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2GR-FKS ENGINE MECHANICAL ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed
and installed, or replaced during engine assembly removal/installation are shown below.
Necessary Procedure After Parts Removed/Installed/Replaced
Effect/Inoperative Function
Replaced Part or Performed
Necessary Procedure when Necessary Procedure Link
Procedure
not Performed
Lane departure alert system (w/
Perform steering sensor zero Steering Control)
point calibration ( )
Battery terminal is Pre-collision system
disconnected/reconnected
Memorize steering angle neutral Parking Assist Monitor System ( )
point Panoramic View Monitor System ( )
Vehicle Identification Number
MIL comes on ( )
(VIN) registration
Replacement of ECM See Service
Perform code registration Bulletin for the
Engine start function
(Immobiliser system) registration
method.

· Replacement of engine
· Poor idle, etc.
assembly
Inspection after repair · Engine start function,
· Gas leak from exhaust ( )
etc.
system is repaired

1. Reset Memory
2. Input transaxle
Replacement of automatic compensation code into
transaxle assembly ECM
3. Perform road test to
allow ECM to learn

1. Reset memory*1 ( )
Replacement of ECM · Large shift shock
2. Transfer transaxle for Initialization
(If possible, read the transaxle · Deterioration of fuel
compensation code
compensation code from the efficiency ( )
3. Perform road test to
previous ECM) allow ECM to learn for Registration

1. Reset memory*1
Replacement of ECM 2. Reset transaxle
(If impossible, read the transaxle compensation code
compensation code from the 3. Perform road test to
previous ECM) allow ECM to learn

· Wireless door lock control

system
· Smart Entry and Start
System (for Entry See Service
Perform code registration Function) Bulletin for the
Replacement of ECM
(Immobiliser function) · Smart Entry and Start registration
System (for Start method.
Function)
· Steering lock function
 Effect/Inoperative Function
Replaced Part or Performed
Necessary Procedure when Necessary Procedure Link
Procedure
not Performed

( )
Rear television camera assembly
for Initialization
optical axis (Back camera Parking assist monitor system
position setting) ( )
for Calibration

Suspension, tires, etc. · Television camera

(The vehicle height changes controller initialization
· Adjust steering angle ( )
because of suspension or tire for Initialization
replacement) · Rear television camera Panoramic view monitor system
assembly optical axis ( )
(Back camera position for Calibration
setting)

Perform headlight ECU sub-

Lighting system (EXT) ( )
assembly LH initialization

· VSC disabled or
malfunctioning
Perform system variant learning · DTCs are output
Front wheel alignment · Slip indicator light
and acceleration sensor zero ( )
adjustment illuminated
point calibration.
· ABS warning light
illuminated

*1: When the ECM is replaced with a new one, reset memory is unnecessary.
CAUTION:
·

An Object Exceeding Weight Limit of Engine

*a
Lifter

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or
the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.
 ·

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is
hot.

PROCEDURE

1. PRECAUTION

NOTICE:
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 hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

2.RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR(for 2GR-FKS)>REMOVAL

3. DISCHARGE FUEL SYSTEM PRESSURE

Click hereEngine / Hybrid System>2GR-FKS FUEL>FUEL SYSTEM>PRECAUTION

4.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION

5.ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

6. SECURE STEERING WHEEL

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL

7.REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 53852K

a. Remove the 3 screws and front wheel opening extension pad LH.

8.REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 53851M

a. Remove the 3 screws and front wheel opening extension pad RH.
 9.REMOVE NO. 1 ENGINE UNDER COVER 51441

a. Remove the bolt, 2 clips, 6 screws and No. 1 engine under cover.

10.REMOVE FRONT FENDER APRON SEAL LH 53737B

a. Remove the 2 screws, clip and front fender apron seal LH from the vehicle body.

11.REMOVE FRONT FENDER APRON SEAL RH 53736

a. Remove the 2 screws, clip and front fender apron seal RH from the vehicle body.

12.REMOVE FRONT BUMPER COVER 52119A

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER>REMOVAL

13.REMOVE FRONT LOWER BUMPER ABSORBER 52618

a.

Remove the 4 bolts.

b. Disengage the 2 claws to remove the front lower bumper absorber.

14.DRAIN ENGINE COOLANT

Click hereGeneral>MAINTENANCE>2GR-FKS COOLANT>REPLACEMENT

15.DRAIN ENGINE OIL

Click hereGeneral>MAINTENANCE>2GR-FKS OIL AND OIL FILTER>REPLACEMENT

16.DRAIN AUTOMATIC TRANSAXLE FLUID

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>TRANSMISSION WIRE>REMOVAL

17.REMOVE V-BANK COVER SUB-ASSEMBLY 11209

a. Disengage the 4 clips in the order shown in the illustration and lift the V-bank cover sub-assembly upward to remove it.
 Hold here Pull in this Direction

NOTICE:
· Pull the V-bank cover sub-assembly straight up to remove it.
· Do not remove the V-bank cover sub-assembly in any direction other than upward. If the V-bank cover sub-
assembly is removed in any direction other than upward, it may be damaged.
· If the clips are not disengaged in the order shown in the illustration, the V-bank cover sub-assembly may be
damaged.

