RM35X0E _51 Engine / Hybrid System _078603 7GR-FKS ENGINE MECHANICAL _0381343 ENGINE ASSEMBLY A

7GR-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, installed, or replaced during the 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	Memorize steering angle neutral point	Parking assist monitor system	(201902,202310,_56,_079315,_0385736,RM100000001GNRA,)
Battery terminal is disconnected/reconnected	Memorize steering angle neutral point	Panoramic view monitor system	(201906,202310,_56,_079315,_0396274,RM100000001IGR3,)
Replacement of ECM	Perform Vehicle Identification Number (VIN) or frame number registration	DTC P063051 is stored	(201902,999999,_51,_078720,_0381907,RM100000001G2WM,)
	ECU communication ID registration	Engine start function	See Service Bulletin for the registration method.
	for RC60J: Performing iMT installation information reset	· iMT system · DTCs are output	(201902,999999,_52,_078740,_0383349,RM100000001GAF2,)
· Engine assembly · Air leaks from intake system · Gas leaks from exhaust system	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(201902,999999,_51,_078720,_0381907,RM100000001G2VV,)
for AC60E: Replacement of automatic transmission assembly	Reset memory	· Large shift shock · Engine overruns	(201902,999999,_52,_078741,_0385245,RM100000001GL7C,)
for AC60E: Replacement of automatic transmission fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly	(201902,999999,_52,_078741,_0385245,RM100000001GL7C,)
Front wheel alignment adjustment	· Perform reset memory · Perform acceleration sensor zero point calibration and store system information memorization.	· VSC is disabled or malfunctions · DTCs are output · Slip indicator light illuminates · ABS warning light illuminates	(201902,999999,_54,_078667,_0385049,RM100000001GK1P,)
Suspension, tires, etc.	Television camera assembly optical axis (Back camera position setting)	Parking assist monitor system	(201902,202310,_56,_079315,_0385736,RM100000001GNRB,)

HINT:

When the cable is disconnected / reconnected to the battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative when not Performed	Necessary Procedures	Link
Lane control system	Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more.	(201902,999999,_58,_078886,_0382740,RM100000001G6XB,)
Pre-collision system		(201902,999999,_58,_078886,_0382740,RM100000001G6XB,)

Learning completes when vehicle is operated normally

Effect/Inoperative when not Performed	Necessary Procedures	Link
Power slide door system	Fully close the slide door by hand. HINT: Initialization is not necessary if the above procedures are performed while the slide door is closed.	(201902,202310,_59,_078503,_0381017,RM100000001FWXM,)
Air conditioning system	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

CAUTION:

2.219,0.813 2.646,0.813 false 2.698,0.729 3.01,0.927 0.313,0.198 10 false *a

*a	An Object Exceeding Weight Limit of Engine Lifter

The engine assembly with transmission 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 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

Hide Display 1. PRECAUTION

NOTICE:: After turning the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) battery terminal.; Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>BEFORE DISCONNECTING BATTERY201902,202310,_V1,_081196,_0393338,RM100000001HX6Q,

Hide Display 2.DISCHARGE FUEL SYSTEM PRESSURE

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL SYSTEM>PRECAUTION201906,202310,_51,_079024,_0383258,RM100000001IZVI,

Hide Display 3.DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Click hereGeneral>MAINTENANCE>7GR-FKS BATTERY>REMOVAL201906,202310,_V1,_078672,_0387105,RM100000001IWL9,

Hide Display 4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

Hide Display 5.SECURE STEERING WHEEL ASSEMBLY

for LHD:

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR (for LHD)>REMOVAL201902,999999,_55,_079314,_0388802,RM100000001H42S_01_0034,

for RHD:

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR (for RHD)>REMOVAL202107,999999,_55,_079314,_0388803,RM0000003TPAIFD_01_0034,

Hide Display 6.REMOVE FRONT WHEELS

Click hereGeneral>MAINTENANCE>TIRE AND WHEEL>REMOVAL201902,999999,_V1,_078672,_0387313,RM100000001GWDK,

Hide Display 51406A 7.REMOVE NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (w/ No. 2 Engine Under Cover Sub-assembly)

Remove the 6 clips, 7 bolts and No. 2 engine under cover sub-assembly.

