Removal

2AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PRECAUTION

CAUTION:
The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair information, or the engine lifter may suddenly drop.

NOTICE:
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Service Precautions.

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

3. DISCHARGE FUEL SYSTEM PRESSURE

Fuel System: Precaution

4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

5. SECURE STEERING WHEEL

6. REMOVE FRONT WHEELS

7. 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.

8. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

9. REMOVE ENGINE UNDER COVER LH

10. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

11. REMOVE ENGINE UNDER COVER RH

12. REMOVE FRONT FENDER APRON SEAL LH

13. REMOVE FRONT FENDER APRON SEAL RH

14. DRAIN ENGINE OIL Replacement

15. DRAIN ENGINE COOLANT Service and Repair

16. DRAIN AUTOMATIC TRANSAXLE FLUID Replacement

17. REMOVE COOL AIR INTAKE DUCT SEAL Removal

18. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the engine cover.

NOTICE:
Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

19. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Remove the 2 bolts and inlet air cleaner assembly.

20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal

21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

(a) Remove the air cleaner filter element sub-assembly.

22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the wire harness clamp.

(b) Remove the 2 bolts and air cleaner case sub-assembly.

23. REMOVE BATTERY

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

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

(c) Remove the battery and battery tray.

24. DISCONNECT NO. 1 RADIATOR HOSE

(a) Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.

(b) Disconnect the No. 1 radiator hose.

25. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disconnect the No. 2 radiator hose.

26. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

27. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the 3 outlet heater water hoses.

28. REMOVE STARTER ASSEMBLY Removal

29. DISCONNECT ENGINE WIRE

(a) Remove the No. 1 relay block cover.

(b) Remove the 2 nuts and disconnect the wire clamp.

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

(d) Disconnect the 4 connectors.

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

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

(g) Disconnect the 2 wire clamps.

30. DISCONNECT NO. 1 AIR CLEANER BRACKET

(a) Disconnect the 2 wire clamps.

(b) Remove the bolt and No. 1 air cleaner bracket.

31. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut and disconnect the transmission control cable from the control shaft lever.

(b) Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.

32. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

33. SEPARATE EARTH WIRE

(a) Remove the bolt and separate the earth wire from the engine moving control rod bracket.

34. REMOVE ENGINE MOVING CONTROL ROD BRACKET

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

35. REMOVE ENGINE MOVING CONTROL ROD

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

HINT
Perform this procedure only when replacement of the engine moving control rod is necessary.

36. DISCONNECT UNION TO CONNECTOR TUBE HOSE

(a) Disconnect the union to connector tube hose.

37. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Removal

38. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for TMMK Made) Removal

39. DISCONNECT NO.1 COOLER REFRIGERANT SUCTION HOSE (for SIA Made) Removal

40. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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

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

NOTICE:
* Check for dirt and foreign objects on 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. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

42. REMOVE FRONT AXLE SHAFT NUT LH Removal

43. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Use the same procedure described for the LH side.

44. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

45. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

46. SEPARATE FRONT SPEED SENSOR LH Removal

47. SEPARATE FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

48. SEPARATE TIE ROD ASSEMBLY LH Removal

49. SEPARATE TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

50. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Removal

51. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

52. SEPARATE FRONT AXLE ASSEMBLY LH Removal

53. SEPARATE FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

54. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

55. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the flywheel housing under cover.

56. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

(a) Turn the crankshaft to gain access to the removal locations of the 6 torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

57. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

Text in Illustration

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.
* To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
* Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from 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 plate RH and LH.

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

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

NOTICE:
* Make sure that the engine is clear of all wiring and hoses.
* While lowering the engine from the vehicle, do not allow it to contact the vehicle.

(e) Install engine hangers Installation.

58. REMOVE ENGINE WIRE

(a) Remove the engine wire from the engine with transaxle.

59. REMOVE V-RIBBED BELT Removal

60. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY Removal

61. REMOVE GENERATOR ASSEMBLY Removal

62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

63. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Removal

64. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

65. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the nut and separate the engine mounting insulator LH.

(b) Remove the bolt and separate the front engine mounting insulator.

(d) Remove the front frame assembly.

(e) Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface.

NOTICE:
* Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally.
* To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
* Using an engine sling device and engine lift, secure the engine assembly before service.

66. REMOVE FRONT ENGINE MOUNTING INSULATOR

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

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

67. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the 2 hole plugs from the front frame assembly.

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

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

68. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Remove the 2 hole plugs from the front frame assembly.

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

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

69. REMOVE DRIVE SHAFT BEARING BRACKET

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

70. REMOVE ENGINE MOUNTING BRACKET RH

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

71. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY Removal

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

73. INSTALL ENGINE STAND

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