18.REMOVE INLET AIR CLEANER ASSEMBLY 17750A

a.

Remove the 2 bolts and inlet air cleaner assembly.

19.REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

a.

*1 No. 1 Fuel Vapor Feed Hose

*2 No. 2 Ventilation Hose

Disengage the 2 clamps to disconnect the No. 1 fuel vapor feed hose from the air cleaner hose.

b. Slide the clip and disconnect the No. 2 ventilation hose from the air cleaner hose.

c.

Loosen the hose clamp.

d.
 *a Pin

Disconnect the mass air flow meter sub-assembly connector.

e. Disengage the 3 wire harness clamps.

f. Disconnect the vacuum hose from the air cleaner hose.

g. Disengage the 3 pins and remove the air cleaner assembly with air cleaner hose.
NOTICE:
Make sure the air cleaner support remains attached to the vehicle body.

20.REMOVE ECM 89661

Click hereEngine / Hybrid System>2GR-FKS ENGINE CONTROL>ECM>REMOVAL

21.DISCONNECT ENGINE ROOM MAIN WIRE 82111

a.

Remove the nut and disconnect the engine wire with engine room main wire from the positive (+) battery terminal.

22.REMOVE BATTERY

Click hereGeneral>MAINTENANCE>2GR-FKS BATTERY>REMOVAL

23.REMOVE BATTERY CLAMP SUB-ASSEMBLY 74404A

a.

Disengage the 5 clamps from the battery clamp sub-assembly.

b. Remove the 3 bolts and battery clamp sub-assembly.

24.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 33820B

a.

*a Clip
*b 45° to 60°

While disengaging the clip as shown in the illustration, disconnect the transmission control cable assembly from the
transmission control shaft lever together with the clip.
b.

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

25.DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 23826

a.

Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.

26.DISCONNECT UNION TO CHECK VALVE HOSE 44773F

a. for LHD:
i.

Slide the clip and disconnect the union to check valve hose from the brake booster assembly.

b. for RHD:
 i.

Slide the clip and disconnect the union to check valve hose from the brake booster assembly.

27.DISCONNECT NO. 2 RADIATOR HOSE 16572D

a.

Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

28.SEPARATE RADIATOR HOSE SUB-ASSEMBLY

a.

Slide the clip and disconnect the radiator hose sub-assembly from the water outlet.

b. Remove the 2 bolts and separate the radiator hose sub-assembly from the engine assembly.

29.DISCONNECT INLET HEATER WATER HOSE 87245

a.

Disengage the clamp.

b. Slide the clip and disconnect the inlet heater water hose from the water outlet.

30.DISCONNECT OUTLET HEATER WATER HOSE 87246

a.

Slide the clip and disconnect the outlet heater water hose from the heater water pipe.

31.DISCONNECT NO. 1 FUEL HOSE 23801F

a.

Disengage the 2 claws to remove the No. 2 fuel pipe clamp.

b.

Remove the No. 1 fuel pipe clamp from the fuel tube connector.

c. Disconnect the No. 1 fuel hose (for Port Injection).

i.

Disconnect the No. 1 fuel hose from the fuel pipe.

Click hereEngine / Hybrid System>2GR-FKS FUEL>FUEL SYSTEM>PRECAUTION

d. Disconnect the No. 1 fuel hose (for Direct Injection).

i.

Disconnect the No. 1 fuel hose from the fuel pipe.

Click hereEngine / Hybrid System>2GR-FKS FUEL>FUEL SYSTEM>PRECAUTION
 e.

Separate the bolt and disengage the No. 1 fuel hose.

32.DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY 88711

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR(for 2GR-FKS)>REMOVAL

33.DISCONNECT SUCTION HOSE SUB-ASSEMBLY 88704

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR(for 2GR-FKS)>REMOVAL

34.DISCONNECT ENGINE WIRE 82121

HINT:
After disconnecting the engine wire, secure it with tape or equivalent to keep it out of the way.

a.

Remove the No. 2 relay block cover from the engine room relay block and junction block assembly.
b.

Remove the nut from the engine room relay block and junction block assembly.

c. Disconnect the 4 connectors from the engine room relay block and junction block assembly.

d. Disengage the 2 clamps.

e. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction
block assembly.

f.

Remove the bolt.

g. Disengage the 2 clamps and disconnect the engine wire from the vehicle body.

35.DISCONNECT EARTH WIRE 82284

 a.

