CAUTION:
As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.
DISCHARGE FUEL SYSTEM PRESSURE
PRECAUTION
Note
After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE NO. 1 ENGINE UNDER COVER
DRAIN ENGINE COOLANT
CAUTION:
Do not remove the radiator reservoir cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
Tech Tips
Collect the engine coolant in a container and dispose of it according to the local regulations.
Loosen the radiator drain cock plug and drain the engine coolant.
*1 | Radiator Reservoir Cap Sub-assembly | *2 | Radiator Reservoir Assembly |
*3 | Radiator Drain Cock Plug | *4 | Cylinder Block Water Drain Cock Plug |
*5 | 2-Way | - | - |
Remove the radiator reservoir cap sub-assembly.
Loosen the cylinder block water drain cock plug and drain the engine coolant from the engine.
DRAIN ENGINE OIL
Remove the oil filler cap.
Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.
Note
Collect the oil in a disposable oil container.
Clean the oil pan drain plug and install it with a new gasket.
REMOVE FRONT SEAT ASSEMBLY RH
REMOVE FRONT DOOR SCUFF PLATE RH
REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY
Roll up the carpet, and remove the 5 bolts and engine service hole sub cover sub-assembly.
REMOVE FAN AND GENERATOR V BELT
Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the fan and generator V belt. Then remove the fan and generator V belt.
Note
When removing the fan and generator V belt, do not use the bolt of the idle pulley.
Tech Tips
After removing the fan and generator V belt, move the tensioner upward to the maximum amount.
DISCONNECT NO. 4 RADIATOR HOSE
Slide the clamp and disconnect the No. 4 radiator hose from the engine.
DISCONNECT NO. 2 RADIATOR HOSE
Slide the clamp and disconnect the No. 2 radiator hose from the No. 1 radiator pipe.
DISCONNECT INLET HEATER WATER HOSE A
Slide the clamp and disconnect the inlet heater water hose A from the heater unit.
DISCONNECT OUTLET HEATER WATER HOSE B
Slide the clamp and disconnect the outlet heater water hose B from the heater unit.
DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY
Slide the clamp and disconnect the fuel vapor feed hose from the purge VSV.
DISCONNECT UNION TO CONNECTOR TUBE HOSE
Slide the clamp and disconnect the union to connector tube hose from the intake manifold.
REMOVE AIR PRESSURE SENSOR
Disconnect the air pressure sensor connector.
Disconnect the vacuum hose.
Detach the wire harness clamp.
Remove the 2 bolts and air pressure sensor together with the bracket.
Remove the bolt and air pressure sensor.
REMOVE INTAKE AIR CONNECTOR
Slide the clamp and disconnect the No. 2 PCV hose from the cylinder head cover sub-assembly.
Disconnect the vacuum hose from the intake air connector.
Loosen the 2 hose clamps.
Remove the 2 bolts and intake air connector.
DISCONNECT NO. 5 AIR HOSE
Slide the clamp and disconnect the No. 5 air hose from the air switching valve assembly.
DISCONNECT NO. 1 FUEL HOSE
Disconnect the No. 1 fuel hose from the fuel pressure pulsation damper assembly Click here.
DISCONNECT NO. 2 FUEL HOSE
Disconnect the No. 2 fuel hose from the fuel delivery pipe sub-assembly Click here.
DISCONNECT VANE PUMP ASSEMBLY
Disconnect the oil pressure switch connector.
Remove the 2 bolts and disconnect the vane pump assembly from the engine.
Support the vane pump assembly securely.
REMOVE ENGINE OIL LEVEL DIPSTICK
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
Remove the bolt and engine oil level dipstick guide.
DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH
Disconnect the compressor and magnetic clutch connector.
Remove the 4 bolts and disconnect the compressor and magnetic clutch from the engine.
Tech Tips
Disconnect the compressor and magnetic clutch with the No. 1 cooler refrigerant suction hose and No. 1 cooler refrigerant discharge hose stuck by suspended from the rope.
Support the compressor and magnetic clutch securely.
DISCONNECT ENGINE WIRE
Disconnect the wire harness support of the ECM.
Disconnect the connectors of the ECM.
Disconnect the clamps of the engine wire and ground cable.
Disconnect the starter connector Click here.
Disconnect the generator connector Click here.
*1 | Nut |
Remove the nut and disconnect the 4 connectors from the engine room junction block.
REMOVE FRONT EXHAUST PIPE ASSEMBLY
REMOVE PROPELLER SHAFT ASSEMBLY
Put matchmarks on both flanges.
