ENGINE (for AWD) REMOVAL

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    SST
    09985-20010   ( 09985-02130, 09985-02150, 09985-02090, 09985-02110, 09985-02010, 09985-02050, 09985-02060, 09985-02070 )

    1. Start the engine.

    2. Turn the A/C switch ON.

    3. Operate the cooler compressor with an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. REMOVE COWL TOP VENTILATOR LOUVER RH


    1. A01GM4S

      Remove the 6 clips and cowl top ventilator louver RH.

  5. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  7. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01GMKRE01

      Using both hands, lift the rear side of the cover upwards to detach the 4 clips labeled B. Then slide the cover toward the front of the vehicle to detach the 2 clips labeled A and remove the V-bank cover sub-assembly.

      Note


      • The V-bank cover sub-assembly may be damaged if its front and rear are lifted at the same time.

      • When detaching the clips labeled A, be sure to slide the cover toward the front of the vehicle.

  8. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY


    1. A01GLYAE01

      Remove the 5 clips labeled A.

    2. Lift up the air cleaner inlet cover sub-assembly to detach the 4 clips labeled B, and remove the air cleaner inlet cover sub-assembly.

  9. REMOVE NO. 1 AIR CLEANER INLET


    1. A01GKZB

      Remove the 2 bolts.

    2. A01GJVME01

      Hold the No. 1 air cleaner inlet by the protrusions labeled A and labeled B, and detach the connections.

    3. Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled C.

    4. Hold the No. 1 air cleaner inlet by the protrusions labeled D and labeled E, and detach the connections.

    5. Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled F.

  10. REMOVE ENGINE ROOM SIDE COVER RH


    1. A01GL9VE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Remove the 5 clips and engine room side cover RH.

  11. REMOVE ENGINE ROOM SIDE COVER LH


    1. A01GK7CE01
      Text in Illustration
      *A for LHD
      *B for RHD

      Remove the 5 clips and engine room side cover LH.

  12. REMOVE FRONT CENTER FLOOR COVER


    1. A01GLG7

      Remove the 3 screws, 2 bolts, clip and front center floor cover.

  13. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01GKN2

      Remove the 4 screws, 2 clips and No. 2 engine under cover.

  14. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH


    1. for 2WD:

      Remove the 2 screws and front wheel opening extension pad LH.

    2. for AWD:

      Remove the 5 screws and front wheel opening extension pad LH.

      A01GJSHE01
      Text in Illustration
      *A for 2WD *B for AWD

  15. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

    Tech Tips

    Use the same procedure described for the LH side.

  16. REMOVE NO. 1 ENGINE UNDER COVER


    1. A01GHO1E01
      Text in Illustration
      *A for 2WD
      *B for AWD

      Remove the 13 screws, 7 clips and No. 1 engine under cover.

  17. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER


    1. A01GI4D

      Remove the 9 bolts and front suspension member protector lower.

  18. DRAIN ENGINE OIL


    1. A01GHVV

      Open the oil filler cap service hole cover.

    2. Remove the oil filler cap.

    3. Remove the oil pan drain plug and drain the engine oil into a container.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  19. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap and vent plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      A01GLBYE01
      Text in Illustration
      *1 Radiator Drain Cock Plug *2 Radiator Reservoir Cap
      *3 Vent Plug *4 Cylinder Block Drain Cock Plug

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01GN7SE02
      Text in Illustration
      *1 Vent Plug

      Remove the radiator reservoir cap, and using a 6 mm hexagon wrench, remove the vent plug.

    3. Drain coolant.

    4. Loosen the 2 cylinder block drain cock plugs.

  20. DRAIN FRONT DIFFERENTIAL OIL


    1. Stop the vehicle on a level place.

    2. A01GIEZ

      for Front Differential:


      1. Using a 10 mm hexagon wrench, remove the filler plug and gasket.

      2. Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.

      3. Using a 10 mm hexagon wrench, install a new gasket and the drain plug.

        Torque:
        39 N*m  { 398 kgf*cm, 29 ft.*lbf }
    3. A01GHOS

      for Rear Differential:


      1. Using a 10 mm hexagon wrench, remove the filler plug and gasket.

      2. Using a 10 mm hexagon wrench, remove the drain plug and gasket, and drain the oil.

      3. Using a 10 mm hexagon wrench, install a new gasket and the drain plug.

        Torque:
        49 N*m  { 500 kgf*cm, 37 ft.*lbf }

  21. DRAIN AUTOMATIC TRANSMISSION FLUID


    1. Lift the vehicle. [*1]

      Note

      Set the vehicle on a lift so that the vehicle is kept level when it is lifted up (make sure that the tilt angle from the front to rear of the vehicle is within +/-1°).

