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Home >> Toyota Truck >> 2008 >> RAV4 2WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Removal

Removal








2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

2. DISCHARGE FUEL SYSTEM PRESSURE Removal

3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

4. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 4 bolts, 12 clips and under cover.
5. REMOVE REAR ENGINE UNDER COVER RH
(a) Remove the 2 clips and under cover.
6. REMOVE REAR ENGINE UNDER COVER LH
(a) Remove the 2 clips and under cover.
7. REMOVE NO. 2 ENGINE UNDER COVER
(a) Remove the 2 clips and under cover.
8. REMOVE FRONT FLOOR COVER Removal

9. DRAIN ENGINE COOLANT Service and Repair

10. DRAIN ENGINE OIL Replacement

11. DRAIN AUTOMATIC TRANSAXLE FLUID
(a) 2WD:
Drain automatic transaxle fluid Service and Repair.
(b) 4WD:
Drain automatic transaxle fluid Service and Repair.
12. DRAIN TRANSFER OIL (for 4WD)
13. REMOVE HOOD SUB-ASSEMBLY







14. REMOVE V-BANK COVER SUB-ASSEMBLY
(a) Detach the 3 clips and remove the V-bank cover.






15. REMOVE RADIATOR SUPPORT OPENING COVER
(a) Remove the 9 clips and cover.






16. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Remove the bolt and loosen the nut.
(b) Detach the 2 wire harness clamps.
(c) Detach the hook of the battery clamp from the battery bracket front, and then remove the battery clamp.
17. REMOVE BATTERY






18. REMOVE FRONT BATTERY BRACKET
(a) Detach the 2 wire harness clamps.
(b) Remove the 4 bolts and front bracket.






19. REMOVE BATTERY BRACKET REINFORCEMENT
(a) Remove the 2 bolts and bracket reinforcement.






20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the VSV (air intake control) connector.
(c) Disconnect the wire harness clamp and 3 vacuum hoses.
(d) Disconnect the No. 2 ventilation hose from the air cleaner hose.
(e) Loosen the No. 1 air cleaner hose clamp.
(f) Unfasten the 2 hook clamps, and then remove the air cleaner cap.
(g) Remove the air cleaner filter element from the air cleaner case.






21. REMOVE AIR CLEANER CASE
(a) Disconnect the harness clamp.
(b) Remove the 3 bolts and air cleaner case.
22. DISCONNECT HOSES AND CONNECTORS
(a) Remove the engine room junction block cover (upper).
(b) Remove the nut and disconnect the engine room junction block cover (side) with 3 connectors and wire.
(c) Remove the nut and disconnect the starter wire.
(d) Disconnect the fuel hoses.
(e) Disconnect the 2 heater hoses.
(f) Disconnect the 2 ECM connectors.
23. REMOVE ECM Removal







24. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY
(a) Remove the 2 bolts, 2 hoses and reservoir tank.
25. REMOVE DISCHARGE HOSE SUB-ASSEMBLY

26. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

27. DISCONNECT RADIATOR HOSE INLET
28. DISCONNECT RADIATOR HOSE OUTLET
29. DISCONNECT OIL COOLER HOSE
30. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) 2WD:
Disconnect the control cable Service and Repair.
(b) 4WD:
Disconnect the control cable Service and Repair.
31. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

32. REMOVE CENTER EXHAUST PIPE ASSEMBLY Removal

33. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

34. REMOVE FRONT WHEELS
35. REMOVE FRONT AXLE HUB NUT LH
(a) Remove the hub nut .
36. REMOVE FRONT AXLE HUB NUT RH
(a) Remove the hub nut .
37. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

38. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

39. DISCONNECT STEERING INTERMEDIATE SHAFT

40. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

41. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

42. REMOVE FRONT DRIVE SHAFT LH
(a) 2WD:
Remove the drive shaft Service and Repair.
(b) 4WD:
Remove the drive shaft Service and Repair.
43. REMOVE FRONT DRIVE SHAFT RH
(a) 2WD:
Remove the drive shaft Service and Repair.
(b) 4WD:
Remove the drive shaft Service and Repair.
44. REMOVE ENGINE WITH TRANSAXLE






(a) Install the No. 1 and No. 2 engine hangers with the 4 bolts as shown in the illustration.
Torque: 33 Nm (337 kgf-cm, 24 ft-lbf)





- Insert the claw of the hanger into hole of the cylinder head.
- Fit the fork part of the hanger onto the rib of the cylinder head.