Remove the 4 nuts, bolts and washers.
Tech Tips
If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.
Remove the propeller shaft assembly.
Insert SST in the transmission to prevent oil leakage.
Note
Do not damage the oil seal.
Use the following SST for the automatic transmission
Use the following SST for the manual transmission
REMOVE FRONT SPEED SENSOR LH
Remove the 2 bolts, and separate the speed sensor from the steering knuckle.
Note
Be careful not to damage the speed sensor.
Prevent foreign matter from adhering to the speed sensor.
REMOVE FRONT SPEED SENSOR RH
Tech Tips
Use the same procedure described for the LH side.
REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY LH
Remove the 2 bolts, and disconnect the brake caliper assembly.
Note
Use a wire or an equivalent to keep the brake caliper from hanging down by the flexible hose.
REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY RH
Tech Tips
Use the same procedure described for the LH side.
SEPARATE FRONT SUSPENSION SUB-ASSEMBLY UPPER LH
Remove the cotter pin and loosen the nut.
Note
Do not remove the nut.
Using SST, separate the steering knuckle from the suspension upper arm and remove the nut.
Note
Fix the steering knuckle with a wire so that the flexible hose does not receive excessive force.
Do not damage the ball joint dust cover.
SEPARATE FRONT SUSPENSION SUB-ASSEMBLY UPPER RH
Tech Tips
Use the same procedure described for the LH side.
SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH
Remove the bolt and separate the front shock absorber from the front suspension lower arm.
SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH
Tech Tips
Use the same procedure described for the LH side.
DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
Move the shift lever to N.
Remove the nut and disconnect the transmission control cable assembly from the transmission control shaft lever LH.
Remove the clip and disconnect the transmission control cable assembly from the transmission control cable bracket.
DISCONNECT OIL COOLER HOSE
Slide the 2 clamps and disconnect the inlet oil cooler hose and outlet oil cooler hose from the oil cooler tube.
SEPARATE STEERING TORQUE SHAFT ASSEMBLY
Loosen bolt (A) and remove bolt (B), then slide the steering torque shaft assembly.
Tech Tips
Do not remove bolt (A).
Do not disconnect the steering torque shaft assembly from the power steering link assembly.
Put matchmarks on the steering torque shaft assembly and the power steering link assembly.
Separate the steering torque shaft assembly from the power steering link assembly.
REMOVE ENGINE ASSEMBLY WITH TRANSMISSION
Using the engine lifter, hold the engine assembly and separate the rear engine mount.
Note
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.
*a | Front Side |
Remove the stabilizer brackets and 16 bolts of the front suspension crossmember sub-assembly.
Operate the engine lifter, and then slowly remove the engine from the vehicle.
Note
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.
Note
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.
INSTALL ENGINE HANGER
*A | LH Side |
*B | RH Side |
Install the 2 engine hangers with the 2 bolts.
Note
Use new 2 bolts for the 2 engine hangers.
Tech Tips
Engine Hangers | 12281-75050 |
Bolt | 91672-81025 |
REMOVE STARTER ASSEMBLY
Detach the wire harness clamp from the wire harness bracket.
Remove the bolt and wire harness bracket.
Remove the bolt and disconnect the wire harness.
Disconnect the starter connector.
Remove the terminal cap.
Remove the nut and disconnect the wire harness.
Remove the 2 bolts and starter assembly.
REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
FIX ENGINE ASSEMBLY
Using wooden blocks or plate lift attachments, set the engine on a flat surface.
Note
Place wooden blocks or plate lift attachments so that the engine is level.
Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
Perform this step while supporting the engine assembly using a sling device and chain block.
REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
Using SST, hold the crankshaft.
Remove the 10 bolts, rear drive plate spacer, drive plate and ring gear sub-assembly and front drive plate spacer.
REMOVE REAR END PLATE
Remove the bolt and disconnect the No. 1 water by-pass pipe from rear end plate.
Remove the bolt and rear end plate.
REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Hold the engine with the engine sling device and chain block.
Remove the 4 bolts from the engine mounting insulator.
Remove the engine assembly by operating the engine sling device and chain block.
REMOVE ENGINE WIRE
Remove the engine wire from the engine assembly.
INSTALL ENGINE TO ENGINE STAND
Note
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.
Install the engine to an engine stand with the bolts.
Remove the 2 bolts and 2 engine hangers.
REMOVE PCV PIPE
Remove the bolt and PCV pipe.
REMOVE THROTTLE BODY ASSEMBLY
Disconnect the throttle motor connector.