Hide Display 52618 8.REMOVE LOWER FRONT BUMPER ABSORBER

0,0 0,0 false

	Bolt
	Screw

Remove the 4 bolts, 4 screws and 4 clips.

Detach the 2 guides and remove the lower front bumper absorber.

Hide Display 51405A 9.REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

w/ No. 2 Engine Under Cover Sub-assembly:

Remove the 10 clips.

ii.

Detach the guide and remove the No. 1 engine under cover sub-assembly.

w/o No. 2 Engine Under Cover Sub-assembly:

Remove the 12 clips and 2 bolts.

ii.

Detach the guide and remove the No. 1 engine under cover sub-assembly.

Hide Display 51407A 10.REMOVE NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY (w/ No. 3 Engine Under Cover Sub-assembly)

0.042,0.031 0.271,0.24 0.229,0.208 10 true *A 0.052,2.365 0.281,2.563 0.229,0.198 10 false *B

*A	for Manual Transmission
*B	for Automatic Transmission

Remove the 4 bolts and No. 3 engine under cover sub-assembly.

Hide Display 51773E 11.REMOVE STEP PLATE COVER RH (w/ Cover)

0.813,0.823 1.031,1.031 0.219,0.208 10 true *A 1.094,0.823 1.313,1.031 0.219,0.208 10 true *B

*A	for Automatic Transmission
*B	for Manual Transmission

Remove the 4 clips, 5 bolts and step plate cover RH.

Hide Display 12.DRAIN ENGINE OIL

Click hereGeneral>MAINTENANCE>7GR-FKS OIL AND OIL FILTER>REPLACEMENT202107,999999,_V1,_078672,_0387903,RM100000001XJ12_02_0002,

Hide Display 13.DRAIN ENGINE COOLANT

Click hereGeneral>MAINTENANCE>7GR-FKS COOLANT>REPLACEMENT202107,999999,_V1,_078672,_0386705,RM0000003TPC183_01_0028,

Hide Display 14.DRAIN CLUTCH FLUID (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH MASTER CYLINDER>REMOVAL201906,202310,_52,_078837,_0382377,RM100000001IPII_01_0006,

Hide Display 15.DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION OIL>REPLACEMENT201902,999999,_52,_078740,_0382067,RM100000001G3M1_01_0001,

Hide Display 16.DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>TRANSMISSION WIRE>REMOVAL202107,999999,_52,_078741,_0382306,RM100000001WUCB_01_0001,

Hide Display 53106B 17.REMOVE RADIATOR COVER SUB-ASSEMBLY

for Wagon:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>RADIATOR GRILLE (for Wagon)>REMOVAL201906,999999,_59,_079322,_0397097,RM100000001IMU6_04_0001,

except Wagon:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>RADIATOR GRILLE (except Wagon)>REMOVAL201906,999999,_59,_079322,_0397096,RM100000001IMTX_03_0016,

Hide Display 18.RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT201906,999999,_58,_079316,_0384872,RM100000001IHVK_01_0002,

Hide Display 85110 19.REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY

Click hereVehicle Exterior>WIPER / WASHER>FRONT WIPER MOTOR>REMOVAL201902,999999,_59,_079320,_0385302,RM100000001GLKU,

Hide Display 47220D 20.DISCONNECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

0.042,0.042 0.281,0.26 0.24,0.219 10 true *A 0.042,2.396 0.26,2.604 0.219,0.208 10 false *B

*A	for LHD
*B	for RHD

Disconnect the connector.

for RHD:

Detach the clamp and disconnect the wire harness from the brake master cylinder reservoir assembly.

0.042,0.031 0.271,0.26 0.229,0.229 10 true *A 0.052,2.344 0.302,2.542 0.25,0.198 10 false *B

*A	for LHD
*B	for RHD

Remove the 2 nuts and disconnect the brake master cylinder reservoir assembly.

