3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–21

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE (See page
FU-20)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
CAUTION:
Wait for least 90 seconds after disconnecting the
cable from the negative (-) battery terminal to
prevent airbag and seat belt pretensioner activation.
3. REMOVE FRONT WHEELS
4. DRAIN ENGINE OIL (for 2WD) (See page LU-5)
5. DRAIN ENGINE OIL (for 4WD) (See page LU-8)
6. DRAIN ENGINE COOLANT (See page CO-7)
7. DRAIN AUTOMATIC TRANSMISSION FLUID (for
2WD) (See page AT-175)
EM
8. DRAIN AUTOMATIC TRANSMISSION FLUID (for
4WD) (See page AT-209)
9. DRAIN FRONT DIFFERENTIAL OIL (for 4WD)
(a) Drain the differential oil plug.
10. REMOVE COOL AIR INTAKE DUCT SEAL
(a) Remove the 7 clips and intake duct seal.

Clip
A105932E01

11. REMOVE ENGINE ROOM COVER SIDE RH

(a) Remove the nut, 2 clip and side cover.
Nut

Clip
A105933E01
 EM–22 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY

12. REMOVE ENGINE ROOM SIDE COVER LH

(a) Remove the 3 clips and side cover.

Clip
A105934E01

13. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Remove the 2 nuts and V-bank cover.
14. REMOVE ENGINE UNDER COVER (See page ET-3)
15. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD)
(a) Remove the 4 screws, 2gromets, 2 spacers and
EM under cover.
16. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See
page EX-8)
A103946

17. REMOVE PROPELLER WITH CENTER BEARING

SHAFT ASSEMBLY (See page PR-8)
18. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
(for 4WD) (See page PR-3)
19. REMOVE NO. 1 AIR CLEANER INLET
(a) Remove the bolt and air cleaner inlet.

A107673

20. REMOVE AIR CLEANER ASSEMBLY WITH HOSE

(a) Disconnect the ventilation hose from the cylinder
head.

A103947
3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–23

(b) Disconnect the MAF meter connector.

(c) Disconnect the clamp from the air cleaner.

A103948

(d) Disconnect the EVAP VSV.

(e) Loosen the hose clamp.
(f) Remove the 3 bolts and air cleaner case.
21. DISCONNECT RADIATOR HOSE INLET (See page
CO-28)
22. DISCONNECT RADIATOR HOSE OUTLET (See page EM
CO-28)
23. DISCONNECT RADIATOR RESERVE TANK HOSE
A103949

24. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Remove the clamp and disconnect the union to
check valve hose.

A107674

25. DISCONNECT HEATER WATER INLET HOSE A

(a) Disconnect the inlet hose.

A107676

26. DISCONNECT HEATER WATER OUTLET HOSE A

(a) Disconnect the outlet hose.
27. DISCONNECT FUEL MAIN TUBE (See page FU-22)

A107679
 EM–24 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY

28. REMOVE ENGINE ROOM ECM COVER

(a) Remove the 3 bolts and engine room ECM cover.

A105290

29. DISCONNECT ENGINE WIRE

(a) Disconnect the ECM connectors.
(b) Using a screwdriver, disconnect the connector
holder.
(c) Disconnect the 6 ECM connectors.
(d) Remove the nut and disconnect the battery positive
EM (+) cable.
(e) Remove the engine room No. 1 relay block, junction
Clip block cover.
A105291E01

(f) Remove the nut and disconnect the wire from the
engine room No. 1 relay block, junction block.
(g) Remove the bolt and disconnect the ground cable.
30. REMOVE FAN AND GENERATOR V BELT (See page
EM-7)

) A108748

31. DISCONNECT WITH PULLEY COMPRESSOR

ASSEMBLY (for 2WD)
(a) Disconnect the magnetic clutch connector.
(b) Remove the 3 bolts and nut.

A109520

(c) Using an E8 "torx" socket, remove the stud bolt and

with pulley compressor.
HINT:
It is not necessary to completely remove the
compressor. With the hoses connected to the
compressor, hang the compressor on the vehicle
body with a rope.

A109604
3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–25

32. DISCONNECT WITH PULLEY COMPRESSOR

ASSEMBLY (for 4WD)
(a) Remove the bolt, nut and bracket.

E105835

(b) Disconnect the magnetic clutch connector.

(c) Remove the 2 bolts and nut.

