ENGINE ASSEMBLY REMOVAL


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  3. REMOVE FRONT WHEEL

  4. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug and engine drain plug, then drain the coolant.

      A01BHB7E02

    2. Remove the radiator cap.

  5. DRAIN ENGINE OIL

    Note


    • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.

    • Exercise caution in order to minimize the duration and frequency of skin contact with used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner to remove any used engine oil. Do not use gasoline, thinners, or solvents.

    • In order to preserve the environment, used oil and the used oil filter must be disposed of only at designated disposal sites.


    1. Remove the oil filler cap.

    2. Remove the oil drain plug, and drain the oil into a container.

    3. Clean the drain plug, and install it with a new gasket.

      Torque:
      35 N*m  { 350 kgf*cm, 25 ft.*lbf }

  6. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)

    Tech Tips

    Use the same procedures described for the LH side. Click here

  7. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)

    Tech Tips

    Use the same procedures described for the LH side. Click here

  8. REMOVE FRONT DOOR SCUFF PLATE RH

  9. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Turn back the carpet, and remove the engine service hole cover sub-assembly.

  10. REMOVE VANE PUMP V BELT


    1. A01BCBTE01

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

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


    1. A01BEBYE01

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

  12. REMOVE FAN & GENERATOR V BELT (w/o Air Conditioning)


    1. A01BBR9E01

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

  13. REMOVE FAN & GENERATOR V BELT (w/ Air Conditioning)


    1. A01BAGHE01

      Loosen the bolts A and B.

    2. Loosen the adjusting bolt C, and remove the V belt.

  14. DISCONNECT RADIATOR HOSE INLET

  15. DISCONNECT RADIATOR HOSE NO.4

  16. DISCONNECT INJECTION PUMP TO FUEL FILTER FUEL HOSE OR PIPE

  17. SEPARATE AIR CLEANER HOSE NO.2


    1. Loosen the bolt, and disconnect the air cleaner hose No.2.

  18. REMOVE COMPRESSOR AND MAGNETIC CLUTCH

    Click here

  19. SEPARATE VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

      Remove the 2 bolts and vane pump oil reservoir assembly.

      Note

      Suspend the vane pump oil reservoir assembly with wire to prevent power steering fluid from spilling out.

  20. DISCONNECT ENGINE WIRE


    1. Remove the wire harness support from the ECM.

    2. Disconnect the connectors from the ECM.

    3. Disconnect the clamp and ground cable of the engine wire.

    4. Remove the nut then remove the starter wire harness.

    5. A01BFD1E02

      Remove the connector and nut, as shown the illustration.

  21. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Long Wheelbase)


    1. Remove the 4 bolts, 2 compression springs.

    2. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front No.2 and 2 gaskets.

  22. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)


    1. Remove the 4 bolts, 2 nuts, 2 compression springs.

    2. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front No.2 and 2 gaskets.

  23. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.1 (for Long Wheelbase)


    1. Loosen the clamp bolt, and separate the exhaust pipe support bracket No.1 from the exhaust pipe sub-assembly front No.1.

    2. Remove the 3 bolts, exhaust pipe sub-assembly front No.1 and gasket from the exhaust manifold.

  24. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.1 (for Super Long Wheelbase)


    1. Loosen the clamp bolt, and separate the exhaust pipe support bracket No.1 from the exhaust pipe sub-assembly front No.1.

    2. Remove the 3 bolts, exhaust pipe sub-assembly front No.1 and gasket from the exhaust manifold.

  25. REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    1. A01BHYPE01

      Put matchmarks on both flanges.

    2. 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.

    3. Remove the propeller shaft assembly.

    4. A01BGHTE01

      Insert SST in the transmission to prevent oil leakage.

      Note

      Do not damage the oil seal.


      1. Use the following SST for the automatic transmission

        SST
        09325-40010

      2. Use the following SST for the manual transmission

        SST
        09325-20010

  26. REMOVE PROPELLER SHAFT ASSEMBLY (for Super Long Wheelbase)


    1. A01BHYPE01

      Put matchmarks on both flanges.

    2. 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 with center bearing shaft assembly from the differential companion flange.

    3. A01BGNF

      Remove the 2 bolts and center support bearing assembly No.1.

    4. Remove the propeller with center bearing shaft assembly.

    5. A01BGHTE01

      Insert SST in the transmission to prevent oil leakage.

      Note

      Do not damage the oil seal.


      1. Use the following SST for the automatic transmission.

        SST
        09325-40010

      2. Use the following SST for the manual transmission.

        SST
        09325-20010

  27. SEPARATE SPEED SENSOR FRONT LH (w/ ABS)


    1. A01BFZEE01

      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.

