from the bank 2 cylinder head.
(c) Disconnect the connector from the knock sensor sub wire.
(d) Disconnect all connectors from the engine.
(e) Disengage all clamps and remove the engine wire.