ENGINE (for 2WD) 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. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE COWL TOP VENTILATOR LOUVER


    1. A01GM4S

      for LHD:

      Remove the 6 clips and cowl top ventilator louver RH.

    2. A01GI9P

      for RHD:

      Remove the 6 clips and cowl top ventilator louver LH.

  4. 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.

  5. 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.

  6. 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.

  7. 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.

  8. 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.

  9. 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.

  10. 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.

  11. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01GNYR

      Remove the 8 bolts and No. 2 engine under cover.

  12. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER


    1. A01GM9J

      Remove the 8 bolts and front suspension member protector lower.

  13. DRAIN ENGINE OIL


    1. A01GISB

      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 }

  14. 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.

  15. 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.

  16. 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.

  17. 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.

  18. REMOVE FRONT BUMPER COVER

    Click here

  19. REMOVE FRONT SUSPENSION LOWER CROSSMEMBER

    A01GLRX

    1. Remove the 2 clips.

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

  20. REMOVE FRAME SIDE RAIL


    1. A01GJLT

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

  21. 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.

  22. 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.

  23. 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.

  24. 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.

  25. 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.

  26. DISCONNECT NO. 1 RADIATOR HOSE

  27. DISCONNECT NO. 2 RADIATOR HOSE

  28. REMOVE ENGINE ROOM ECU OUTLET DUCT


    1. A01GJC3

      Remove the engine room ECU outlet duct.

  29. 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.

  30. 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.

  31. DISCONNECT HOSES AND CONNECTORS


    1. A01GKWD

      Remove the engine room ECU cover.

    2. Disconnect the 3 TCM connectors and 4 ECM connectors from the ECU box.

    3. A01GKA3

      Detach the clamp and disconnect the cooler compressor connector.

    4. A01GHUK

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

    5. A01GK6A

      Remove the bolt and disconnect the ground wire.

    6. A01GL3W

      Remove the 2 nuts and disconnect the wires with No. 1 engine room junction block.

    7. A01GMRW

      Disconnect the 2 heater hoses.

    8. A01GNN3

      Disconnect the purge line hose.

  32. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  33. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. A01GLG9

      Remove the 2 bolts and No. 1 exhaust pipe support bracket sub-assembly.

  34. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  35. REMOVE FRONT STABILIZER BAR

    Click here

  36. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Remove the RH side following the same procedures as the LH side.

  37. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A01GKBX

      Remove the 4 bolts and front suspension member reinforcement LH from the vehicle.

  38. REMOVE STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/ VGRS)


    1. A01GJFBE02
      Text in Illustration
      *a Front of the vehicle

      Loosen bolt A and remove bolt B, then slide the steering sliding with shaft yoke.

      Note


      • Do not remove bolt A.

      • Do not separate the steering sliding with shaft yoke from the power steering link.

    2. A01GHO5E04
      Text in Illustration
      *1 No. 2 steering intermediate shaft
      *2 Power steering link
      *a Matchmark

      Put matchmarks on the steering sliding with shaft yoke, No. 2 steering intermediate shaft and power steering link.

    3. Remove the bolt and the steering sliding with shaft yoke from the power steering link.

    4. A01GKZRE03
      Text in Illustration
      *1 Steering sliding with shaft yoke
      *2 No. 2 steering intermediate shaft

      Separate the steering sliding with shaft yoke from the No. 2 steering intermediate shaft.

      Tech Tips

      Insert a screwdriver or equivalent into the yoke's hole. Hold down the intermediate shaft's claw and remove the No. 2 steering intermediate shaft. If the claw is damaged, remove the claw. The intermediate shaft does not have to be replaced.

  39. REMOVE STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)


    1. A01GJFBE02
      Text in Illustration
      *a Front of the Vehicle

      Loosen bolt A and remove bolt B, then slide the steering sliding with shaft yoke.

      Note


      • Do not remove bolt A.

      • Do not separate the steering sliding with shaft yoke from the intermediate shaft.

    2. A01GHO5E04
      Text in Illustration
      *1 No. 2 steering intermediate shaft
      *2 Intermediate shaft
      *a Matchmark

      Put matchmarks on the steering sliding with shaft yoke, No. 2 steering intermediate shaft and intermediate shaft.