  28. SEPARATE SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  29. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A01BB1EE01

      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.

  30. SEPARATE FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  31. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER LH


    1. A01BCPDE01

      Remove the cotter pin and loosen the nut.

      SST
      09628-62011

      Note

      Do not remove the nut.

    2. 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.

  32. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  33. SEPARATE SHOCK ABSORBER ASSEMBLY FRONT LH


    1. A01BCXLE02

      Remove the bolt and separate the front shock absorber from the front suspension lower arm.

  34. SEPARATE SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  35. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A01BG2ME01

      Put matchmarks on the control cable assembly and the outer lever.

    2. Remove the 2 nuts and separate the transmission control cable from the outer lever.

    3. A01BE24

      Using a screwdriver, disengage the claws of the 2 clips.

    4. Remove the transmission control cable and 2 clips from the transmission control cable bracket No.1.

  36. DISCONNECT WIRE HARNESS


    1. A01BC02

      Disconnect the 2 connectors and clamp.

  37. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01BI54

      Remove the 2 bolts and separate the clutch release cylinder.

  38. SEPARATE STEERING TORQUE SHAFT ASSEMBLY


    1. A01BH0EE01

      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.

    2. A01BG7RE01

      Put matchmarks on the steering torque shaft assembly and the power steering link assembly.

    3. Separate the steering torque shaft assembly from the power steering link assembly.

  39. REMOVE ENGINE W/ TRANSMISSION ASSEMBLY


    1. Using the engine lifter, hold the engine assembly and separate the rear engine mounting.

    2. A01BCFWE02

      Remove the stabilizer bracket and 16 bolts of the front suspension cross member.

    3. Remove the engine assembly w/ transmission to the vehicle.

  40. REMOVE STARTER ASSEMBLY (for 2.2 kW Type)


    1. Disconnect the starter connector.

    2. Remove the terminal cap.

    3. Remove the nut, and disconnect the 30 terminal.

    4. Remove the nut, 2 bolts, and stay.

    5. Remove the nut 2 bolts, and starter assembly.

  41. REMOVE STARTER ASSEMBLY (for 2.7 kW Type)


    1. Disconnect the starter connector.

    2. Remove the terminal cap.

    3. Remove the nut, and disconnect the 30 terminal.

    4. Remove the nut and, 2 bolts, stay and starter assembly.

  42. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  43. REMOVE CLUTCH COVER ASSEMBLY


    1. A01BAUVE01

      Put matchmarks on the clutch cover assembly and the flywheel sub-assembly.

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

      Note

      Do not drop the clutch disc assembly.

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

  44. REMOVE CLUTCH DISC ASSEMBLY

    Note

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

  45. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A01BH90E01

      Fix the crankshaft with SST, then remove the 8 bolts and flywheel.

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

  46. REMOVE REAR END PLATE


    1. Remove the 2 bolts and rear end plate.

  47. REMOVE ENGINE WIRE


    1. Remove the engine wire to the engine assembly.

  48. SEPARATE VANE PUMP ASSEMBLY


    1. A01BB47E01

      Using SST, stop the pulley rotation and loosen the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the nut and vane pump pulley from the vane pump shaft.

    3. Remove the 2 bolts and nut, and separate the vane pump assembly.

      Tech Tips

      Separate the vane pump with the hoses connected, and it should be hung with a rope.

  49. INSTALL ENGINE HANGER NO.2


    1. A01BB5HE01

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

      Torque:
      37 N*m  { 380 kgf*cm, 27 ft.*lbf }
      Part No.:
      Engine hanger No.2 12282-54060
      Bolt 91622-61022

  50. SEPARATE ENGINE MOUNTING INSULATOR FRONT


    1. Remove the 4 bolts, and separate the engine mounting insulator front.

  51. REMOVE FAN BELT ADJUSTING BAR (w/o Air Conditioning)


    1. A01BBSP

      Remove the 3 bolts and fan belt adjusting bar.

  52. REMOVE COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning)


    1. A01BDQD

      Remove the 3 bolts and compressor mounting bracket.

    2. A01BDNC

      Remove the bolt and spacer.

    3. A01BFW5

      Remove the 4 bolts and compressor mounting bracket.

  53. REMOVE TIMING BELT

    Click here

  54. REMOVE INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Disconnect the ventilation hose.

    2. Disconnect the turbo pressure sensor connector.

    3. A01BCJN

      Remove the bolt, 3 nuts, intake air connector and gasket.