Remove the 2 bolts and disconnect the earth wire from the vehicle body.

36.SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 45220

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL

37.REMOVE EXHAUST MANIFOLD

Click hereEngine / Hybrid System>2GR-FKS INTAKE / EXHAUST>EXHAUST MANIFOLD>REMOVAL

38.REMOVE FRONT DRIVE SHAFT ASSEMBLY

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>FRONT DRIVE SHAFT ASSEMBLY(for 2GR-FKS)>REMOVAL

39.REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side) 17571

a.

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

40.REMOVE FLYWHEEL HOUSING UNDER COVER 11361J

a.
 Remove the 2 bolts and flywheel housing under cover.

41.REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 32101A

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

42.REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

a. Set an engine lifter.

NOTICE:
· Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
· Do not perform any procedures 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
to or removed from an engine stand.
· To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is
secured to an engine stand.
· To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan
sub-assembly of the engine assembly with transaxle.

b.

Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

c.

Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the front No. 1 engine
mounting bracket LH.
d.

Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket sub-assembly
LH.

e.

Bolt

Nut

Remove the 8 bolts and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the
front frame assembly and vehicle body.

f. Remove the 4 bolts, 2 nuts and front suspension member bracket sub-assembly RH and front suspension member bracket
sub-assembly LH from the front frame assembly and vehicle body.

g. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
NOTICE:
· Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
 · While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

43.DISCONNECT VACUUM HOSE

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

44.REMOVE STARTER ASSEMBLY 28100

Click hereEngine / Hybrid System>2GR-FKS STARTING>STARTER>REMOVAL

45.REMOVE BREATHER PLUG HOSE 35104V

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

46.DISCONNECT NO. 1 WATER BY-PASS HOSE 16261G

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

47.DISCONNECT WATER BY-PASS HOSE ASSEMBLY 16260

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

48.REMOVE ENGINE WIRE 82121

a. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.

49.INSTALL ENGINE HANGERS

a.

*A for Bank 1
*B for Bank 2
*1 No. 1 Engine Hanger
*2 No. 2 Engine Hanger

Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
Torque:
33 N*m (337 kgf*cm, 24 ft.*lbf)

HINT:
No. 1 Engine Hanger 12281-31121
No. 2 Engine Hanger 12282-31100
Bolt 91671-10825

b. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.
 NOTICE:
· Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine
assembly.
· Do not perform any procedures 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
to or removed from an engine stand.

50.REMOVE FRONT FRAME ASSEMBLY 51100G

a.

Remove the bolt and separate the front engine mounting insulator from the front engine mounting bracket.

b.

Remove the 4 nuts and separate the rear engine mounting insulator from the front frame assembly.

51.REMOVE FRONT ENGINE MOUNTING INSULATOR 12361A

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

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

52.REMOVE REAR ENGINE MOUNTING INSULATOR 12371A

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

Click hereEngine / Hybrid System>2GR-FKS ENGINE CONTROL>ACTIVE CONTROL ENGINE MOUNT(for Rear Side)>REMOVAL

53.REMOVE FRONT ENGINE MOUNTING BRACKET 12311A

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

54.REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 30500

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

55.REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 32101

Click hereEngine / Hybrid System>2GR-FKS ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>REMOVAL

56.REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 19315

Click hereEngine / Hybrid System>2GR-FKS ENGINE MECHANICAL>REAR CRANKSHAFT OIL SEAL>REMOVAL

57.INSTALL ENGINE ASSEMBLY TO ENGINE STAND

a. Install the engine assembly to an engine stand.

58.REMOVE ENGINE HANGERS

a. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and cylinder head
LH.

59.REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 12305

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

a.

Disengage the clamp.

b. Remove the bolt, nut and separate the radiator reserve tank assembly.
 c.

Remove the bolt and separate the bracket from the engine mounting insulator sub-assembly RH.

d.

Remove the bolt and disconnect the No. 1 bond cable from the engine mounting insulator sub-assembly RH.

e.

Disengage the clamp.

f. Remove the nut, 2 bolts and engine mounting insulator sub-assembly RH from the engine mounting spacer and vehicle
body.

60.REMOVE ENGINE MOUNTING SPACER 12341

HINT:
Perform this procedure only when replacement of the engine mounting spacer is necessary.
 a.

Remove the 2 bolts and engine mounting spacer from the vehicle body.

61.REMOVE ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH 12304

HINT:
Perform this procedure only when replacement of the engine mounting bracket sub-assembly LH is necessary.

a.

Remove the 4 bolts and engine mounting bracket sub-assembly LH from the vehicle body.

62.REMOVE ENGINE MOUNTING INSULATOR LH 12372A

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

Click hereDrivetrain>UA80E AUTOMATIC TRANSMISSION / TRANSAXLE>AUTOMATIC TRANSAXLE ASSEMBLY>REMOVAL

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