EM

A109521

(d) Using an E8 "torx" socket, remove the stud bolt and

with pulley compressor.
HINT:
It is not necessary to completely remove the
compressor. With the hoses connected to the
compressor, hang the compressor on the vehicle
body with a rope.
33. DISCONNECT HEIGHT CONTROL SENSOR LINK
(a) Remove the nut and disconnect the height control
A109605
sensor link.
34. REMOVE FRONT SUSPENSION MEMBER
PROTECTOR LOWER (for 2WD)
(a) Remove the 4 bolts and protector.
35. REMOVE FRONT AXLE HUB NUT RH (for 4WD) (See
page AH-7)
36. REMOVE FRONT AXLE HUB NUT LH (for 4WD) (See
page AH-7)
37. REMOVE TIE ROD ASSEMBLY RH (for 2WD) (See
page PS-66)
38. REMOVE TIE ROD ASSEMBLY LH (for 2WD) (See
page PS-65)
39. REMOVE TIE ROD ASSEMBLY RH (for 4WD) (See
page PS-77)
40. REMOVE TIE ROD ASSEMBLY LH (for 4WD) (See
page PS-76)
41. REMOVE FRONT SHOCK ABSORBER ASSEMBLY
RH (for 2WD) (See page SP-12)
 EM–26 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY

42. REMOVE FRONT SHOCK ABSORBER ASSEMBLY

LH (for 2WD) (See page SP-12)
43. REMOVE FRONT SHOCK ABSORBER ASSEMBLY
RH (for 4WD) (See page SP-21)
44. REMOVE FRONT SHOCK ABSORBER ASSEMBLY
LH (for 4WD) (See page SP-21)
45. REMOVE FRONT LOWER BALL JOINT ASSEMBLY
RH (for 4WD) (See page DS-5)
46. REMOVE FRONT LOWER BALL JOINT ASSEMBLY
LH (for 4WD) (See page DS-5)
47. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT
ASSEMBLY (for 2WD) (See page PS-65)
48. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT
ASSEMBLY (for 4WD) (See page PS-76)
EM 49. DISCONNECT POWER STEERING LINK WIRE
HARNESS (for 2WD) (See page PS-66)
50. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD
SUB-ASSEMBLY (for 2WD) (See page AT-219)
51. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD
SUB-ASSEMBLY (for 4WD) (See page AT-209)
52. REMOVE ENGINE AND TRANSMISSION (for 2WD)
(a) Set the engine lifter.
(b) Remove the 4 bolts, then separate the engine rear
mounting member.

C104745

(c) Remove the 12 bolts shown in the illustration.

(d) Operate the engine lifter, then slowly remove the
engine from the vehicle.
NOTICE:
Make sure the engine is clear of all wiring and
hoses.

A109622
3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–27

(e) Install the 2 engine hangers with the 4 bolts as

shown in the illustration.
Part No.:
Engine hanger No. 1 12281 - 31070
Engine hanger No. 2 12282 - 31070
Bolts 91671 - 10825

Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)

(f) Attach an engine sling device and hang the engine
A108856 a the chain block.
53. REMOVE ENGINE AND TRANSMISSION (for 4WD)
(a) Set the engine lifter.
(b) Remove the 4 bolts, then separate the engine rear
mounting member.

EM

C104745

(c) Remove the 8 bolts shown in the illustration.

(d) Operate the engine lifter, then slowly remove the
engine and transmission with crossmember sub-
assembly from the vehicle.
NOTICE:
Make sure the engine is clear of all wiring and
hoses.

A108855

(e) Install the 2 engine hangers with the 4 bolts as

shown in the illustration.
Part No.:
Engine hanger No. 1 12281 - 31070
Engine hanger No. 2 12282 - 31070
Bolts 91671 - 10825

Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf)

(f) Attach an engine sling device and hang the engine
A108856 with a chain block.
54. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for
4WD) (See page DS-6)
55. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for
4WD) (See page DS-6)
56. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(for 2WD) (See page AT-220)
57. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
(for 4WD) (See page AT-212)
 EM–28 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY

58. REMOVE DRIVE PLATE AND RING GEAR SUB-

ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021

SST

A108859E01

(b) Remove the 8 bolts, front spacer, drive plate and

rear spacer.

EM

A108862

59. REMOVE FRONT ENGINE MOUNTING INSULATOR

RH LH
(a) Remove the 2 bolts, then remove the front
suspension crossmember sub-assembly from the
engine.
60. FIX ENGINE ON ENGINE STAND
(a) Fix the engine onto a engine stand with the bolts.
61. REMOVE ENGINE WIRE
(a) Remove the engine wire from the engine.
A108858E01

62. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

2WD
(a) Remove the oil level gauge.
(b) Remove the 2 bolts, then remove the oil level gauge
guide No. 1 and No. 2.
(c) Remove the O-ring from the oil level gauge guide.
63. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 6 nuts, exhaust manifold and gasket.

