Toyota Avalon (XX50): Engine Assembly

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Engine / 2gr-fks Engine Mechanical / Engine Assembly

Components

COMPONENTS

ILLUSTRATION

*A	Type A	*B	Type B
*1	FRONT FENDER APRON SEAL LH	*2	FRONT FENDER APRON SEAL RH
*3	FRONT LOWER BUMPER ABSORBER	*4	FRONT WHEEL OPENING EXTENSION PAD LH
*5	FRONT WHEEL OPENING EXTENSION PAD RH	*6	NO. 1 ENGINE UNDER COVER
*7	REAR ENGINE UNDER COVER LH	*8	REAR ENGINE UNDER COVER RH
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE	*2	INLET AIR CLEANER ASSEMBLY
*3	BATTERY	*4	BATTERY CLAMP SUB-ASSEMBLY
*5	ECM	*6	V-BANK COVER SUB-ASSEMBLY
*7	NO. 2 BATTERY CLAMP	*8	NO. 2 VENTILATION HOSE
*9	MASS AIR FLOW METER SUB-ASSEMBLY CONNECTOR	*10	VACUUM HOSE
*11	NO. 1 FUEL VAPOR FEED HOSE	*12	ENGINE ROOM MAIN WIRE
*13	EARTH WIRE	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	INLET HEATER WATER HOSE	*2	NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY
*3	NO. 1 FUEL HOSE	*4	NO. 1 FUEL VAPOR FEED HOSE
*5	NO. 2 RADIATOR HOSE	*6	OUTLET HEATER WATER HOSE
*7	RADIATOR HOSE SUB-ASSEMBLY	*8	SUCTION HOSE SUB-ASSEMBLY
*9	TRANSMISSION CONTROL CABLE ASSEMBLY	*10	UNION TO CHECK VALVE HOSE
*11	NO. 1 FUEL PIPE CLAMP	*12	O-RING
*13	RADIATOR RESERVE TANK ASSEMBLY	*14	NO. 2 FUEL PIPE CLAMP
	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Compressor oil ND-OIL 12 or equivalent	-	-

ILLUSTRATION

*1	ENGINE ASSEMBLY WITH TRANSAXLE	*2	FRONT FRAME ASSEMBLY
*3	REAR ENGINE MOUNTING INSULATOR	*4	WIRE HARNESS
*5	VACUUM HOSE	*6	NO. 1 WATER BY-PASS HOSE
*7	WATER BY-PASS HOSE ASSEMBLY	*8	TRANSMISSION BREATHER CLAMP
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*1	ENGINE ASSEMBLY WITH TRANSAXLE	*2	ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH
*3	ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH	*4	ENGINE MOUNTING SPACER
*5	ENGINE WIRE	*6	FRONT ENGINE MOUNTING INSULATOR
*7	FRONT FRAME ASSEMBLY	*8	ENGINE MOUNTING INSULATOR LH
*9	STEERING INTERMEDIATE SHAFT ASSEMBLY	*10	FRONT BUMPER EXTENSION SUB-ASSEMBLY RH
*11	FRONT BUMPER EXTENSION SUB-ASSEMBLY LH	*12	FRONT SUSPENSION MEMBER BRACKET SUB-ASSEMBLY RH
*13	FRONT SUSPENSION MEMBER BRACKET SUB-ASSEMBLY LH	*14	NO. 2 RELAY BLOCK COVER
*15	NO. 2 ENGINE MOUNTING STAY RH	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque

ILLUSTRATION

*1	AUTOMATIC TRANSAXLE ASSEMBLY	*2	FRONT ENGINE MOUNTING BRACKET
*3	BREATHER PLUG HOSE	*4	BREATHER PLUG SUB-ASSEMBLY
*5	NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)	*6	STARTER ASSEMBLY
*7	REAR DRIVE PLATE SPACER	*8	NO. 1 CRANKSHAFT POSITION SENSOR PLATE
*9	DRIVE PLATE AND RING GEAR SUB-ASSEMBLY	*10	FLYWHEEL HOUSING UNDER COVER
*11	DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT	-	-
*a	BLACK COLOR: x 1 SILVER COLOR: x 5	-	-
	Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
	Adhesive 1324	★	Precoated part

Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

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

Click here

2. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

HINT:

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

(a) Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A).

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.

3. INSTALL ENGINE MOUNTING SPACER

HINT:

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

(a) Install the engine mounting spacer to the vehicle body with the 2 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

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

(a) Install the engine mounting insulator sub-assembly RH to the engine mounting spacer and vehicle body with the nut and 2 bolts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

(b) Engage the clamp.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Install the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration.

