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EM–262GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-13)
2. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM (See page AC-172)
3. REMOVE BATTERY
(a) Disconnect the negative battery terminal.
(b) Disconnect the positive battery terminal.
(c) Loosen the nut, and remove the bolt and battery
clamp.
(d) Remove the battery and battery tray.
4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
5. REMOVE FRONT WHEELS
6. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY
(a) Remove the 8 bolts, 4 clips and No. 1 engine under
cover assembly.
7. REMOVE FRONT FENDER APRON SEAL RH
(a) Remove the 2 bolts, clip and front fender apron seal
RH.
8. REMOVE FRONT FENDER APRON SEAL LH
(a) Remove the 2 bolts, clip and front fender apron seal
LH.
9. DRAIN ENGINE OIL (See page LU-4)
10. DRAIN ENGINE COOLANT (See page CO-6)
11. DRAIN AUTOMATIC TRANSAXLE FLUID (See page
AX-159)
12. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
13. REMOVE WINDSHIELD WIPER ARM AND BLADE
ASSEMBLY RH (See page WW-4)
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–27
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14. REMOVE WINDSHIELD WIPER ARM AND BLADE
ASSEMBLY LH (See page WW-4)
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
16. REMOVE FRONT WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
17. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(a) Remove the 2 bolts, 2 clips and No. 1 cowl top to
cowl brace inner.
18. REMOVE FRONT OUTER COWL TOP PANEL SUB-
ASSEMBLY
(a) Remove the nut, and separate the fuel pump
resistor.
(b) Remove the 2 clips, and separate the engine wire.
(c) Remove the 7 bolts and front outer cowl top panel
sub-assembly.
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EM–282GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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19. REMOVE V-BANK COVER SUB-ASSEMBLY
(a) Hold the front of the V-bank cover and raise it to
disengage the 2 clips on the front of the cover.
Continue to raise the cover to disengage the clip on
the rear of the cover and remove the cover.
NOTICE:
Attempting to disengage both front and rear
clips at the same time may cause the cover to
break.
20. REMOVE NO. 2 AIR CLEANER INLET
(a) Disconnect the vacuum switching valve clamp.
(b) Disconnect the 2 vacuum hoses.
(c) Remove the 2 bolts and No. 2 air cleaner inlet.
21. REMOVE NO. 1 AIR CLEANER INLET
(a) Remove the bolt and No. 1 air cleaner inlet.
22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See
page IT-4)
23. REMOVE AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
(a) Disconnect the vacuum switching valve connector.
(b) Disconnect the vacuum hose.
(c) Remove the 3 bolts and air cleaner case.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–29
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25. REMOVE AIR CLEANER BRACKET
(a) Remove the 2 bolts and air cleaner bracket.
26. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY
(a) Remove the clip, bolt and intake air resonator.
27. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove bolt, 2 nuts and No. 2 engine mounting
stay RH.
28. REMOVE ENGINE MOVING CONTROL ROD
(a) Remove the 3 bolts and engine moving control rod.
29. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
(a) Remove the clamp and disconnect the No. 1 fuel
vapor feed hose.
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EM–302GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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30. DISCONNECT RADIATOR INLET HOSE
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect radiator inlet hose from the water
outlet.
31. DISCONNECT RADIATOR OUTLET HOSE
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect the radiator outlet hose from the
water inlet.
32. DISCONNECT HEATER WATER OUTLET HOSE B
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect heater water inlet hose B from the
water inlet.
33. DISCONNECT HEATER WATER INLET HOSE B
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect heater water outlet hose B from
the water outlet.
34. DISCONNECT FUEL TUBE SUB-ASSEMBLY
(a) Remove the No. 1 fuel pipe clamp.
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2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLYEM–31
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(b) Disconnect the fuel tube from the fuel pipe while
pinching part A with your fingers as shown in the
illustration.
NOTICE:
• Check for contamination in the pipe and
around the connector. Clean if necessary and
then disconnect the connector.
• Disconnect the connector by hand.
• Do not bend, fold or rotate the nylon tube.
• If the pipe and connector are stuck together,
push and pull the connector until it becomes
free.
• Put the pipe and connector ends in vinyl bags
to prevent damage and contamination.
35. DISCONNECT NO. 1 OIL COOLER INLET HOSE
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect the No. 1 oil cooler inlet hose from
the No. 1 oil cooler inlet tube.
36. REMOVE NO. 1 OIL COOLER OUTLET HOSE
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect the No. 1 oil cooler outlet hose
from the No. 1 oil cooler outlet tube.
37. DISCONNECT TRANSMISSION CONTROL CABLE
ASSEMBLY
(a) Remove the nut from the control shaft lever.
(b) Disconnect the transmission control cable assembly
from the control shaft lever.
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EM–322GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
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(c) Remove the clip and disconnect the transmission
control cable assembly from the control cable
bracket.
(d) Disconnect the control cable from the control cable
clamp.
38. DISCONNECT RETURN TUBE SUB-ASSEMBLY
(a) Using pliers, grip the claws of the 2 clips and slide
the 2 clips to disconnect the 2 return tube sub-
assemblies.
(b) Drain the power steering fluid.
NOTICE:
Take care not to damage the hose protector.
39. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP
HOSE
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect the No. 1 oil reservoir to pump
hose from the oil reservoir tank.
40. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the engine room
junction block.
(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, unlock the engine room
junction block. Pull the engine room junction
block upward.
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(b) Remove the bolt and 2 clamps from the body.
(c) Remove the 2 bolts and 2 ground cables.
(d) Disconnect the engine wire from the ECM and
passenger side junction block.
41. DISCONNECT UNION TO CHECK VALVE HOSE
(a) Using pliers, grip the claws of the clip and slide the
clip to disconnect the union to check valve hose.
42. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for
4WD)
(a) Remove the center exhaust pipe assembly (See
page EX-8).
43. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for
4WD)
(a) Remove the front exhaust pipe assembly (See page
EX-9).
44. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for
2WD)
(a) Remove the front exhaust pipe assembly (See page
EX-3).
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