Hide Display 55738D 21.REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL

0.042,0.031 0.281,0.25 0.24,0.219 10 true *A 0.042,2.385 0.302,2.615 0.26,0.229 10 false *B

*A	for LHD
*B	for RHD

for LH Side:

Detach the 2 claws and remove the No. 2 heater air duct splash shield seal from the outer cowl top panel sub-assembly.

0.042,0.031 0.281,0.271 0.24,0.24 10 false *A 0.063,2.385 0.281,2.594 0.219,0.208 10 false *B

*A	for LHD
*B	for RHD

for RH Side:

Detach the 2 claws and remove the No. 2 heater air duct splash shield seal from the outer cowl top panel sub-assembly.

Hide Display 55701J 22.REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

0.031,0.031 0.271,0.25 0.24,0.219 10 true *A 0.042,2.51 0.26,2.719 0.219,0.208 10 true *B

*A	for LHD
*B	for RHD

for LHD:

Detach the 6 clamps and disconnect the wire harness from the outer cowl top panel sub-assembly.

for RHD:

Detach the 7 clamps and disconnect the wire harness from the outer cowl top panel sub-assembly.

0.073,0.094 0.323,0.26 0.25,0.167 10 true *A 0.083,2.594 0.344,2.75 0.26,0.156 10 true *B

*A	for LHD
*B	for RHD

Remove the 10 bolts and outer cowl top panel sub-assembly.

Hide Display 11209 23.REMOVE V-BANK COVER SUB-ASSEMBLY (w/ Cover)

Raise the front of the V-bank cover to detach the 3 pins. Then remove the V-bank cover sub-assembly.

Hide Display 17751 24.REMOVE NO. 1 AIR CLEANER INLET

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>REMOVAL201906,999999,_51,_079310,_0386774,RM100000001IZPV_01_0141,

Hide Display 17881 25.REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

Disconnect the mass air flow meter sub-assembly connector.

Detach the 2 wire harness clamps.

Slide the clamp and disconnect the No. 2 PCV hose from the No. 1 air cleaner hose.

Loosen the hose clamp.

Remove the 3 bolts and air cleaner assembly with air cleaner hose.

Hide Display 44360 26.DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>REMOVAL201906,999999,_51,_079310,_0386774,RM100000001IZPV_01_0142,

Hide Display 16470 27.REMOVE RADIATOR RESERVE TANK ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>REMOVAL201906,999999,_51,_079310,_0386774,RM100000001IZPV_01_0143,

Hide Display 16571C 28.REMOVE NO. 1 RADIATOR HOSE

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>REMOVAL201906,999999,_51,_079310,_0386774,RM100000001IZPV_01_0144,

Hide Display 16572D 29.REMOVE NO. 2 RADIATOR HOSE

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>REMOVAL201906,999999,_51,_079310,_0386774,RM100000001IZPV_01_0145,

Hide Display 32941 30.REMOVE NO. 1 OIL COOLER INLET HOSE AND NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>OIL COOLER (for 7GR-FKS)>REMOVAL202107,999999,_52,_078741,_0382309,RM100000001WUCF_01_0009,

Hide Display 16711 31.REMOVE FAN SHROUD

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>RADIATOR>REMOVAL201906,999999,_51,_079310,_0386774,RM100000001IZPV_01_0147,

Hide Display 32.REMOVE FRONT BUMPER

for Wagon:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for Wagon)>REMOVAL201906,999999,_59,_079322,_0397092,RM100000001IMT8,

except Wagon:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (except Wagon)>REMOVAL201906,999999,_59,_079322,_0397093,RM100000001IMTD,

Hide Display 82121 33.DISCONNECT ENGINE WIRE

0.031,0.042 0.271,0.25 0.24,0.208 10 true *A 0.042,2.469 0.26,2.667 0.219,0.198 10 false *B

*A	for LHD
*B	for RHD

Disconnect the 4 connectors from the ECM.

Click hereEngine / Hybrid System>7GR-FKS (ENGINE CONTROL)>ECM>REMOVAL201906,202310,_51,_078720,_0381918,RM100000001IOND,

Disconnect the 2 connectors from the instrument panel wire.

