FRONT SUSPENSION MEMBER(When Using the Engine Support Bridge for 2GR-FKS) REMOVAL

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine 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.

    Click here

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  3. SECURE STEERING WHEEL

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  5. REMOVE FRONT WHEELS

  6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  8. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  9. REMOVE NO. 2 ENGINE UNDER COVER

    Click here

  10. REMOVE FRONT FLOOR COVER LH

    Click here

  11. SEPARATE FRONT FENDER LINER LH

    Click here

  12. SEPARATE FRONT FENDER LINER RH

    Click here

  13. REMOVE FRONT FENDER APRON SEAL LH

    Click here

  14. REMOVE FRONT FENDER APRON SEAL RH

    Click here

  15. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH

    Click here

  16. REMOVE RADIATOR SIDE SEAL RH

    Click here

  17. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  18. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  19. REMOVE INLET AIR CLEANER ASSEMBLY

    Click here

  20. DRAIN ENGINE COOLANT

    Click here

  21. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

    Click here

  22. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  23. REMOVE THROTTLE BODY GASKET

    Click here

  24. REMOVE BATTERY

    Click here

  25. DISCONNECT ENGINE WIRE


    1. A0028QA

      Remove the 2 bolts and nut, disconnect the engine wire from the automatic transaxle case sub-assembly.

  26. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)

    Click here

  27. DISCONNECT VENTILATION HOSE

    Click here

  28. DISCONNECT PURGE VALVE (PURGE VSV)

    Click here

  29. REMOVE NO. 2 SURGE TANK STAY

    Click here

  30. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  31. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET

    Click here

  32. REMOVE WIRE HARNESS CLAMP BRACKET

    for 2WD: Click here

    for AWD: Click here

  33. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  34. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

    Click here

  35. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  36. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  37. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  38. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  39. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  40. SEPARATE TIE ROD ASSEMBLY LH

    Click here

  41. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

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

    Tech Tips

    Perform the same procedure as for the LH side.

  44. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for AWD)


    1. A0029IW

      Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.

  45. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (for AWD)

    Tech Tips

    Perform the same procedure as for the LH side.

  46. SEPARATE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY (for AWD)

    Click here

  47. SEPARATE STEERING LINK ASSEMBLY (for AWD)

    Click here

  48. SEPARATE TRANSMISSION OIL THERMOSTAT


    1. A002726

      Remove the 2 bolts and separate the transmission oil thermostat from the front frame assembly.

  49. SEPARATE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY


    1. Remove the hole plug.

    2. A002A8R

      Remove the 3 nuts and separate the front engine mounting insulator assembly.

  50. SEPARATE ENGINE MOUNTING INSULATOR LH


    1. Remove the 2 hole plugs.

    2. A002A13

      Remove the 3 nuts and separate the engine mounting insulator LH from the front frame assembly.

  51. SEPARATE ENGINE MOUNTING INSULATOR RH


    1. Remove the 2 hole plugs.

    2. A0027Q2

      Remove the 3 nuts and separate the engine mounting insulator RH from the front frame assembly.

  52. SEPARATE REAR ENGINE MOUNTING INSULATOR ASSEMBLY


    1. Remove the 2 hole plugs.

    2. A002927

      Remove the 2 nuts and separate the rear engine mounting insulator assembly from the front frame assembly.

  53. INSTALL ENGINE HANGERS

    for 2WD: Click here

    for AWD: Click here

  54. INSTALL ENGINE SUPPORT BRIDGE

    for 2WD: Click here

    for AWD: Click here

  55. INSTALL BELT

    for 2WD: Click here

    for AWD: Click here

  56. REMOVE FRONT FRAME ASSEMBLY


    1. A002A0AC03
      *a Chain Block Assembly
      B003Z57 Turn

      Using the chain block assembly, lift the engine with automatic transaxle assembly until the engine is slightly raised off the front frame assembly.

      Note


      • When suspending the engine with automatic transaxle assembly, do not tighten the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf).

      • Lift the engine with automatic transaxle assembly until the engine is slightly raised off the front frame assembly.