    2. Remove the drain plug and gasket, and drain the ATF. [*2]

    3. Temporarily install the gasket and drain plug. [*3]

      Tech Tips

      Reuse the old gasket. A new gasket will be installed in step [*15].

    4. A01GN87E01

      Remove the refill plug and overflow plug. [*4]

    5. A01GMAIE01

      Add fluid to the refill hole until it flows out of the overflow plug hole. [*5]

      Note

      Use Toyota Genuine ATF WS.

    6. Wait until the fluid flow slows and only drops come out. [*6]

    7. Temporarily install the gasket and overflow plug. [*7]

      Tech Tips

      Reuse the old gasket. The plug will be removed again to adjust the fluid level.

    8. Add fluid to the refill hole using the amount of fluid specified for removal and installation of the oil pan. [*8]

      Tech Tips

      Specified amount of fluid is 3.2 liters (3.38 US qts, 2.82 Imp. qts).

    9. Temporarily install the gasket and refill plug to avoid fluid spillage. [*9]

      Tech Tips

      Reuse the old gasket. The plug will be removed again to adjust the fluid level.

    10. Lower the vehicle. [*10]

    11. Start the engine. [*11]

      Note

      Make sure that the A/C switch is off.

    12. Slowly move the shift lever from P to S, and then back to P. [*12]

    13. Allow the engine to idle for 30 seconds to warm it up. [*13]

    14. Turn the engine switch off. [*14]

    15. Repeat steps [*1] to [*14].

    16. Repeat steps [*1] to [*2].

    17. Install a new gasket and the drain plug. [*15]

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    18. Repeat steps [*4] to [*10].

    19. Adjust the fluid level Click here.

    20. Lower the vehicle.

    21. Operation complete.

  22. DISCONNECT NO. 1 OIL COOLER INLET HOSE


    1. A01GHMP

      Disconnect the No. 1 oil cooler inlet hose from the radiator.

      Note

      Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.

  23. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE


    1. A01GL3M

      Disconnect the No. 1 oil cooler outlet hose from the radiator.

      Note

      Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.

  24. REMOVE FRONT BUMPER COVER

    Click here

  25. REMOVE FRONT SUSPENSION LOWER CROSSMEMBER

    A01GLRX

    1. Remove the 2 clips.

    2. Remove the 4 bolts and front suspension lower crossmember.

  26. REMOVE REAR FRAME SIDE RAIL


    1. A01GHK2

      Remove the 6 bolts, 4 nuts and 2 rear frame side rails.

  27. REMOVE INTAKE AIR CONNECTOR PIPE


    1. Disconnect the No. 1 and No. 2 ventilation hoses from the intake air connector pipe.

      A01GMWQE01
      Text in Illustration
      *a w/ Intake Air Sound Creator *b w/ Intake Air Resonator

    2. Using a clip remover, detach the 2 wire harness clamps.

    3. Loosen the 3 hose clamps, and remove the intake air connector pipe.

    4. Remove the intake air sound creator.

      Tech Tips

      Only perform this procedure when replacement of the intake air sound creator is necessary.


      1. Loosen the hose clamp and remove the intake air sound creator.

  28. REMOVE AIR CLEANER ASSEMBLY LH


    1. A01GJIY

      Disconnect the mass air flow meter connector.

    2. Disconnect the 2 clamps and remove the air cleaner cap LH.

    3. Remove the air cleaner filter element from air cleaner case LH.

    4. A01GJKZ

      Remove the 2 nuts, clip and air cleaner case LH.

  29. REMOVE AIR CLEANER ASSEMBLY RH


    1. A01GIMA

      Disconnect the mass air flow meter connector.

    2. Disconnect the 2 clamps and remove the air cleaner cap RH.

    3. Remove the air cleaner filter element from air cleaner case RH.

    4. A01GM6U

      Remove the 2 nuts, clip and air cleaner case RH.