  55. REMOVE INTAKE AIR CONNECTOR BRACKET


    1. A01BDYM

      Remove the 2 bolts and intake air connector bracket.

  56. REMOVE VENTURI ASSEMBLY


    1. A01BAY2E01

      Disconnect the throttle open switch connector.

    2. A01BFXZE01

      Disconnect the throttle control motor connector.

    3. Remove the venturi and gasket.

  57. REMOVE INJECTION PIPE SET


    1. Loosen the 8 union nuts of the 4 injection pipes.

    2. Remove the 2 nuts, 2 upper pipe clamps, and 4 injection pipes with lower pipe clamps.

  58. REMOVE GLOW PLUG NO.1 CONNECTOR


    1. Remove the vehicle's side wire harness, glow plug screw grommets and nuts, and disconnect the glow plug No.1 connector.

  59. REMOVE NOZZLE LEAKAGE PIPE ASSEMBLY


    1. Disconnect the fuel hose from the leakage pipe.

    2. Remove the 4 nuts, leakage pipe and the 4 ring packing washers.

  60. REMOVE NOZZLE HOLDER & NOZZLE SET


    1. Using SST, remove the 4 injection nozzles, 4 injection nozzle seats and 4 injection nozzle seat gaskets.

      SST
      09268-64010   ( 09268-64020 )

  61. REMOVE GLOW PLUG ASSEMBLY


    1. Using a 12 mm deep socket wrench, remove the 4 glow plugs.

  62. REMOVE INJECTION PUMP DRIVE PULLEY


    1. A01BEIWE01

      Using SST, remove the pulley nut.

      SST
      09213-14010   ( 91651-60865 )
      09330-00021
    2. A01BADXE01

      Using SST, remove the drive pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  63. REMOVE INJECTION OR SUPPLY PUMP ASSEMBLY


    1. Disconnect the engine speed sensor connector.

    2. Disconnect the spill control valve connector.

    3. Disconnect the correction unit connector.

    4. Disconnect the timer control valve connector.

    5. Disconnect the fuel temperature sensor connector.

    6. Disconnect the engine wire clamp.

    7. Disconnect the 3 fuel hoses.

    8. A01BBBJ

      Disconnect the 3 bolts and injection pump stay No.1.

    9. Remove the 2 nuts and injection or supply pump assembly.

  64. REMOVE CRANK POSITION SENSOR


    1. Disconnect the crank position sensor connector.

    2. A01BG03

      Remove the bolt and crank position sensor.

  65. REMOVE WATER OUTLET HOUSING


    1. A01BEX8

      Remove the 3 bolts, water outlet, outlet housing assembly and gasket.

  66. REMOVE INTAKE MANIFOLD


    1. A01BDG0

      Remove the 6 bolts, 2 nuts, intake manifold and gasket.

  67. REMOVE WATER BY-PASS HOSE UNION


    1. Remove the water by-pass hose union.

  68. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    1. Remove the cylinder block water drain cock sub-assembly.

  69. REMOVE ENGINE OIL LEVEL SENSOR


    1. A01BC4M

      Remove the 4 bolts and engine oil level sensor.

  70. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1


    1. A01BBDT

      Remove the 2 bolts, exhaust pipe support bracket No.1 and stiffener plate RH.

  71. REMOVE PUMP BRACKET


    1. A01BHPZ

      Remove the 6 bolts and pump bracket.

  72. REMOVE GENERATOR W/ VACUUM PUMP ASSEMBLY


    1. A01BFJB

      Remove the bolt and disconnect the hose.

    2. Remove the clip and disconnect the hose.

    3. A01BCCL

      Remove the bolt and generator w/ vacuum pump assembly.

  73. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH


    1. A01BGGI

      Remove the 6 bolts and engine mounting bracket front No.1 RH.

  74. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY

  75. REMOVE OIL LEVEL GAGE GUIDE


    1. Remove the oil level gage guide.

  76. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. Remove the 3 bolts and exhaust manifold heat insulator No.1.

  77. REMOVE EXHAUST MANIFOLD


    1. A01BB18

      Remove the 6 bolts, 2 nuts and exhaust manifold.

    2. Remove the exhaust manifold gasket from the cylinder head.

  78. REMOVE OIL FILTER SUB-ASSEMBLY


    1. Using SST, remove the oil filter.

      SST
      09228-44011

  79. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A01BACH

      Remove the 10 bolts, 2 nuts, oil filter bracket, and gasket.

  80. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01BA4M

      Using a 24 mm deep socket wrench, remove the oil pressure switch.

  81. REMOVE WIRE HARNESS CLAMP BRACKET


    1. Remove the bolt and wire harness clamp bracket.