Page 1119 of 3000
2GR-FE FUEL – FUEL INJECTORFU–13
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page CO-6)
5. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
6. REMOVE FRONT WIPER ARM RH (See page WW-4)
7. REMOVE FRONT WIPER ARM LH (See page WW-4)
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
9. REMOVE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
10. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(a) Remove the 2 bolts and the No. 1 cowl top to cowl
brace inner.
11. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
(a) Remove the wire harness clamp.
(b) Disconnect the fuel pump resistor connector.
(c) Remove the 7 bolts and the cowl top panel outer
front.
12. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the 3 vacuum hoses.
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Page 1134 of 3000
2GR-FE FUEL – FUEL INJECTORFU–13
FU
REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
See page FU-1.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE NO. 1 ENGINE UNDER COVER
4. DRAIN ENGINE COOLANT (See page CO-6)
5. REMOVE FRONT WIPER ARM HEAD CAP (See page
WW-4)
6. REMOVE FRONT WIPER ARM RH (See page WW-4)
7. REMOVE FRONT WIPER ARM LH (See page WW-4)
8. REMOVE COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-4)
9. REMOVE WINDSHIELD WIPER MOTOR AND LINK
ASSEMBLY (See page WW-4)
10. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
(a) Remove the 2 bolts and the No. 1 cowl top to cowl
brace inner.
11. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
(a) Remove the wire harness clamp.
(b) Disconnect the fuel pump resistor connector.
(c) Remove the 7 bolts and the cowl top panel outer
front.
12. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-28)
13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the 3 vacuum hoses.
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Page 1163 of 3000
2GR-FE FUEL – FUEL TANKFU–43
FU
(f) Set up a transmission jack under the fuel tank
assembly.
(g) Remove the 6 set bolts of the 3 fuel tank bands.
(h) While operating the transmission jack, unfasten the
4 claws for the wire harness and disconnect the fuel
pump connector, then remove the fuel tank and the
3 fuel tank bands from the vehicle.
6. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(See page FU-30)
7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH
PUMP AND GAUGE (See page FU-31)
8. DRAIN FUEL
9. REMOVE FUEL TANK TO FILLER PIPE HOSE
(a) Loosen the hose clamp bolt and remove the fuel
tank to filler pipe hose from the fuel tank.
10. REMOVE FUEL TANK VENT HOSE
(a) Remove the hose of the fuel tank vent hose from the
3 hose clamps.
(b) Remove the fuel tank vent hose.
(1) Deeply push the connector to release the
locking tab.
(2) Pinch portion A.
(3) Pull out the connector.
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Page 1166 of 3000
2GR-FE FUEL – FUEL TANKFU–43
FU
(f) Set up a transmission jack under the fuel tank
assembly.
(g) Remove the 6 set bolts of the 3 fuel tank bands.
(h) While operating the transmission jack, unfasten the
4 claws for the wire harness and disconnect the fuel
pump connector, then remove the fuel tank and the
3 fuel tank bands from the vehicle.
6. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY
(See page FU-30)
7. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH
PUMP AND GAUGE (See page FU-31)
8. DRAIN FUEL
9. REMOVE FUEL TANK TO FILLER PIPE HOSE
(a) Loosen the hose clamp bolt and remove the fuel
tank to filler pipe hose from the fuel tank.
10. REMOVE FUEL TANK VENT HOSE
(a) Remove the hose of the fuel tank vent hose from the
3 hose clamps.
(b) Remove the fuel tank vent hose.
(1) Deeply push the connector to release the
locking tab.
(2) Pinch portion A.
(3) Pull out the connector.
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Page 1235 of 3000
CO–122GR-FE COOLING – WATER PUMP
CO
8. REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(b) Remove the 4 bolts and water pump pulley.
9. REMOVE WATER INLET HOUSING
(a) Disconnect the water hose.
(b) Remove the 2 bolts, nut and water inlet housing.
(c) Remove the water inlet housing gasket and water
outlet pipe O-ring.
10. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 16 bolts, water pump assembly and
water pump gasket.
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole and air hole for coolant
leakage.
(b) Turn the pulley, and check that the water pump
bearing moves smoothly and noiselessly.
If the bearing does not move smoothly and
noiselessly, replace the water pump.
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Page 1250 of 3000
2GR-FE COOLING – RADIATORCO–35
CO
28. DISCONNECT INLET SUB-ASSEMBLY
(a) Disconnect the inlet hose from the radiator.
(b) Remove the bolt and inlet sub-assembly from the
radiator.
DISASSEMBLY
1. REMOVE RADIATOR WATER INLET
(a) Remove the 2 bolts and radiator water inlet.
2. REMOVE DRAIN PLUG
(a) Remove the drain plug and air drain plug.
(b) Remove the 2 O-rings.
3. REMOVE LOWER RADIATOR TANK
(a) Install the claw to the overhaul handle, inserting it in
the hole in Part A as shown in the illustration.
SST 09230-01010 (09231-01010, 09231-01030)
(b) While squeezing the handle, adjust the stopper bolt
so that dimension B is as specified below.
Dimension B:
0.2 to 0.3 mm (0.008 to 0.012 in.)
NOTICE:
If the stopper bolt is not adjusted, the claw may
be damaged.
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Page 1257 of 3000
2GR-FE COOLING – RADIATORCO–39
CO
• Do not use SST to crimp the circled areas
indicated in the illustration. Use pliers and be
careful not to damage the core plates.
(f) Check the lock plate height A after completing the
crimping.
Standard plate height A:
8.8 mm (0.347 in.)
If the height is not as specified, readjust the stopper
bolt of the handle and crimp the lock plate again.
2. INSTALL UPPER RADIATOR TANK
HINT:
The installation procedure for the upper radiator tank is
the same as that for the lower radiator tank.
3. INSTALL DRAIN PLUG
(a) Install a new O-ring to the drain plug.
(b) Install a new O-ring to the air drain plug.
(c) Install the drain plug and air drain plug.
4. INSPECT FOR WATER LEAK
(a) Plug the inlet and outlet pipes of the radiator with
SST.
SST 09230-01010 (09231-00030, 09231-00060)
(b) Using a radiator cap tester, apply pressure to the
radiator.
Standard test pressure:
177 kPa (1.8 kgf/cm
2, 26 psi)
(c) Submerge the radiator in water.
(d) Inspect for leak.
HINT:
On radiators with resin tanks, there is clearance
between the tank and lock plate where a minute
amount of air will remain, giving the appearance of
an air leak when the radiator is submerged in water.
Therefore, before doing the water leak test, first
swish the radiator around in the water until all air
bubbles disappear.
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Page 1266 of 3000
CO–122GR-FE COOLING – WATER PUMP
CO
8. REMOVE WATER PUMP PULLEY
(a) Using SST, hold the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
(b) Remove the 4 bolts and water pump pulley.
9. REMOVE WATER INLET HOUSING
(a) Disconnect the water hose.
(b) Remove the 2 bolts, nut and water inlet housing.
(c) Remove the water inlet housing gasket and water
outlet pipe O-ring.
10. REMOVE WATER PUMP ASSEMBLY
(a) Remove the 16 bolts, water pump assembly and
water pump gasket.
INSPECTION
1. INSPECT WATER PUMP ASSEMBLY
(a) Visually check the drain hole and air hole for coolant
leakage.
(b) Turn the pulley, and check that the water pump
bearing moves smoothly and noiselessly.
If the bearing does not move smoothly and
noiselessly, replace the water pump.
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