4WD

A108857E01
 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–29

64. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Using a precision straightedge and feeler gauge,
measure the surface contacting the cylinder head
for warpage.
Maximum warpage:
0.7 mm (0.028 in.)
HINT:
The maximum allowable warpage of each
installation surface is 0.3 mm (0.012 in.).
A109514 If the warpage is greater than the maximum, replace
the manifold.
65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Disconnect the heated oxygen sensor connector.
(b) Remove the 6 nuts, exhaust manifold and gasket.
66. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Using a precision straightedge and feeler gauge,
measure the surface contacting the cylinder head EM
for warpage.
Maximum warpage:
0.7 mm (0.028 in.)
HINT:
The maximum allowable warpage of each
installation surface is 0.3 mm (0.012 in.).
A109515 If the warpage is greater than the maximum, replace
the manifold.
67. REMOVE GENERATOR ASSEMBLY (See page CH-9)
68. REMOVE FRONT DIFFERENTIAL ASSEMBLY (for
4WD) (See page DF-12)
69. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, plate and idler pulley.
70. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
2WD (for 2WD)
(a) Remove the 5 bolts, then remove the V-ribbed belt
tensioner assembly.

A109610E01

71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

4WD (for 4WD)
(a) Remove the 4 bolts, then remove the V-ribbed belt
tensioner assembly.
72. REMOVE WATER PUMP PULLEY (See page CO-11)

A109610E02
 EM–30 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY

73. REMOVE INJECTOR DRIVER

(a) Remove the bolt, 2 nuts and injector driver.
74. DISCONNECT NO. 1 WATER BY-PASS HOSE
75. DISCONNECT NO. 2 WATER BY-PASS HOSE

A105899

76. REMOVE REAR ENGINE COVER SUB-ASSEMBLY

(a) Remove the 3 clips and engine cover.
77. REMOVE NO. 3 WATER BY-PASS PIPE
(a) Remove the bolt and water by-pass pipe.
78. REMOVE NO. 4 WATER BY-PASS PIPE
EM (a) Remove the bolt and water by-pass pipe.
79. REMOVE INTAKE AIR SURGE TANK SUB-
Clip ASSEMBLY
A105938E01
(a) Remove the 2 bolts and intake manifold stay.
(b) Remove the 4 bolts and 2 surge tank stays.
(c) Using a 5 mm hexagon socket wrench, remove the
7 bolts, 2 nuts and gasket.
HINT:
Cover the intake manifold port to prevent foreign
matter from entering it.

Nut
A103978E01

80. INSPECT INTAKE AIR SURGE TANK SUB-

ASSEMBLY
(a) Using a precision straightedge and feeler gauge,
measure the surface contacting the cylinder head
for warpage.
Maximum warpage:
0.3 mm (0.011 in.) When installed
2.5 mm (0.098 in.) When not installed

A109516
If the warpage is greater than the maximum, replace
the surge tank.
 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–31

Front
81. REMOVE INTAKE MANIFOLD
(a) Remove the 4 bolts, 2 nuts, intake manifold and
gasket.
HINT:
Cover the cylinder head intake port to prevent
foreign matter from entering it.

A103979E01

82. INSPECT INTAKE MANIFOLD

Surge Tank Side (a) Surge tank side:
(1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
cylinder head for warpage.
Maximum warpage:
0.1 mm (0.003 in.) EM
If the warpage is greater than the maximum,
replace the intake manifold.
(b) Cylinder head side:
Cylinder Head Side (1) Using a precision straightedge and feeler
gauge, measure the surface contacting the
cylinder head for warpage.
Maximum warpage:
0.1 mm (0.003 in.)
If the warpage is greater than the maximum,
replace the intake manifold.
83. REMOVE FUEL PRESSURE PULSATION DAMPER
ASSEMBLY (See page FU-47)
A109517E01 84. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (See
page FU-24)
85. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (See
page FU-67)
86. REMOVE HIGH PRESSURE SIDE FUEL PUMP (See
page FU-68)
87. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-
ASSEMBLY (See page FU-24)
88. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
(See page FU-25)
89. REMOVE FUEL INJECTOR ASSEMBLY (See page
FU-25)
 EM–32 3GR-FSE ENGINE MECHANICAL – ENGINE ASSEMBLY

90. REMOVE KNOCK SENSOR

(a) Remove the 2 bolts and 2 sensors.
91. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 4 bolts and mounting bracket.
92. REMOVE ENGINE MOUNTING BRACKET LH
Front
(a) Remove the 4 bolts and mounting bracket.
93. REMOVE OIL FILLER CAP SUB-ASSEMBLY
A103956E01 94. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 ignition coils.
95. REMOVE ENGINE OIL LEVEL SENSOR
(a) Remove the 4 bolts, then remove the oil level
sensor and gasket.
96. REMOVE OIL PRESSURE SWITCH ASSEMBLY
2WD (a) Using a 24 mm deep socket wrench, remove the oil
EM pressure switch.

4WD

A108808E01

97. REMOVE ENGINE COOLANT TEMPERATURE

SENSOR
(a) Using a 19 mm deep socket wrench, remove the
temperature sensor.

A108860