ENGINE ASSEMBLY REMOVAL


  1. DISCONNECT BATTERY NEGATIVE TERMINAL

  2. DRAIN COOLANT

  3. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1

  4. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.2

  5. REMOVE FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)


    1. A01KHOR

      Remove the seat track cover.

    2. Remove the 4 bolts.

    3. Remove the front seat assembly RH.

  6. REMOVE TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  7. REMOVE PARKING BRAKE LEVER ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  8. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)


    1. Remove the front door scuff.

    2. Remove the floor mat.

    3. Remove the 7 bolts and the engine service hole sub-cover.

  9. DISCONNECT RADIATOR HOSE INLET

  10. REMOVE FAN SHROUD


    1. Remove the 2 bolts, and then disconnect the fan shroud.

    2. Remove the 4 nuts holding the fan with coupling, and also the fan shroud together with fan with coupling.

  11. DISCONNECT HEATER WATER INLET HOSE A (W/ HEATER)

  12. DISCONNECT HEATER WATER OUTLET HOSE B (W/ HEATER)

  13. DISCONNECT RADIATOR HOSE OUTLET

  14. REMOVE THROTTLE CONTROL CABLE SUPPORT

    Tech Tips

    Remove the throttle control cable support with the accelerator flexible wire connected.

  15. DISCONNECT MAIN TUBE, NO.1 FUEL HOSE

  16. DISCONNECT FUEL RETURN TUBE FUEL HOSE

  17. REMOVE VANE PUMP V BELT


    1. A01KGPKE01

      Loosen the nut A and bolt B, and remove the V belt.

  18. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (W/ AIR CONDITIONER)


    1. A01KHWGE01
      Text in Illustration
      *1 Idler pulley

      Loosen the nut A and bolt B, and remove the V belt.

  19. REMOVE FAN AND GENERATOR V BELT


    1. A01KEJTE01

      For vehicles with A/C.


      1. Loosen the bolts A and B, and remove the V belt.

    2. A01KG4FE01

      For vehicles without A/C.


      1. Loosen the bolts A and B, and remove the V belt.

  20. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)

    Tech Tips

    Disconnect the compressor and magnetic clutch with the high and low pressure hoses connected, and it should be hung with rope.

  21. REMOVE AIR CLEANER HOSE NO.1

  22. DISCONNECT ENGINE WIRE

  23. REMOVE EXHAUST PIPE ASSEMBLY FRONT NO.2

    Click here

  24. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (INDEPENDENT FRONT SUSPENSION)

    A01KHFIE01

    1. Remove the cotter pin and nut.

    2. Using SST, disconnect the tie rod end from the steering knuckle arm.

      SST
      09610-20012

  25. DISCONNECT TIE ROD END SUB-ASSEMBLY RH (INDEPENDENT FRONT SUSPENSION)

    Tech Tips

    Remove the RH side by the same procedures with the LH side.

  26. DISCONNECT TIE ROD END SUB-ASSEMBLY LH (RIGID FRONT SUSPENSION)


    1. Loosen the lock nut.

    2. Remove the tie rod end and lock nut.

  27. DISCONNECT TIE ROD END SUB-ASSEMBLY RH (RIGID FRONT SUSPENSION)

    Tech Tips

    Remove the RH side by the same procedures with the LH side.

  28. REMOVE FRONT SPRING BUMPER NO.1 (INDEPENDENT FRONT SUSPENSION)


    1. Remove the nut and front spring bumper No.1 RH and LH.

  29. DISCONNECT STEERING TORQUE SHAFT ASSEMBLY (INDEPENDENT FRONT SUSPENSION)


    1. Remove the 3 bolts, steering link protector UPR and steering link protector LWR.

    2. Remove the 2 bolts.

    3. A01KHJHE01
      Text in Illustration
      *a Matchmark

      Shift the sliding yoke and place the matchmarks to the sliding yoke and steering gear.

    4. Remove the bolt.

    5. A01KEEOE01
      Text in Illustration
      *a Matchmark

      Shift the torque shaft and place the matchmarks to the torque shaft and bevel gear.

    6. Remove the torque shaft.

  30. DISCONNECT PRESSURE FEED TUBE ASSEMBLY (INDEPENDENT FRONT SUSPENSION)

    A01KGVN

    1. Remove the union bolt and gasket, and disconnect the feed tube.

  31. DISCONNECT STEERING GEAR OUTLET RETURN TUBE (INDEPENDENT FRONT SUSPENSION)

    A01KIMS

    1. Remove the bolt (LHD steering position type only).

    2. A01KEK0

      Remove the clip and disconnect the return hose.

    3. A01KFQW

      Remove the return tube.

  32. REMOVE FRONT SUSPENSION MEMBER ASSEMBLY (INDEPENDENT FRONT SUSPENSION)


    1. Remove the front stabilizer cover RH and LH.

    2. Disconnect the front shock absorber assembly RH and LH at the lower arm part.

    3. Using an engine lifter to hold the front suspension member assembly, remove the 4 bolts.

    4. Remove the front stabilizer bar, power steering gear assembly, lower arm RH and LH, and front suspension member assembly all together.

  33. DISCONNECT VANE PUMP ASSEMBLY

    Click here

  34. REMOVE PROPELLER SHAFT ASSEMBLY REAR



  35. DISCONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Tech Tips

    Disconnect the clutch release cylinder assembly with the hose connected, and then it should be hung with rope.

  36. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT


    1. Remove the clip and nut, and then disconnect the select cable from the transmission.

  37. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT


    1. Remove the clip and nut, and then disconnect the shift cable from the transmission.

  38. REMOVE ENGINE W/TRANSMISSION ASSEMBLY


    1. Using an engine lifter to hold the engine, separate the mount of the transmission.

    2. Disconnect the parking brake cable No. 3 (for vehicles with center brake).

    3. First remove the engine front mounting bracket RH and LH, and then the engine assembly with transmission.

    4. A01KHDHE01
      Text in Illustration
      *1 No. 2 Engine hanger
      *2 Bolt

      Install the No. 2 engine hanger in the correct direction.

      Part No.
      No. 2 engine hanger 12282-54060
      Bolt 91612-61022
      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }

    5. Using a chain block and engine sling device, hang up the engine assembly so as not tilt it.

      CAUTION:

      Do not attempt to hang the engine by hooking the chain to any other part.

  39. REMOVE ENGINE WIRE

  40. REMOVE STARTER ASSEMBLY



  41. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY



  42. REMOVE CLUTCH COVER ASSEMBLY


    1. A01KHECE02
      Text in Illustration
      *a Matchmark

      Place the matchmarks on the clutch cover with the one on the flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the set bolts, and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  43. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Keep the lining part of the clutch disc assembly, the pressure plate and surface of the flywheel away from oil and foreign attachment.

  44. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01KIMWE01

      Using SST to fix the crank shaft pulley, remove the fly wheel.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

  45. REMOVE REAR END PLATE

  46. REMOVE FLYWHEEL HOUSING DUST SEAL