Slide the clamp and disconnect the water by-pass hose from the throttle body assembly.
Slide the clamp and disconnect the No. 2 water by-pass hose from the throttle body assembly.
Remove the 4 bolts and throttle body assembly.
Remove the gasket from the intake manifold.
REMOVE INTAKE MANIFOLD
Disconnect the vacuum switching valve connector.
Slide the clamp and disconnect the purge line hose from the vacuum switching valve.
Detach the 2 wire harness clamps from the wire harness bracket.
Slide the clamp and disconnect the No. 3 PCV hose from the intake manifold.
Slide the clamp and disconnect the vacuum hose from the intake manifold.
Remove the bolt and wire harness bracket from the intake manifold.
Remove the 5 bolts, 2 nuts and intake manifold.
Remove the gasket from the intake manifold.
Remove the intake manifold insulator from the intake manifold.
REMOVE IGNITION COIL ASSEMBLY
Remove the 4 bolts and 4 ignition coil assemblies.
REMOVE SPARK PLUG
Using a 16 mm spark plug wrench, remove the 4 spark plugs.
REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
Note
Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.
Disconnect the vacuum hose from the fuel pressure regulator assembly.
Slide the clamp and disconnect the No. 2 fuel hose from the fuel pressure regulator assembly.
Disconnect the 4 fuel injector connectors.
Remove the 2 bolts, fuel pressure pulsation damper assembly and O-ring.
Remove the 2 bolts and fuel delivery pipe sub-assembly together with the 4 fuel injector assemblies.
Note
Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.
Remove the 2 No. 1 delivery pipe spacers from the cylinder head sub-assembly.
Remove the 4 injector vibration insulators.
*a | Protective Tape |
Using a screwdriver, pry out the 4 injector spacers and 4 O-rings from the cylinder head sub-assembly.
Tech Tips
Tape the screwdriver tip before use.
REMOVE FUEL INJECTOR ASSEMBLY
Pull out the 4 fuel injector assemblies from the fuel delivery pipe sub-assembly.
Pull Out |
Remove the O-rings from the fuel injector assemblies.
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Remove the 4 bolts and No. 1 exhaust manifold heat insulator.
REMOVE NO. 4 INTAKE PIPE
Remove the 4 nuts and No. 4 intake pipe.
Remove the 2 gaskets.
REMOVE AIR SWITCHING VALVE ASSEMBLY
Disconnect the air switching valve connector.
Remove the 2 nuts and air switching valve assembly.
REMOVE EXHAUST MANIFOLD
Remove the 8 nuts, exhaust manifold and gasket.
REMOVE FAN PULLEY
Remove the 4 nuts, fan pulley and fan spacer.
REMOVE NO. 1 WATER BY-PASS PIPE
Remove the bolt, 2 nuts, No. 1 water by-pass pipe and gasket.
REMOVE WATER INLET
Remove the 2 nuts and bolt and disconnect the water inlet.
Remove the gasket.
REMOVE THERMOSTAT
Remove the thermostat and gasket.
REMOVE GENERATOR ASSEMBLY
Disconnect the generator connector.
Remove the terminal cap.
Remove the nut and disconnect the wire harness from terminal B.
Remove the bolt and disconnect the wire harness clamp.
Remove the 3 bolts and generator assembly.
REMOVE IDLE PULLEY ASSEMBLY
Loosen the bolt, and then remove the idle pulley assembly.
Tech Tips
The bolt in the illustration cannot be removed from the idle pulley assembly.
REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET
Remove the 5 bolts and No. 1 compressor mounting bracket.
REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
Remove the bolt, collar and No. 1 idler pulley sub-assembly.
REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
Remove the 2 bolts and V-ribbed belt tensioner assembly.
REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
REMOVE KNOCK CONTROL SENSOR
Disconnect the knock control sensor connector.
Remove the bolt and knock control sensor.
REMOVE ENGINE COOLANT TEMPERATURE SENSOR
Disconnect the engine coolant temperature sensor connector.
Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.
REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH
Tech Tips
Perform this procedure only when replacement of the front No. 1 engine mounting bracket RH is necessary.
Remove the 4 bolts and front No. 1 engine mounting bracket RH.
REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
Tech Tips
Perform this procedure only when replacement of the front No. 1 engine mounting bracket LH is necessary.
Remove the 4 bolts and front No. 1 engine mounting bracket LH.
REMOVE ENGINE OIL LEVEL SENSOR
Remove the 4 bolts and engine oil level sensor.