      • Do not lift the engine with automatic transaxle assembly excessively.

      • Do not shake the engine with automatic transaxle assembly excessively while it is suspended.

    2. A0028MMC01
      *a Engine Lifter
      *b Attachment
      B004057 Attachment Placement Location

      Support the front frame assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

      CAUTION:


      • The front frame assembly is a very heavy component. Make sure that it is supported securely.

      • If the front frame assembly is not securely supported, it may drop, resulting in serious injury.

      A0027TV

      Note

      Use attachments to keep the front frame assembly level.

    3. A002BMGC01
      B003ZIE Bolt
      B003Z8F Nut

      Remove the 6 bolts, 2 nuts and frame side rail plate RH and frame side rail plate LH.

    4. Remove the 6 bolts, 2 nuts and front suspension member rear brace RH and front suspension member rear brace LH.

    5. Slowly lower the front frame assembly.

      Note

      When lowering the front frame assembly, be careful not to damage the vehicle body or other components installed to the vehicle.

  57. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for 2WD)


    1. A002CEE

      Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.

  58. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (for 2WD)

    Tech Tips

    Perform the same procedure as for the LH side.

  59. REMOVE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY (for 2WD)


    1. Remove the front stabilizer bar with 2 front No. 2 stabilizer brackets, 2 front No. 1 stabilizer bar bushings and 2 front stabilizer link assemblies from the front frame assembly.

  60. REMOVE STEERING LINK ASSEMBLY (for 2WD)


    1. A002942

      Remove the 2 bolts, 2 nuts and steering link assembly from the front frame assembly.

      Note

      Keep the nut from rotating while turning the bolt because the nut has its own stopper.

  61. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH


    1. A00272B

      Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly LH from the front frame assembly.

      Note

      Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut secured.

  62. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  63. REMOVE NO. 2 FRAME CROSSMEMBER DYNAMIC DAMPER


    1. for 2WD:


      1. A00294E

        Remove the 2 bolts and No. 2 frame crossmember dynamic damper from the front frame assembly.

    2. for AWD:


      1. A002AIW

        Remove the 2 bolts and No. 2 frame crossmember dynamic damper from the front frame assembly.

  64. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER


    1. Remove the 2 front suspension member body mounting front stoppers from the front frame assembly.

  65. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER


    1. Remove the 2 front suspension member body mounting rear stoppers from the front frame assembly.

  66. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION


    1. B003YXMC01
      *1 Front Suspension Member Body Mounting Front Cushion

      Install SST as shown in the illustration.

      SST
      09830-10010   ( 09830-01010, 09830-01040, 09830-01050 )
      09950-40011   ( 09951-04020, 09952-04010, 09954-04010, 09955-04011, 09958-04011 )
    2. B00402VC04
      *a Turn
      *b Hold

      Using SST, remove each front suspension member body mounting front cushion from the front frame assembly.

      Note


      • Make sure that the claws of SST are securely engaged to the mounting cushion.

      • Tighten SST slowly and evenly.

      • Be careful as the mounting cushion may fly out.

      • The mounting cushion cannot be reused.

  67. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH


    1. B003ZXGC01
      *1 Front Suspension Member Body Mounting Rear Cushion LH

      Install SST as shown in the illustration.

      SST
      09830-10010   ( 09830-01010, 09830-01040, 09830-01050 )
      09950-40011   ( 09951-04020, 09952-04010, 09954-04010, 09955-04011, 09958-04011 )
    2. B003Z3JC04
      *a Turn
      *b Hold

      Using SST, remove the front suspension member body mounting rear cushion LH from the front frame assembly.

      Note


      • Make sure that the claws of SST are securely engaged to the mounting cushion.

      • Tighten SST slowly and evenly.

      • Be careful as the mounting cushion may fly out.

      • The mounting cushion cannot be reused.

  68. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH

    Tech Tips

    Perform the same procedure as for the LH side.

  69. REMOVE HOLE PLUG


    1. Remove the 10 hole plugs from the front frame assembly.

      Tech Tips

      There are 2 different shapes of hole plug.

      A002CM2N01