0.042,0.042 0.26,0.26 0.219,0.219 10 true *A 0.063,2.49 0.323,2.719 0.26,0.229 10 false *B

*A	for LHD
*B	for RHD

for LHD:

Detach the 2 clamps and grommet, and pull out the engine wire from the bracket.

for RHD:

Detach the clamp and grommet, and pull out the engine wire from the bracket.

Hide Display 34.DISCONNECT WIRE HARNESS

Detach the 2 claws and remove the upper No. 1 relay block cover from the No. 1 engine room relay block.

Detach the claw and remove the relay block cover from the No. 1 engine room relay block.

Remove the 2 bolts and disconnect the 2 wire harnesses from the No. 1 engine room relay block.

Remove the 2 bolts and disconnect the wire harness from the body.

Disconnect the connector.

Detach the 3 clamps and disconnect the wire harness from the No. 1 engine room relay block and bracket.

Detach the claw and 3 connectors from the No. 1 engine room relay block.

Detach the clamp and disconnect the wire harness from the bracket.

Hide Display 87245A 35.DISCONNECT HEATER WATER HOSE ASSEMBLY

Slide the 2 clamps and disconnect the 2 heater water hose assemblies from the water pipe.

Hide Display 23901 36.DISCONNECT FUEL TUBE SUB-ASSEMBLY

Remove the No. 2 fuel pipe clamp.

Disconnect the 2 fuel tube sub-assemblies.

Click hereEngine / Hybrid System>7GR-FKS (FUEL)>FUEL SYSTEM>PRECAUTION201906,202310,_51,_079024,_0383258,RM100000001IZVI,

Hide Display 37.DISCONNECT VACUUM HOSE ASSEMBLY

Click hereBrake>BRAKE SYSTEM (OTHER)>VACUUM PUMP (for 7GR-FKS)>REMOVAL201906,202310,_54,_078668,_0381541,RM100000001IPID_01_0044,

Hide Display 44310 38.DISCONNECT VANE PUMP ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (COOLING)>WATER PUMP>REMOVAL201902,999999,_51,_079310,_0386772,RM100000001GTQ0_01_0093,

Hide Display 27020 39.REMOVE GENERATOR ASSEMBLY

Click herePower Source / Network>7GR-FKS (BATTERY / CHARGING)>GENERATOR>REMOVAL201906,202310,_57,_078664,_0386628,RM100000001IWL6_01_0004,

Hide Display 88703 40.DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for 7GR-FKS)>REMOVAL201902,999999,_58,_079316,_0384886,RM100000001GIU1_01_0004,

Hide Display 88704 41.DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for 7GR-FKS)>REMOVAL201902,999999,_58,_079316,_0384886,RM100000001GIU1_01_0003,

Hide Display 88320 42.REMOVE COMPRESSOR ASSEMBLY WITH MAGNET CLUTCH (w/ Air Conditioning System)

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for 7GR-FKS)>REMOVAL201902,999999,_58,_079316,_0384886,RM100000001GIU1_01_0007,

Hide Display 16603K 43.REMOVE IDLER PULLEY SUB-ASSEMBLY (w/o Air Conditioning System)

Remove the bolt, 2 plate washers and idler pulley sub-assembly.

Hide Display 16631D 44.REMOVE NO. 1 IDLER PULLEY BRACKET (w/o Air Conditioning System)

Remove the 3 bolts and No. 1 idler pulley bracket.

Hide Display 17346 45.DISCONNECT NO. 6 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

Slide the clip and disconnect the No. 6 air injection system hose from the air tube assembly.