  30. REMOVE RADIATOR RESERVOIR ASSEMBLY


    1. A01GI8P

      Disconnect the 2 reservoir hoses.

    2. Remove the 2 bolts and radiator reservoir assembly.

  31. REMOVE ENGINE ROOM ECU OUTLET DUCT


    1. A01GL42

      Remove the engine room ECU outlet duct from the fan shroud and ECU box.

  32. DISCONNECT NO. 1 RADIATOR HOSE

  33. DISCONNECT NO. 2 RADIATOR HOSE

  34. REMOVE RESONATOR BRACKET SUB-ASSEMBLY


    1. A01GJK0

      Remove the bolt and resonator bracket sub-assembly.

  35. REMOVE V-RIBBED BELT


    1. A01GK62

      Rotate the tensioner pulley counterclockwise to loosen the belt tension.

      Tech Tips

      The pulley bolt for the belt tensioner has a left-handed thread.


      1. A01GMRNE01

        While turning the belt tensioner counterclockwise, align the holes. Insert a bar with a diameter of 5 mm (0.197 in.) into the holes to fix the belt tensioner in place.

    2. Remove the V-ribbed belt.

  36. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Disconnect the switch connector.

    2. A01GHPWE01
      Text in Illustration
      *A for 2WD
      *B for AWD

      Using a 24 mm deep socket wrench, remove the switch.

  37. REMOVE OIL TEMPERATURE SENSOR


    1. Disconnect the oil temperature sensor connector.

    2. A01GJ1K

      Remove the oil temperature sensor and gasket.

      Note

      Do not subject the oil temperature sensor to any impacts.

      If the oil temperature sensor is subjected to an impact, replace the oil temperature sensor with a new one.

  38. DISCONNECT NO. 3 FUEL HOSE

    A01GJKKE01

    1. Remove the fuel pipe clamp.

    2. Pinch the tube connector and then pull out the fuel hose.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

  39. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY


    1. A01GK6QE01

      Lift up the retainer to release its lock.

    2. Pinch the tube connector and then pull out the fuel hose.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

  40. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A01GKIX

      Remove the bolt and disconnect the discharge hose sub-assembly from the with pulley compressor assembly.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  41. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A01GJY8

      Remove the bolt and disconnect the suction tube sub-assembly B from the with pulley compressor assembly.

    2. Remove the O-ring from the cooler refrigerant suction tube sub-assembly B.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  42. DISCONNECT HOSES AND CONNECTORS


    1. A01GJJ7

      Remove the 3 bolts and engine room ECU cover.

    2. A01GM4GE01

      Disconnect the 4 TCM connectors and 2 wiring harness support connectors.

    3. Detach the 2 wiring harness support clamps, and then detach the clamp of connector A from the ECU box.

      Tech Tips

      It is not necessary to disconnect the connection at A in the illustration.

    4. A01GJFK

      Lift up the wiring harness support and disconnect the 4 ECM connectors.

    5. A01GI7Y

      Detach the 2 clamps. Then remove the 2 nuts and disconnect the wires with No. 1 engine room junction block.

    6. A01GHUK

      Detach the clamp and disconnect the 3 connectors with front controller.

    7. A01GK5EE01

      Release the locks of the power steering ECU connector A and disconnect the connectors B.

    8. Detach the 2 clamps.

    9. A01GK6A

      Remove the bolt and disconnect the ground wire.

    10. A01GJIE

      Disconnect the 2 connectors and detach the 5 clamps.

    11. A01GMRW

      Disconnect the 2 heater hoses.

    12. A01GNN3

      Disconnect the purge line hose.

  43. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Click here.

  44. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A01GLPQ

      Detach the 2 claws, and remove the bolt and No. 1 air duct sub-assembly.

      Note

      Be careful not to damage the air duct as its connection to the vehicle is very tight.

  45. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01GLV7E02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the No. 2 steering intermediate shaft and steering column.

    2. Remove the bolt.

    3. A01GKUZE02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the No. 2 steering intermediate shaft and power steering link.

    4. Remove the bolt.

    5. A01GKW4

      Remove the clamp and No. 2 steering intermediate shaft.

  46. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  47. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  48. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  49. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY


    1. Move the shift lever to N.

    2. A01GK04

      Remove the nut and disconnect the shifting rod from the connecting rod swivel.