(b) Install an engine sling device to the engine and hold the engine with a chain block.
CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

(c) Set an engine lifter underneath the engine.
(d) Remove the column hole cover. Loosen the bolt holding the intermediate shaft, and slide the intermediate shaft.
(e) Put matchmarks on the intermediate shaft and pinion.






(f) Remove the 2 bolts and 2 nuts, and disconnect the engine mounting insulator RH.






(g) Remove the bolt and nut, and disconnect the engine mounting insulator LH.






(h) Remove the 6 bolts and front suspension member brace rear RH and LH.
(i) Remove the 6 bolts, crossmember and suspension member.
(j) Using the chain block, slowly remove the engine from the vehicle and the intermediate shaft from the pinion. Then set the engine on the engine lifter.
NOTICE:
- Make sure that the engine is clear of all wiring and hoses.
- While lowering the engine from the vehicle, do not allow it to contact the vehicle.
HINT: Place the engine on wooden blocks or an equivalent so that the engine is level.

(k) Remove the sling device from the engine.
45. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY
(a) Install a chain block.






(b) Remove the bolt, nut and crossmember.
46. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY






(a) Remove the bolt and suspension crossmember.
47. REMOVE ENGINE WIRE
(a) Remove the engine wire from the engine.
48. REMOVE STARTER ASSEMBLY

49. REMOVE TRANSFER ASSEMBLY (for 4WD)

50. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
(a) 2WD:
Remove the automatic transaxle Service and Repair.
(b) 4WD:
Remove the automatic transaxle Service and Repair.
51. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY





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






(b) Remove the 8 bolts, front spacer, drive plate and rear spacer.
NOTE: Do not reuse the bolts.

52. INSTALL ENGINE TO ENGINE STAND
(a) Install the engine to an engine stand. Remove the sling device and chain block from the engine.
53. REMOVE INTAKE AIR SURGE TANK ASSEMBLY





(a) Disconnect the 2 water by-pass hoses from the throttle body.
(b) Disconnect the vapor feed hose.
(c) Disconnect the throttle body connector and clamp.






(d) Disconnect the No. 2 ventilation hose.
(e) Disconnect the union to check valve hose.






(f) Remove the bolt and vacuum hose clamp.






(g) Disconnect the connector.






(h) Using a 5 mm socket hexagon wrench, remove the 4 bolts.
(i) Remove the 2 nuts, 2 bolts and surge tank.
(j) Remove the gasket from the surge tank.
54. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 6 bolts and 6 coils from the cylinder head.
55. REMOVE NO. 2 ENGINE MOUNTING STAY RH
(a) Remove the bolt and mounting stay.
56. REMOVE FUEL INJECTOR ASSEMBLY Removal







57. REMOVE INTAKE MANIFOLD
(a) Remove the 6 bolts, 4 nuts, intake manifold and 2 gaskets.






58. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the air fuel ratio sensor connector clamp.
(b) Uniformly loosen and remove the 6 nuts.
(c) Remove the manifold and gasket.
59. REMOVE FAN AND GENERATOR V BELT Removal

60. REMOVE COMPRESSOR WITH PULLEY ASSEMBLY

61. REMOVE GENERATOR ASSEMBLY







62. REMOVE OIL DIPSTICK GUIDE
(a) Remove the dipstick.
(b) Remove the 2 bolts, and the No. 1 and No. 2 guides.
(c) Remove the O-rings from the guide.






63. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and manifold stay.
64. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Remove the 3 bolts and insulator.






65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Uniformly loosen and remove the 6 nuts.
(b) Remove the manifold and gasket.
66. REMOVE ENGINE MOUNTING BRACKET RH
(a) Remove the 3 bolts and bracket.
67. REMOVE DRIVE SHAFT BEARING BRACKET
(a) Remove the 3 bolts and drive shaft bearing bracket.
68. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
(a) Remove the 5 bolts and V-ribbed belt tensioner assembly.
69. REMOVE NO. 2 TIMING GEAR COVER
(a) Remove the 2 bolts and gear cover.






70. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Remove the bolt, plate and idler pulley.
71. REMOVE WATER PUMP PULLEY Removal

72. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH
(a) Remove the 6 bolts and bracket.






73. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Using a 24 mm deep socket wrench, remove the pressure switch.
74. REMOVE KNOCK SENSOR Removal







75. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
(a) Using a 19 mm deep socket wrench, remove the sensor and gasket.
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