Hide Display 17126 46.REMOVE NO. 2 SURGE TANK STAY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL201902,202310,_51,_079308,_0385725,RM100000001GNNS_01_0172,

Hide Display 17125 47.REMOVE NO. 1 SURGE TANK STAY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL201902,202310,_51,_079308,_0385725,RM100000001GNNS_01_0173,

Hide Display 22267A 48.REMOVE THROTTLE BODY BRACKET

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL201902,202310,_51,_079308,_0385725,RM100000001GNNS_01_0174,

Hide Display 17190 49.REMOVE INTAKE AIR SURGE TANK ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL201902,202310,_51,_079308,_0385725,RM100000001GNNS_01_0175,

Hide Display 17403 50.REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0157,

Hide Display 17410 51.REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0151,

Hide Display 17450B 52.REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0145,

Hide Display 17118 53.REMOVE MANIFOLD STAY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0147,

Hide Display 11409 54.REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

Remove the engine oil level dipstick.

Remove the bolt and engine oil level dipstick guide.

Remove the O-ring from the engine oil level dipstick guide.

Hide Display 17361N 55.REMOVE NO. 1 AIR TUBE (w/ Secondary Air Injection System)

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0155,

Hide Display 17140 56.REMOVE EXHAUST MANIFOLD ASSEMBLY RH

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0149,

Hide Display 17119 57.REMOVE NO. 2 MANIFOLD STAY

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0152,

Hide Display 17362 58.REMOVE NO. 2 AIR TUBE (w/ Secondary Air Injection System)

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0156,

Hide Display 17150 59.REMOVE EXHAUST MANIFOLD ASSEMBLY LH

Click hereEngine / Hybrid System>7GR-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL201902,999999,_51,_079308,_0385727,RM100000001GNNW_01_0142,

Hide Display 51569A 60.REMOVE PROPELLER SHAFT GUARD

for Standard Roof:

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY (for Standard Roof)>REMOVAL201902,999999,_52,_079136,_0383777,RM100000001GCJB_01_0007,

for High Roof:

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY (for High Roof)>REMOVAL201902,999999,_52,_079136,_0383776,RM100000001GCJ0_01_0007,

Hide Display 61.REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

for Standard Roof:

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY (for Standard Roof)>REMOVAL201902,999999,_52,_079136,_0383777,RM100000001GCJB_01_0001,

for High Roof:

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY (for High Roof)>REMOVAL201902,999999,_52,_079136,_0383776,RM100000001GCJ0_01_0001,

Hide Display 28192 62.REMOVE STARTER COVER

Click hereEngine / Hybrid System>7GR-FKS (STARTING)>STARTER>REMOVAL201906,202310,_51,_078665,_0382031,RM100000001IWL0_01_0014,

Hide Display 28100 63.REMOVE STARTER ASSEMBLY

Click hereEngine / Hybrid System>7GR-FKS (STARTING)>STARTER>REMOVAL201906,202310,_51,_078665,_0382031,RM100000001IWL0_01_0003,

Hide Display 11363A 64.REMOVE FLYWHEEL HOUSING SIDE COVER

Click hereEngine / Hybrid System>7GR-FKS (STARTING)>STARTER>REMOVAL201906,202310,_51,_078665,_0382031,RM100000001IWL0_01_0015,

Hide Display 65.DISCONNECT INTERMEDIATE SHAFT ASSEMBLY

for LHD:

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR (for LHD)>REMOVAL201902,999999,_55,_079314,_0388802,RM100000001H42S_01_0029,

for RHD:

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR (for RHD)>REMOVAL202107,999999,_55,_079314,_0388803,RM0000003TPAIFD_01_0029,

Hide Display 89543 66.DISCONNECT FRONT SPEED SENSOR LH

Click hereDrivetrain>AXLE AND DIFFERENTIAL>FRONT AXLE HUB>REMOVAL201906,999999,_52,_079259,_0385113,RM100000001JMA9_02_0035,

Hide Display 89542 67.DISCONNECT FRONT SPEED SENSOR RH

HINT:: Use the same procedure described for the LH side.

Hide Display 45047 68.DISCONNECT TIE ROD END SUB-ASSEMBLY LH

for LHD:

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR (for LHD)>REMOVAL201902,999999,_55,_079314,_0388802,RM100000001H42S_01_0016,

for RHD:

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR (for RHD)>REMOVAL202107,999999,_55,_079314,_0388803,RM0000003TPAIFD_01_0016,

Hide Display 45046 69.DISCONNECT TIE ROD END SUB-ASSEMBLY RH

HINT:: Use the same procedure described for the LH side.