    3. Remove the bolt and the steering sliding with shaft yoke from the steering intermediate shaft.

    4. A01GKZRE03
      Text in Illustration
      *1 Steering sliding with shaft yoke
      *2 No. 2 steering intermediate shaft

      Separate the steering sliding with shaft yoke from the No. 2 steering intermediate shaft.

      Tech Tips

      Insert a screwdriver or equivalent into the yoke's hole. Hold down the intermediate shaft's claw and remove the intermediate shaft. If the claw is damaged, remove the claw. The intermediate shaft does not have to be replaced.

  40. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01GKDGE02
      Text in Illustration
      *a Matchmark

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

    2. Remove the bolt.

    3. A01GHOW

      Remove the clamp and No. 2 steering intermediate shaft.

  41. REMOVE POWER STEERING LINK ASSEMBLY (w/ VGRS)


    1. for LHD:

      Detach the 3 clips and disconnect the 5 connectors.

      A01GHNH

    2. for RHD:

      Detach the 5 clips and disconnect the 5 connectors.

      A01GJLR

    3. Remove the 4 bolts, 4 nuts and power steering link from the front frame and rack housing bracket.

      A01GIG5E02
      Text in Illustration
      *A for LHD *B for RHD

  42. REMOVE POWER STEERING LINK ASSEMBLY (w/o VGRS)


    1. for LHD:

      Detach the 3 clips and disconnect the 3 connectors.

      A01GMV3

    2. for RHD:

      Detach the 2 clips and disconnect the 3 connectors.

      A01GJO6

    3. Remove the 4 bolts, 4 nuts and power steering link from the front frame and rack housing bracket.

      A01GHVAE02
      Text in Illustration
      *A for LHD *B for RHD

  43. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GLSA

      Disconnect the air fuel ratio sensor connector.

    2. A01GKZT

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  44. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)


    1. A01GKNI

      Remove the 8 nuts and exhaust manifold LH.

    2. A01GJ4K

      Remove the gasket.

      Text in Illustration
      A01GKOV Front

  45. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. A01GISS

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

      Tech Tips

      It is not necessary to completely remove the cooler compressor assembly. With the hoses connected to the cooler compressor assembly, hang the cooler compressor assembly on the vehicle body with a rope.

  46. DISCONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY

    Click here

  47. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    A01GLZN

    1. Remove the nut and disconnect the floor shift gear shifting rod sub-assembly.

  48. REMOVE ENGINE AND TRANSMISSION


    1. A01GM58

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

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

    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. A01GIFF

      Remove the 6 engine rear mounting member's bolts.

    5. A01GKUU

      Remove the 4 bolts shown in the illustration.

    6. Operate the engine lifter then 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.

  49. 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.

  50. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01GIJH

      Remove the engine oil level dipstick.

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

  51. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GMCN

      Disconnect the air fuel ratio sensor connector.

    2. A01GLZZ

      Remove the 3 bolts and No. 1 exhaust manifold heat insulator.

  52. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 2)


    1. A01GMH5

      Remove the 8 nuts and exhaust manifold RH.

    2. A01GK39

      Remove the gasket.

      Text in Illustration
      A01GKOV Front

  53. REMOVE OIL COOLER TUBE


    1. Remove the 2 bolts and 2 clamps.

      A01GMM8E02
      Text in Illustration
      *1 Oil Cooler Tube Inlet *2 Oil Cooler Tube Outlet

    2. Loosen the union nuts of the oil cooler tube inlet and oil cooler tube outlet and disconnect them.

  54. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01GINW

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

  55. REMOVE ENGINE WIRE


    1. for Engine LH Side:


      1. A01GL7Z

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

      7. A01GK4OE01

        Disconnect the engine coolant temperature sensor connector.

      8. Disconnect the oil pressure switch connector.

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

      10. Remove the 3 bolts and disconnect the 3 clamps and ground wire.

      11. Remove the bolt and clamp bracket.

    2. for Engine RH Side:


      1. A01GKJ7

        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 engine wire connector.