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(e) Engage the clamp.

5. INSTALL ENGINE HANGERS

Click here

6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

7. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1

Click here

8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click here

9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

Click here

10. INSTALL FRONT ENGINE MOUNTING BRACKET

Click here

11. INSTALL REAR ENGINE MOUNTING INSULATOR

HINT:

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

Click here

12. INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

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

(a) Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

13. INSTALL FRONT FRAME ASSEMBLY

(a) Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(b) Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

14. REMOVE ENGINE HANGERS

Click here

15. INSTALL ENGINE WIRE

(a) Connect all connectors and clamps, and install the engine wire to the engine assembly with transaxle.

16. CONNECT WATER BY-PASS HOSE ASSEMBLY

Click here

17. CONNECT NO. 1 WATER BY-PASS HOSE

Click here

18. INSTALL BREATHER PLUG HOSE

Click here

19. INSTALL STARTER ASSEMBLY

Click here

20. CONNECT VACUUM HOSE

Click here

21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:

Perform Inspection After Repair after replacing the engine assembly.

Click here

(a) Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front frame assembly level, set an engine lifter underneath the engine assembly with transaxle and front frame assembly.

NOTICE:

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.

(b) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

(c) Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 8 bolts.

	Bolt
	Nut

Torque:

Bolt (A) :

9.0 N·m {92 kgf·cm, 80 in·lbf}

Bolt (B) :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

Bolt (C) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

(d) Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 4 bolts and 2 nuts.

Torque:

Bolt (D) :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

Bolt (E) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Nut :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

(e) Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

(f) Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH with the 3 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

42 N·m {428 kgf·cm, 31 ft·lbf}

(g) Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

22. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click here

23. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

24. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)

(a) Install the No. 1 exhaust pipe support bracket to the oil pan sub-assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

25. INSTALL FRONT DRIVE SHAFT ASSEMBLY

Click here

26. INSTALL EXHAUST MANIFOLD

Click here

27. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

28. CONNECT EARTH WIRE

(a) Connect the earth wire to the vehicle body with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

29. CONNECT ENGINE WIRE

(a) Engage the 2 clamps and connect the engine wire to the vehicle body.

(b) Connect the engine wire with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Engage the claw and connect the engine wire to the engine room relay block and junction block assembly.

(e) Install the nut to the engine room relay block and junction block assembly.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(f) Connect the 4 connectors to the engine room relay block and junction block assembly.

(g) Install the No. 2 relay block cover to the engine room relay block and junction block assembly.

30. CONNECT SUCTION HOSE SUB-ASSEMBLY

Click here

31. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

Click here

32. CONNECT NO. 1 FUEL HOSE

(a) Install the No. 1 fuel hose with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

(b) Connect the No. 1 fuel hose (for Port Injection).

(1) Connect the No. 1 fuel hose to the fuel pipe.

Click here

(1) Connect the No. 1 fuel hose to the fuel pipe.

Click here

(d) Install the No. 1 fuel pipe clamp to the fuel tube connector.

(e) Engage the 2 claws to install the No. 2 fuel pipe clamp.

33. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose to the heater water pipe and slide the clip to secure it.

34. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose to the water outlet and slide the clip to secure it.

(b) Engage the clamp.

35. CONNECT RADIATOR HOSE SUB-ASSEMBLY

(a) Connect the radiator hose sub-assembly to the water outlet and slide the clip to secure it.

(b) Install the radiator hose sub-assembly to the engine assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

36. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

37. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose to the brake booster assembly and slide the clip to secure it.

38. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve and slide the clip to secure it.

39. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(b) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

NOTICE:

Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

*a	Correct
*b	Incorrect

40. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly with the 3 bolts.

Torque:

18.5 N·m {189 kgf·cm, 14 ft·lbf}

(b) Engage the 5 clamps to the battery clamp sub-assembly.

41. INSTALL BATTERY

Click here

42. CONNECT ENGINE ROOM MAIN WIRE

(a) Connect the engine wire with engine room main wire to the positive (+) battery terminal with the nut.

Torque:

7.6 N·m {77 kgf·cm, 67 in·lbf}

43. INSTALL ECM

Click here

44. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

(a) Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly.

NOTICE:

Align the cutout of the air cleaner hose assembly with the protrusion of the throttle body with motor assembly.

*a	Protrusion
*b	Cutout
*c	Hose Clamp End
*d	2.0 mm (0.0787 in.)
*e	Paint Mark

(b) Tighten the hose clamp in the position shown in the illustration.

NOTICE:

Make sure that the end of the hose clamp is positioned as shown in the illustration.