Hide Display 70.DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH

Click hereDrivetrain>AXLE AND DIFFERENTIAL>FRONT AXLE HUB BOLT>REPLACEMENT201902,999999,_52,_079259,_0385112,RM100000001GKGC_01_0018,

Hide Display 71.DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY RH

HINT:: Use the same procedure described for the LH side.

Hide Display 43512 72.REMOVE FRONT DISC

Click hereBrake>BRAKE (FRONT)>FRONT BRAKE>REMOVAL201902,999999,_54,_078670,_0387338,RM100000001GWHP_01_0020,

Hide Display 48069 73.DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

Click hereSuspension>FRONT SUSPENSION>FRONT LOWER SUSPENSION ARM>REMOVAL201906,999999,_53,_078876,_0384534,RM100000001J043_01_0056,

Hide Display 48068 74.DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:: Use the same procedure described for the LH side.

Hide Display 48810 75.REMOVE FRONT STABILIZER LINK ASSEMBLY LH

Click hereSuspension>FRONT SUSPENSION>FRONT STABILIZER BAR>REMOVAL202107,202310,_53,_078876,_0384535,RM100000001XZU0_01_0040,

Hide Display 48820B 76.REMOVE FRONT STABILIZER LINK ASSEMBLY RH

HINT:: Use the same procedure described for the LH side.

Hide Display 77.REMOVE FRONT AXLE ASSEMBLY LH

Click hereDrivetrain>AXLE AND DIFFERENTIAL>FRONT AXLE HUB>REMOVAL201906,999999,_52,_079259,_0385113,RM100000001JMA9_02_0008,

Hide Display 78.REMOVE FRONT AXLE ASSEMBLY RH

HINT:: Use the same procedure described for the LH side.

Hide Display 79.INSTALL ENGINE HANGER

2.906,0.583 3,0.24 3,0.24 3.146,0.24 true 0.531,0.469 0.938,0.469 true 3.146,0.135 3.365,0.354 0.219,0.219 10 true *1 0.313,0.375 0.521,0.563 0.208,0.188 10 true *2

*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger

Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Torque:: 33 N*m (337 kgf*cm, 24 ft.*lbf)

HINT:

No. 1 Engine Hanger	12281-31070
No. 2 Engine Hanger	12282-31161
Bolt	91671-10825

Hide Display 80.REMOVE CLUTCH ACCUMULATOR HEAT INSULATOR SUB-ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH ACCUMULATOR (for 7GR-FKS)>REMOVAL201902,999999,_52,_078837,_0382383,RM100000001GF9J_01_0003,

Hide Display 31349 81.REMOVE CLUTCH CABLE HEAT INSULATOR (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0047,

Hide Display 31482D 82.REMOVE CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH ACCUMULATOR (for 7GR-FKS)>REMOVAL201902,999999,_52,_078837,_0382383,RM100000001GF9J_01_0004,

Hide Display 31490 83.REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH ACCUMULATOR (for 7GR-FKS)>REMOVAL201902,999999,_52,_078837,_0382383,RM100000001GF9J_01_0001,

Hide Display 31470 84.REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH RELEASE CYLINDER>REMOVAL201902,999999,_52,_078837,_0382381,RM100000001G4HS_01_0002,

Hide Display 31482 85.REMOVE CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0048,

Hide Display 33825 86.REMOVE TRANSMISSION CONTROL CABLE INSULATOR (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0045,

Hide Display 33820B 87.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>SHIFT AND SELECT TRANSMISSION CONTROL CABLE>REMOVAL201902,999999,_52,_078740,_0383470,RM100000001GB9U_01_0012,

Hide Display 51446B 88.REMOVE NO. 2 ENGINE UNDER COVER BRACKET (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0050,

Hide Display 58041C 89.REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR SUB-ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0053,

Hide Display 90.SUPPORT MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0017,

Hide Display 57209B 91.REMOVE REAR ENGINE MOUNTING MEMBER SUB-ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0015,

Hide Display 12380 92.REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0023,

Hide Display 93.DISCONNECT WIRE HARNESS (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0025,

Hide Display 88539C 94.DISCONNECT NO. 2 COOLER UNIT DRAIN HOSE (for Manual Transmission)

for LHD:

Detach the clamp and disconnect the No. 2 cooler unit drain hose.

for RHD:

Detach the clamp and disconnect the No. 2 cooler unit drain hose.