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

      7. Disconnect the camshaft position sensor connector.

      8. Remove the nut and disconnect the generator wire and connector.

      9. Remove the nut and disconnect the starter wire and connector.

      10. Disconnect the crankshaft position sensor connector.

      11. Disconnect the engine oil level sensor connector.

      12. Remove the 3 bolts and disconnect the 3 clamp brackets and 2 clamps.

    3. Disconnect the throttle body connector.

    4. A01GLQV

      Disconnect the 4 injector driver connectors as shown in the illustration.

    5. A01GK60

      Disconnect the purge VSV connector.

    6. Disconnect the intake air control valve actuator connector.

    7. Remove the 2 bolts and disconnect the 2 clamp brackets and clamp.

    8. Remove the 4 nuts and engine wire.

  56. REMOVE STARTER ASSEMBLY


    1. A01GJOO

      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.

  57. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A01GMMC

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

  58. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY


    1. Support the automatic transmission assembly with a transmission jack.

      Note


      • In order to protect the oil pan, place attachments onto the transmission jack.

      • Make sure that the attachments and the oil pan are centered on the transmission jack.

  59. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01GI1XE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
    2. A01GMQK

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

  60. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01GMGFE01

      Remove the 2 nuts, then remove the front suspension crossmember sub-assembly from the engine.

  61. 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.

  62. REMOVE ENGINE MOUNTING SPACER


    1. A01GHQ6E01

      Remove the 2 engine mounting spacers.

  63. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01GJ9XE02

      Remove the 2 nuts and 2 front engine mounting insulators.

  64. 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.

  65. REMOVE ENGINE MOUNTING DAMPER


    1. A01GLZF

      Remove the 2 nuts and 2 engine mounting dampers.

  66. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A01GJXB

      Remove the 6 bolts and front No. 1 engine mounting bracket RH.

  67. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A01GL6N

      Remove the 6 bolts and front No. 1 engine mounting bracket LH.

  68. REMOVE INJECTOR DRIVER


    1. A01GNQVE01

      Disconnect the 4 injector driver connectors.

      Tech Tips

      To disconnect the injector driver connectors, push the claw downward and move the lock lever to release the lock.

    2. Disconnect the 2 clamps from the injector driver.

    3. Remove the 2 bolts, 2 nuts and injector driver from the intake manifold.

  69. REMOVE NO. 1 ENGINE COVER

  70. REMOVE NO. 2 ENGINE COVER (for LHD)


    1. A01GJU6

      Remove the 4 nuts and No. 2 engine cover.

  71. 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.

  72. REMOVE VENTILATION HOSE

  73. 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.

  74. 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.

  75. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    A01GK9J

  76. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

    A01GLVL

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

    A01GKCB

  78. 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.

  79. 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.

  80. 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.

  81. 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.

  82. REMOVE ENGINE COVER SUB-ASSEMBLY

    A01GI5SE01

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

  83. 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.

  84. 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.

  85. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Tech Tips

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

  86. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

    A01GLBZ

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

    2. A01GN1D

      Disconnect the fuel hose from the fuel pump.

  87. 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.

  88. 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.

  89. 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.

  90. 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.

  91. REMOVE SEPARATOR CASE


    1. A01GN04

      Disconnect the fuel pressure sensor connector.

    2. A01GMYW

      Remove the 4 bolts and separator case.

  92. REMOVE ENGINE WIRE


    1. A01GIHL

      Disconnect the 4 knock sensor connectors.

    2. Remove the 2 bolts and engine wire.

  93. REMOVE NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. A01GLMD

      Remove the No. 4 engine cover sub-assembly.

  94. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01GKEI

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

  95. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A01GHYJ

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

  96. 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.

  97. REMOVE WATER INLET HOUSING


    1. A01GLOQ

      Remove the 3 bolts, water inlet housing and gasket.

  98. 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.

  99. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01GIMM

      Disconnect the engine oil level sensor connector.

    2. Remove the 4 bolts.

    3. A01GNFY

      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.

  100. 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.

  101. REMOVE KNOCK SENSOR


    1. A01GJ2KE01

      Disconnect the 4 knock sensor connectors.

    2. Remove the 4 bolts and 4 knock sensors.

  102. 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.