NOTICE:

Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports at the same time.
Check that the pins are securely inserted into air cleaner supports.

*a	Air Cleaner Support

(d) Engage the vacuum hose to the air cleaner hose.

(e) Engage the 3 wire harness clamps.

(f) Connect the mass air flow meter sub-assembly connector.

(g) Connect the No. 2 ventilation hose to the air cleaner hose and slide the clip to secure it.

NOTICE:

Make sure that the condition of the clip is as shown in the illustration.

*1	No. 1 Fuel Vapor Feed Hose
*2	No. 2 Ventilation Hose
*a	Top
*b	Paint Mark
*c	Rear of Vehicle
*d	180° (Claw of Clip Location)

(h) Engage the 2 clamps to connect the No. 1 fuel vapor feed hose to the air cleaner hose.

45. INSTALL INLET AIR CLEANER ASSEMBLY

(a) Install the inlet air cleaner assembly with the 2 bolts in the order shown in the illustration.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

46. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly.

NOTICE:

Make sure that the clips are engaged securely.
Do not subject the clips to shock or apply excessive force to the clips when engaging them or they may be damaged.
If the clips are not engaged in the order shown in the illustration, the V-bank cover sub-assembly may be damaged.

47. INSPECT VACUUM HOSES

(a) Inspect the vacuum hoses.

48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

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

Click here

49. ADD ENGINE OIL

Click here

50. ADD ENGINE COOLANT

Click here

51. ADD AUTOMATIC TRANSAXLE FLUID

Click here

52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here

53. WARM UP ENGINE

Click here

54. INSPECT SHIFT LEVER POSITION

Click here

55. ADJUST SHIFT LEVER POSITION

Click here

56. INSPECT FOR ENGINE OIL LEAK

Click here

57. INSPECT FOR COOLANT LEAK

Click here

58. INSPECT FOR REFRIGERANT LEAK

Click here

59. INSPECT FOR FUEL LEAK

Click here

60. INSPECT FOR EXHAUST GAS LEAK

Click here

61. CHECK ENGINE OIL LEVEL

Click here

62. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

Click here

63. INSTALL FRONT LOWER BUMPER ABSORBER

(a) Engage the 2 claws to the front lower bumper absorber.

(b) Install the 4 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

64. INSTALL FRONT BUMPER COVER

Click here

65. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 screws and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

66. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 screws and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

67. INSTALL REAR ENGINE UNDER COVER RH

(a) Install the rear engine under cover RH with the 2 screws and 3 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

68. INSTALL REAR ENGINE UNDER COVER LH

(a) Install the rear engine under cover LH with the 2 screws and 3 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

69. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the No. 1 engine under cover with the bolt, 6 screws and 2 clips.

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

70. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

(a) Install the front wheel opening extension pad LH with the 3 screws.

71. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

(a) Install the front wheel opening extension pad RH with the 3 screws.

72. INSTALL FRONT WHEELS

Click here

73. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

74. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

75. PERFORM INITIALIZATION

Click here

76. INSPECT IGNITION TIMING

Click here

77. INSPECT ENGINE IDLE SPEED

Click here

78. INSPECT CO/HC

Click here

79. CHECK FOR SPEED SENSOR SIGNAL

Click here

Removal

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

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane departure alert system (w/ Steering Control)
		Pre-collision system
		Intelligent Clearance Sonar System*1
		Lighting System (for Gasoline Model with Cornering Light)
	Memorize steering angle neutral point	Parking Assist Monitor System
	Memorize steering angle neutral point	Panoramic View Monitor System
Replacement of ECM	Vehicle Identification Number (VIN) registration	MIL comes on
Replacement of ECM	ECU communication ID registration (Immobiliser system)	Engine start function
Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.
Replacement of automatic transaxle assembly	Perform reset memory Input transaxle compensation code into ECM Perform road test to allow ECM to learn	Large shift shock Deterioration of fuel efficiency	for Initialization for Registration
Replacement of ECM (If transaxle compensation code read from ECM)	Perform reset memory*2 Transfer transaxle compensation code Perform road test to allow ECM to learn
Replacement of ECM (If transaxle compensation code not read from ECM)	Perform reset memory*2 Reset transaxle compensation code Perform road test to allow ECM to learn
Replacement of automatic transaxle fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly
Replacement of ECM	Code registration (Smart Key System (for Start Function))	Wireless Door Lock Control System Smart Key System (for Entry Function) Smart Key System (for Start Function) Steering lock function
Suspension, tires, etc.	Measure ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent Clearance Sonar System Intuitive Parking Assist System
	Rear television camera assembly optical axis adjustment (Back camera position setting)	Parking Assist Monitor System	for Initialization for Calibration
	Parking assist ECU initialization Adjust steering angle Television camera assembly optical axis adjustment (Back camera position setting)	Panoramic View Monitor System	for Initialization for Calibration
	Perform headlight ECU sub-assembly LH initialization	Lighting system (for Gasoline Model with Cornering Light)
Front wheel alignment adjustment	Perform system variant learning and acceleration sensor zero point calibration.	VSC is disabled or malfunctions DTCs are output Slip indicator light illuminates ABS warning light illuminates

*1: When performing learning using the Techstream.
Click here
*2: Not necessary when ECM replaced with new one.

CAUTION:

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.

*a

An Object Exceeding Weight Limit of 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 here

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click here

3. DISCHARGE FUEL SYSTEM PRESSURE

Click here

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

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

Click here

5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

6. SECURE STEERING WHEEL

Click here

7. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

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

8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

(a) Remove the 3 screws and front wheel opening extension pad RH.

9. REMOVE NO. 1 ENGINE UNDER COVER

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

10. REMOVE REAR ENGINE UNDER COVER LH

(a) Remove the 2 screws, 3 clips and rear engine under cover LH.

11. REMOVE REAR ENGINE UNDER COVER RH

(a) Remove the 2 screws, 3 clips and rear engine under cover RH.

12. REMOVE FRONT FENDER APRON SEAL LH

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

13. REMOVE FRONT FENDER APRON SEAL RH

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

14. REMOVE FRONT BUMPER COVER

Click here

15. REMOVE FRONT LOWER BUMPER ABSORBER

(a) Remove the 4 bolts.

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

16. DRAIN ENGINE COOLANT

Click here

17. DRAIN ENGINE OIL

Click here

18. DRAIN AUTOMATIC TRANSAXLE FLUID

Click here

19. REMOVE V-BANK COVER SUB-ASSEMBLY

(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.

20. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Remove the 2 bolts and inlet air cleaner assembly.

21. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

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

*1	No. 1 Fuel Vapor Feed Hose
*2	No. 2 Ventilation Hose

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

(d) 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.

22. REMOVE ECM

Click here

23. DISCONNECT ENGINE ROOM MAIN WIRE

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

24. REMOVE BATTERY

Click here

25. REMOVE BATTERY CLAMP SUB-ASSEMBLY

(a) Disengage the 5 clamps from the battery clamp sub-assembly.

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

26. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) 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.

*a	Clip
*b	45° to 60°

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

27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

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

28. DISCONNECT UNION TO CHECK VALVE HOSE

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

29. DISCONNECT NO. 2 RADIATOR HOSE

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

30. 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.

31. DISCONNECT INLET HEATER WATER HOSE

(a) Disengage the clamp.

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

32. DISCONNECT OUTLET HEATER WATER HOSE

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

33. DISCONNECT NO. 1 FUEL HOSE

(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.

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

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

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

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(e) Separate the bolt and disengage the No. 1 fuel hose.

34. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

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35. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

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36. DISCONNECT ENGINE WIRE

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.

(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.

37. DISCONNECT EARTH WIRE

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

38. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

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39. REMOVE EXHAUST MANIFOLD

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40. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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

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

42. REMOVE FLYWHEEL HOUSING UNDER COVER

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

43. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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44. 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.

	Bolt
	Nut

(e) 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.

45. DISCONNECT VACUUM HOSE

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46. REMOVE STARTER ASSEMBLY

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47. REMOVE BREATHER PLUG HOSE

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48. DISCONNECT NO. 1 WATER BY-PASS HOSE

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49. DISCONNECT WATER BY-PASS HOSE ASSEMBLY

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50. REMOVE ENGINE WIRE

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

51. INSTALL ENGINE HANGERS

(a) 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}

No. 1 Engine Hanger	12281-31121
No. 2 Engine Hanger	12282-31100
Bolt	90119-A0117

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

(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.

52. REMOVE FRONT FRAME ASSEMBLY

(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.

53. REMOVE FRONT ENGINE MOUNTING INSULATOR

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.

54. REMOVE REAR ENGINE MOUNTING INSULATOR

HINT:

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

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55. REMOVE FRONT ENGINE MOUNTING BRACKET

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56. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

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57. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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58. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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59. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

(a) Install the engine assembly to an engine stand.

60. 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.

61. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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.

(d) Disengage the clamp.

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

62. REMOVE ENGINE MOUNTING SPACER

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.

63. REMOVE ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

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.

64. REMOVE ENGINE MOUNTING INSULATOR LH

HINT:

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

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Drive Belt

Engine Unit

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