Hide Display 95.REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>RC60J (MANUAL TRANSMISSION / TRANSAXLE)>MANUAL TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL201906,202310,_52,_078740,_0385768,RM100000001IFFQ_01_0027,

Hide Display 31210 96.REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH UNIT>REMOVAL201906,202310,_52,_078837,_0382379,RM100000001IPJ3_01_0010,

Hide Display 31250 97.REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

Click hereDrivetrain>CLUTCH>CLUTCH UNIT>REMOVAL201906,202310,_52,_078837,_0382379,RM100000001IPJ3_01_0011,

Hide Display 13405 98.REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>REAR CRANKSHAFT OIL SEAL>REMOVAL201906,202310,_51,_078603,_0381342,RM100000001J10Q_01_0008,

Hide Display 53288B 99.REMOVE RADIATOR SUPPORT EXTENSION LH (for LHD)

Detach the 2 claws and remove the radiator support extension LH.

Hide Display 53287B 100.REMOVE RADIATOR SUPPORT EXTENSION RH

0.031,0.031 0.25,0.25 0.219,0.219 10 true *A 0.031,2.354 0.302,2.573 0.271,0.219 10 false *B

*A	for LHD
*B	for RHD

Detach the 2 claws and remove the radiator support extension RH.

Hide Display 44402 101.DISCONNECT NO. 1 POWER STEERING OIL COOLER SUB-ASSEMBLY

0.042,0.031 0.271,0.24 0.229,0.208 10 true *A 0.042,2.302 0.26,2.49 0.219,0.188 10 false *B

*A	for LHD
*B	for RHD

Remove the bolt and disconnect the return tube sub-assembly.

for LHD:

Remove the bolt and disconnect the return tube sub-assembly.

0.021,0.031 0.281,0.229 0.26,0.198 10 false *A 0.042,2.271 0.25,2.49 0.208,0.219 10 false *B

*A	for Type A
*B	for Type B

for LHD:

Remove the 2 bolts and disconnect the No. 1 power steering oil cooler sub-assembly.

for RHD:

Remove the 2 bolts and disconnect the No. 1 power steering oil cooler sub-assembly.

Hide Display 51108C 102.REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

Remove the 4 bolts and rear side rail reinforcement sub-assembly LH.

Hide Display 51107D 103.REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

Remove the 4 bolts and rear side rail reinforcement sub-assembly RH.

Hide Display 104.REMOVE ENGINE ASSEMBLY (for Manual Transmission)

0,0 0,0 false

Place Wooden Block or Plate Attachments

Set the engine on an engine lifter.

NOTICE:: ·

Place wooden blocks or plate lift attachments so that the engine is level.

·

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

·

Never install attachments to the oil pan of the engine assembly as doing so may deform the oil pan.

0,0 0,0 false

	Bolt
	Nut

Remove the 6 bolts and 2 nuts shown in the illustration.

Operate the engine lifter, then slowly remove the engine assembly from the vehicle.

NOTICE:: ·

Make sure the engine is clear of all wiring and hoses.

·

While lowering the engine from the vehicle, do not allow it to contact the vehicle.

Attach an engine sling device and hang the engine with a chain block.

NOTICE:: Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

Hide Display 58041C 105.REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR SUB-ASSEMBLY (for Automatic Transmission)

Remove the 3 bolts and front No. 1 floor heat insulator sub-assembly.

Hide Display 82122A 106.DISCONNECT NO. 2 ENGINE WIRE (for Automatic Transmission)

Remove the 2 bolts and disconnect the No. 2 engine wire from the vehicle body.