  50. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH


    1. A01GIP1

      Remove the bolt. Then disconnect the front lower shock absorber bracket sub-assembly RH.

  51. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH


    1. A01GK6F

      Remove the bolt. Then disconnect the front lower shock absorber bracket sub-assembly LH.

  52. REMOVE ENGINE AND TRANSMISSION


    1. A01GK00

      Place a mark (with spray, etc.) over the rear right vehicle side attachment area of the front frame, which is indicated in the illustration.

    2. Place a mark (with spray, etc.) over the rear left vehicle side attachment area of the front frame.

    3. Set an engine lifter underneath the engine.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    4. A01GNQK

      Remove the 4 rear engine mounting member's bolts.

    5. A01GLSD

      Remove the 4 bolts shown in the illustration.

    6. Operate the engine lifter and slowly remove the engine from the vehicle.

      Note


      • Make sure that the engine is clear of all wiring and hose.

      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.

  53. INSTALL NO. 1 ENGINE HANGER


    1. A01GKK4

      Install the 2 No. 1 engine hangers with the 2 bolts as shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 engine hanger 12281-38150
      Bolt 90119-14120
    2. A01GMJRE01

      Attach an engine sling device and hang the engine with a chain block.

      Note

      When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or No. 1 engine hangers may be damaged.

  54. REMOVE FRONT FRAME ASSEMBLY


    1. A01GKTHE01

      Remove the 4 nuts and front frame assembly.

  55. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01GKMQE01

      Remove the engine oil level dipstick.

    2. Remove the 2 bolts and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  56. REMOVE GENERATOR ASSEMBLY

    A01GN07

    1. Remove the nut, and disconnect the harness from the +B terminal.

    2. Disconnect the generator connector.

    3. A01GLG5

      Remove the 2 bolts and 2 nuts.

    4. A01GHPM

      Using an E8 "TORX" socket wrench, remove the 2 stud bolts and generator.

  57. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GK4G

      Remove the 3 bolts and heat insulator.

  58. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GJU8

      Remove the 3 bolts and heat insulator.

  59. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01GIXPE02

      Remove the 2 nuts, 2 engine mounting spacers and 2 front engine mounting insulators.

  60. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01GJVK

      Remove the 5 bolts and front No. 1 engine mounting bracket RH.

  61. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01GNKZ

      Remove the 5 bolts and front No. 1 engine mounting bracket LH.

  62. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01GJ6G

      Disconnect the air fuel ratio sensor connector.

    2. A01GMUB

      Remove the 8 nuts and exhaust manifold RH.

    3. Remove the gasket.

  63. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01GKQT

      Disconnect the air fuel ratio sensor connector.

    2. A01GMPG

      Remove the 8 nuts and exhaust manifold LH.

    3. Remove the gasket.

  64. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET RH


    1. A01GIOL

      Remove the 2 nuts and front No. 2 engine mounting bracket RH.

  65. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. A01GM4E

      Remove the 2 nuts and front No. 2 engine mounting bracket LH.

  66. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GLOGE01

      Remove the 3 bolts and No. 3 exhaust manifold heat insulator.

  67. REMOVE STARTER ASSEMBLY


    1. A01GKQ1

      Remove the 2 bolts and disconnect the starter assembly.

    2. A01GIQK

      Open the terminal cap.

    3. Remove the 2 nuts and disconnect the starter wire.

    4. Disconnect the starter connector and remove the starter assembly.

  68. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  69. REMOVE NO. 1 OIL COOLER TUBE

    A01GLXSE01

    1. Disconnect the 2 oil cooler hoses.

    2. Remove the 2 bolts and No. 1 oil cooler tube sub-assembly.

  70. REMOVE NO. 3 COVER SUB-ASSEMBLY

    A01GI6O

    1. Remove the 2 bolts and bracket.

    2. A01GMNK

      Remove the 2 clips and No. 3 engine cover.

  71. DISCONNECT WIRE HARNESS AND CONNECTOR

    A01GN46E02

    1. Disconnect the transmission wire connector and park/neutral position switch connector.

      Tech Tips

      Detach the claw, press down the lever, and then disconnect the transmission wire connector.

    2. Detach the connector clamp and 6 harness clamps from the automatic transmission.

  72. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A01GN3J

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

  73. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY


    1. Using wooden blocks or equivalent, fix the transmission assembly in place so that it is level.

      Note


      • Do not allow the wooden blocks or equivalent to contact the oil pan when lifting or supporting the transmission assembly, as the oil pan may be deformed as a result.

      • Support the engine assembly with a sling device and chain block while working.

      • Be sure to perform this procedure with several people as the transmission assembly is very heavy.

    2. A01GKRF

      Remove the 10 bolts, and then remove the automatic transmission from the engine.

      Note

      To prevent damage to the knock pins, do not pry between the automatic transmission and engine.

  74. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01GKMYE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
    2. A01GLUN

      Remove the 10 bolts, rear spacer plate, drive plate and ring gear sub-assembly and crankshaft position sensor rotor.

  75. INSTALL ENGINE ON ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hangers may be damaged or deformed if the angle is incorrect.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    2. Remove the 2 bolts and 2 No. 1 engine hangers.

  76. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. A01GISS

      Remove the 2 bolts, 2 nuts, 2 stud bolts and cooler compressor assembly.

  77. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY


    1. Support the front differential carrier assembly with a jack.

      CAUTION:

      As the front differential carrier assembly is very heavy, securely support it with the jack.

    2. A01GKZE

      Remove the 4 bolts and front differential carrier assembly.

      Note


      • Do not damage the installation surface when removing the front differential carrier assembly.

      • The remaining oil may leak out when removing the front differential carrier assembly.

  78. REMOVE NO. 5 ENGINE COVER SUB-ASSEMBLY


    1. A01GJYN

      Remove the 2 nuts and No. 5 engine cover sub-assembly.

  79. REMOVE NO. 6 ENGINE COVER SUB-ASSEMBLY


    1. A01GLHN

      Remove the 2 nuts and No. 6 engine cover sub-assembly.

  80. REMOVE ENGINE WIRE


    1. for Engine LH Side:


      1. A01GJOM

        Disconnect the camshaft timing control valve connector.

      2. Disconnect the 4 ignition coil connectors.

      3. Disconnect the 2 VVT sensor connectors.

      4. Disconnect the fuel pump connector (for high pressure).

      5. Disconnect the No. 8 engine wire connector.

      6. Disconnect the 4 wire harness clamps.

    2. for Engine Front Side:


      1. A01GL85

        Disconnect the engine coolant temperature sensor connector.

      2. Disconnect the 2 camshaft timing control motor connectors (for Bank 1).

      3. Disconnect the 2 camshaft timing control motor connectors (for Bank 2).

      4. Remove the 3 bolts and disconnect the clamp and ground wire.

      5. Remove the bolt and clamp bracket.

    3. for Engine RH Side:


      1. A01GMF8

        Disconnect the camshaft timing control valve connector.

      2. Disconnect the 4 ignition coil connectors.

      3. Disconnect the 2 VVT sensor connectors.

      4. Disconnect the fuel pump connector (for high pressure).

      5. Disconnect the camshaft position sensor connector.

      6. Detach the 4 wire harness clamps.

      7. Disconnect the crankshaft position sensor connector.

      8. Remove the 2 bolts and disconnect the engine oil level sensor connector.

    4. for Engine Rear Side:


      1. A01GKNX

        Disconnect the engine wire connector.

      2. Disconnect the fuel relief valve connector.

      3. Detach the 8 wire harness clamps.

      4. Remove the 2 bolts and disconnect the ground wire.

    5. Disconnect the throttle body connector.

    6. A01GJP2E01

      Disconnect the 8 injector driver connectors and detach the 2 clips as shown in the illustration.

    7. A01GMCC

      Disconnect the purge VSV connector.

    8. Disconnect the intake air control valve actuator connector.

    9. Remove the 2 bolts and disconnect the 2 clamp brackets and 2 clamps.

    10. Remove the 4 nuts and engine wire.

  81. REMOVE INJECTOR DRIVER


    1. Remove the 8 nuts and 2 injector drivers from the injector driver bracket.

  82. REMOVE NO. 1 ENGINE COVER


    1. A01GLAF

      Remove the No. 1 engine cover.

  83. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    A01GMYS

    1. Slide the 4 clamps and disconnect the heater water inlet hose, heater water outlet hose, water inlet hose, and No. 3 water by-pass hose from the water by-pass pipe sub-assembly.

    2. Remove the 2 bolts and water by-pass pipe sub-assembly.

  84. REMOVE PURGE VSV

    A01GKVX

    1. Disconnect the purge VSV connector.

    2. Disconnect the 2 purge line hoses from the purge VSV.

    3. Remove the bolt and purge VSV.

  85. REMOVE VENTILATION HOSE

  86. REMOVE THROTTLE BODY ASSEMBLY


    1. A01GMXV

      Disconnect the throttle motor connector.

    2. Remove the 4 bolts and throttle body assembly.

    3. A01GKZ4

      Disconnect the No. 4 and No. 5 water by-pass hoses from the throttle body assembly.

    4. Remove the gasket from the intake manifold.

  87. REMOVE INTAKE MANIFOLD


    1. A01GJ1M

      Disconnect the No. 1 ventilation hose from the intake manifold.

    2. A01GHKS

      Remove the 8 bolts, 2 nuts and intake manifold.

    3. Remove the 2 gaskets from the intake manifold.

  88. REMOVE FUEL TUBE SUB-ASSEMBLY

    A01GJYYE04

    1. Lift up the retainer to release its lock.

    2. Pinch the tube connector and then pull out the fuel tube.

      Note


      • Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.

      • Do not use any tools to separate the pipe and connector.

      • Do not forcefully bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.

      • Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.

      • If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the tube.

  89. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    A01GIRN

    1. Remove the bolt and bracket.

    2. A01GK8I

      Disconnect the connector from the delivery pipe.

    3. A01GMXIE01

      Disconnect the 3 fuel hoses.

    4. A01GLV5E02

      Using SST, loosen the 2 fuel pressure pulsation dampers.

      SST
      09612-24014   ( 09617-24011 )
    5. A01GJTO

      Remove the 2 clamp bolts shown in the illustration.

    6. Remove the 2 pulsation dampers, 4 gaskets and No. 1 fuel pipe.

  90. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. Remove the fuel pump connector.

    2. A01GMO2E01

      Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union nut and disconnect the fuel pipe from the fuel pump.

      Note

      Do not loosen the union bolt on the fuel pump side. If the union bolt is accidentally loosened, replace the fuel pump.

    3. A01GHWLE01

      Remove the 2 bolts on the delivery pipe side and remove the fuel pipe.

    4. Remove the O-ring, backup ring and E-ring from the fuel pipe.

  91. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tech Tips

    The removal procedures are the same as the No. 3 fuel pipe.

  92. REMOVE ENGINE COVER SUB-ASSEMBLY (for Bank 1)

    A01GI5SE01

    1. Detach the 5 claws and remove the engine cover LH and RH from the fuel pump.

  93. REMOVE ENGINE COVER SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    The removal procedures are the same as the bank 1 side.

  94. REMOVE FUEL PUMP ASSEMBLY (for Bank 1)

    A01GLBZ

    1. Remove the 2 nuts, fuel pump and fuel pump insulator.

    2. A01GN1D

      Disconnect the fuel hose from the fuel pump.

  95. REMOVE FUEL PUMP ASSEMBLY (for Bank 2)

    Tech Tips

    The removal procedures are the same as the bank 1 side.

  96. REMOVE FUEL DELIVERY PIPE (for Port Injection)


    1. A01GJ8RE04

      Disconnect the 2 delivery pipe connectors.

    2. A01GJK6E01

      Disconnect the 4 wire harness clamps.

    3. A01GJ7D

      Remove the 4 bolts and 2 fuel delivery pipes.

      Note

      When removing the delivery pipe, hold the pipe by both ends and pull it straight upward.

    4. Remove the 4 delivery pipe spacers and 8 insulators from the cylinder head.

  97. REMOVE FUEL INJECTOR ASSEMBLY (for Port Injection)


    1. A01GN3EE01

      Remove the 8 fuel injectors from the fuel delivery pipes.

      Note

      For reinstallation, attach a tag or label to the injector shaft.

    2. A01GIP3

      Disconnect the connector from the injector.

    3. A01GJCME02

      Remove the O-ring from the fuel injector.

  98. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    A01GK9J

  99. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

    A01GLVL

  100. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

    A01GKCB

  101. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    A01GN7HE06
    Text in Illustration
    *1 Union Nut Wrench

    1. Using a 19 mm union nut wrench, remove the No. 4 fuel pipe sub-assembly.

  102. REMOVE FUEL DELIVERY PIPE (for Direct Injection)


    1. A01GIDN

      Disconnect the No. 3 fuel hose.

    2. A01GIJF

      Disconnect the 4 fuel injector connectors.

    3. A01GJ4N

      Remove the 5 bolts and fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  103. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection)

    A01GN04E03

    1. Disconnect the fuel pressure sensor connector.

    2. A01GJ3S

      Disconnect the 4 fuel injector connectors.

    3. A01GLUR

      Remove the 5 bolts and No. 2 fuel delivery pipe from the cylinder head.

      Note


      • Be extremely careful not to touch or strike the tips of the fuel injector assemblies.

      • Pull and remove the No. 2 fuel delivery pipe in a straight line without tilting it.

    4. Remove the 4 injector vibration insulators from the cylinder head.

  104. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)


    1. A01GM5SE01

      Secure the fuel delivery pipe between aluminum plates in a vise and pull out the fuel injector assembly in a straight line.

      Note


      • Pull and remove the fuel injector assembly in a straight line to avoid damage to the seal surface of the fuel delivery pipe O-ring.

      • For reinstallation, attach a tag or label to the fuel injector assembly shaft.

    2. Remove the nozzle holder clamp from the fuel injector assembly.

    3. Remove the O-ring, No. 1 backup ring, No. 2 backup ring, No. 3 backup ring and E-ring from the fuel injector assembly.

  105. REMOVE FUEL INJECTOR SEAL (for Direct Injection)


    1. A01GN80

      Using the tips of needle-nose pliers, pinch and pull one of the 2 fuel injector seals at several points to stretch it. Repeat this for the other fuel injector seal.

      Note


      • Excessively pinching the fuel injector seal may damage the groove of the fuel injector assembly.

      • If a fuel injector assembly is dropped or the tip of the fuel injector assembly is struck, replace it with a new one.

    2. Remove the 2 fuel injector seals from the fuel injector assembly.

  106. REMOVE SEPARATOR CASE


    1. A01GN04

      Disconnect the fuel pressure sensor connector.

    2. A01GMYW

      Remove the 4 bolts and separator case.

  107. REMOVE ENGINE WIRE


    1. A01GNRA

      Detach the 5 clamps and remove the 2 bolts and engine wire.

    2. Disconnect the 4 knock sensor connectors.

  108. REMOVE NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. A01GLMD

      Remove the No. 4 engine cover sub-assembly.

  109. REMOVE KNOCK SENSOR


    1. A01GJ2KE01

      Disconnect the 4 knock sensor connectors.

    2. Remove the 4 bolts and 4 knock sensors.

  110. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01GN8T

      Remove the bolt and No. 2 idler pulley sub-assembly.

  111. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01GHYJ

      Remove the bolt and No. 1 idler pulley sub-assembly.

  112. REMOVE WATER PUMP PULLEY


    1. A01GIPTE01

      Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the 4 bolts and water pump pulley.

  113. REMOVE WATER INLET HOUSING


    1. A01GIQD

      Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the water by-pass hose and water inlet hose.

    2. A01GLOQ

      Remove the 3 bolts, water inlet housing and gasket.

  114. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01GNNO

      Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts.

    3. A01GJZ5

      Rotate the engine oil level sensor 180° and remove it.

    4. A01GHRLE02

      Cut off the gasket as shown in the illustration.

    5. Remove the gasket from the oil level sensor.

      Tech Tips

      After cutting away the parts of the gasket shown in the illustration, remove only the outer part of the gasket.

  115. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. Disconnect the engine coolant temperature sensor connector.

    2. A01GILK

      Using a 19 mm ball joint lock nut wrench, remove the engine coolant temperature sensor and gasket.

    3. Remove the gasket from the engine coolant temperature sensor.

  116. REMOVE IGNITION COIL ASSEMBLY


    1. A01GKPD

      Disconnect the 8 ignition coil assembly connectors.

    2. Remove the 8 bolts.

    3. A01GNKFE02

      Using a screwdriver, pry up each spark plug tube gasket at the cutouts to remove the 8 ignition coil assemblies together with the 8 spark plug tube gaskets.

      Note

      Do not damage the cylinder head cover when removing the spark plug tube gasket.

      Tech Tips

      Tape the screwdriver tip before use.