Remove the 2 bolts and disconnect the No. 2 engine wire from the engine assembly with automatic transmission assembly.

Hide Display 88539C 107.DISCONNECT NO. 2 COOLER UNIT DRAIN HOSE (for Automatic Transmission)

for LHD:

Detach the clamp and disconnect the No. 2 cooler unit drain hose.

for RHD:

Detach the clamp and disconnect the No. 2 cooler unit drain hose.

Hide Display 108.REMOVE ENGINE ASSEMBLY WITH AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

0,0 0,0 false

Place Wooden Block or Plate Attachments

Set the engine on an engine lifter.

NOTICE:: ·

Place wooden blocks or plate lift attachments so that the engine is level.

·

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

·

Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

Remove the 4 bolts, and then separate the rear engine mounting member sub-assembly.

0,0 0,0 false

	Bolt
	Nut

Remove the 6 bolts and 2 nuts shown in the illustration.

Operate the engine lifter, then slowly remove the engine assembly with automatic transmission assembly from the vehicle.

NOTICE:: ·

Make sure the engine is clear of all wiring and hoses.

·

While lowering the engine from the vehicle, do not allow it to contact the vehicle.

Attach an engine sling device and hang the engine with a chain block.

NOTICE:: Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

Hide Display 32921 109.REMOVE NO. 1 OIL COOLER INLET TUBE AND NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>OIL COOLER (for 7GR-FKS)>REMOVAL202107,999999,_52,_078741,_0382309,RM100000001WUCF_01_0008,

Hide Display 110.DISCONNECT ENGINE WIRE (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>AUTOMATIC TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL202107,202310,_52,_078741,_0382312,RM100000001WUCK_01_0012,

Hide Display 111.REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>AUTOMATIC TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL202107,202310,_52,_078741,_0382312,RM100000001WUCK_01_0015,

Hide Display 11361J 112.REMOVE FLYWHEEL HOUSING UNDER COVER (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>AUTOMATIC TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL202107,202310,_52,_078741,_0382312,RM100000001WUCK_01_0014,

Hide Display 57209B 113.REMOVE REAR ENGINE MOUNTING MEMBER SUB-ASSEMBLY (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>AUTOMATIC TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL202107,202310,_52,_078741,_0382312,RM100000001WUCK_01_0017,

Hide Display 12380 114.REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>AUTOMATIC TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL202107,202310,_52,_078741,_0382312,RM100000001WUCK_01_0018,

Hide Display 35000 115.REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

Click hereDrivetrain>AC60E (AUTOMATIC TRANSMISSION / TRANSAXLE)>AUTOMATIC TRANSMISSION ASSEMBLY (for 7GR-FKS)>REMOVAL202107,202310,_52,_078741,_0382312,RM100000001WUCK_01_0020,

Hide Display 32101 116.REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

Click hereEngine / Hybrid System>7GR-FKS (ENGINE MECHANICAL)>REAR CRANKSHAFT OIL SEAL>REMOVAL201906,202310,_51,_078603,_0381342,RM100000001J10Q_01_0004,

Hide Display 51100H 117.DISCONNECT FRONT FRAME ASSEMBLY

0.031,0.031 0.25,0.24 0.219,0.208 10 true *A 0.052,2.354 0.302,2.563 0.25,0.208 10 false *B

*A	for LH Side
*B	for RH Side

Remove the 4 bolts and disconnect the front frame assembly from the engine assembly.

Hide Display 12361E 118.REMOVE FRONT ENGINE MOUNTING INSULATOR

0.031,0.052 0.271,0.271 0.24,0.219 10 true *A 0.042,2.354 0.26,2.583 0.219,0.229 10 false *B

*A	for LH Side
*B	for RH Side

Remove the 2 nuts and 2 front engine mounting insulators from the front No. 1 engine mounting bracket RH and front No. 1 engine mounting bracket LH.

Hide Display 119.INSTALL ENGINE TO ENGINE STAND

Install the engine onto an engine stand with bolts.

NOTICE:: ·

Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

·

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

Remove the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts.