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ENGINE ASSEMBLY (w/ DPF) REMOVAL

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  1. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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).

    • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  2. Click here

    REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. A01DNPL

      Remove the 8 bolts and hood.

      Note:

      If the hood support is detached from the ball joint, it becomes non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

  3. Click here

    REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    (Click here)

  4. Click here

    REMOVE FRONT BUMPER LOWER COVER


    1. Remove the clip, 5 bolts and front bumper lower cover.

  5. Click here

    REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Remove the 4 bolts and No. 1 engine under cover.

  6. Click here

    REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  7. Click here

    REMOVE REAR ENGINE UNDER COVER ASSEMBLY


    1. Remove the 4 bolts and rear engine under cover.

  8. Click here

    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.

      Tip:

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DPA5

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. A01DNO9E01

      Loosen the cylinder block drain cock plug.

      Table 1. Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug
  9. Click here

    DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and then drain the engine oil into a container.

    3. Wipe the oil pan and drain plug.

    4. Install a new gasket and the oil pan drain plug.

      34 N*m 347 kgf*cm 25 ft.*lbf
  10. Click here

    DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket and then drain the manual transmission oil.

    3. Install a new gasket and the drain plug.

      37 N*m 377 kgf*cm 27 ft.*lbf
  11. Click here

    DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


    1. Remove the drain plug and gasket, and drain the ATF.

    2. Install a new gasket and the drain plug.

      20 N*m 204 kgf*cm 15 ft.*lbf
  12. Click here

    DRAIN POWER STEERING FLUID

  13. Click here

    REMOVE RADIATOR ASSEMBLY

    (Click here)

  14. Click here

    REMOVE BATTERY HOLD DOWN CLAMP


    1. Remove the 2 nuts and battery hold down clamp.

  15. Click here

    REMOVE BATTERY

  16. Click here

    REMOVE BATTERY TRAY

  17. Click here

    REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A01DSATE01

      Remove the 2 nuts.

      Table 2. Text in Illustration
      *1 No. 1 Engine Cover Hook
      *2 No. 3 Engine Cover Bracket

    2. Detach the 2 No. 1 engine cover hooks from the No. 3 engine cover bracket and remove the No. 1 engine cover.

  18. Click here

    REMOVE NO. 1 AIR CLEANER HOSE


    1. A01DNR2

      Loosen the 2 hose clamps and remove the No. 1 air cleaner hose.

  19. Click here

    REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. except Cold Area Specification Vehicles:

      Detach the 2 clamps and disconnect the mass air flow meter connector.

      Table 3. Text in Illustration
      *A except Cold Area Specification Vehicles
      *B for Cold Area Specification Vehicles

    2. for Cold Area Specification Vehicles:

      Detach the 3 clamps and disconnect the mass air flow meter connector.

    3. Detach the 4 clamps and remove the air cleaner cap sub-assembly.

  20. Click here

    REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  21. Click here

    REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01DMCQ

      Remove the 3 bolts and air cleaner case sub-assembly.

  22. Click here

    REMOVE COMPRESSOR OUTLET ELBOW


    1. A01DTR4

      Detach the 3 wire harness clamps.

    2. Remove the bolt and wire harness bracket.

    3. A01DS15

      Loosen the hose clamp and remove the 2 bolts and compressor outlet elbow.

  23. Click here

    REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (for Cold Area Specification Vehicles)


    1. Disconnect the viscous heater connector.

    2. A01DP9N

      Disconnect the water by-pass hose and water hose.

    3. A01DRFR

      Remove the 2 bolts and viscous heater with magnet clutch.

  24. Click here

    REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. A01DQ4P

      Remove the 4 bolts and No. 1 viscous heater bracket.

  25. Click here

    DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A01DR5G

      Disconnect the compressor connector.

    2. Remove the 4 bolts and disconnect the cooler compressor.

  26. Click here

    DISCONNECT NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A01DTH4

      Remove the bolt and disconnect the No. 4 vacuum transmitting pipe.

  27. Click here

    DISCONNECT INTERCOOLER AIR HOSE


    1. A01DQ82

      Loosen the hose clamp and disconnect the intercooler air hose.

  28. Click here

    REMOVE NO. 1 INTAKE PIPE


    1. A01DO4G

      Disconnect the 2 connectors from the intake air temperature sensor and throttle position sensor.

    2. Detach the 2 wire harness clamps.

    3. A01DRSZ

      Loosen the 2 hose clamps of the No. 1 air hose.

    4. Remove the 2 bolts and No. 1 intake pipe.

  29. Click here

    REMOVE FUEL FILTER ASSEMBLY

    (Click here)

  30. Click here

    DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01DUMX

      Remove the 3 bolts and disconnect the vane pump oil reservoir.

  31. Click here

    DISCONNECT PRESSURE FEED TUBE ASSEMBLY


    1. A01DLZL

      Disconnect the power steering oil pressure switch connector.

    2. A01DRHY

      Remove the union bolt and gasket and disconnect the pressure feed tube.

  32. Click here

    REMOVE NO. 1 ENGINE COVER BRACKET


    1. A01DURY

      Remove the bolt and No. 1 engine cover bracket.

  33. Click here

    REMOVE NO. 3 ENGINE COVER BRACKET


    1. A01DU9H

      Remove the 2 nuts and No. 3 engine cover bracket.

  34. Click here

    REMOVE ENGINE COVER BRACKET INSULATOR


    1. A01DU9R

      Remove the 2 nuts and 2 engine cover bracket insulators.

  35. Click here

    REMOVE NO. 4 ENGINE COVER BRACKET


    1. A01DND6

      Remove the bolt and No. 4 engine cover bracket.

  36. Click here

    DISCONNECT INLET HEATER WATER HOSE


    1. A01DOS8

      Disconnect the inlet heater water hose.

  37. Click here

    DISCONNECT WATER PIPE AND HOSE SUB-ASSEMBLY


    1. A01DU6G

      Remove the bolt and disconnect the water pipe and hose.

  38. Click here

    DISCONNECT FUEL HOSE


    1. A01DOHU

      Disconnect the fuel hose from the fuel supply pump.

  39. Click here

    DISCONNECT NO. 2 FUEL HOSE


    1. A01DSIG

      Disconnect the No. 2 fuel hose from the No. 3 nozzle leakage pipe.

  40. Click here

    REMOVE GLOVE COMPARTMENT DOOR SUB-ASSEMBLY

    (Click here)

  41. Click here

    DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. A01DMKM

      Remove the nut and detach the 2 claws.

    3. A01DTWF

      Disconnect the 4 injection driver connectors.

    4. A01DO4Z

      Disconnect the connector and detach the clamp.

    5. A01DROE

      Remove the bolt.

    6. A01DLZY

      Remove the nut and disconnect the engine wire.

    7. A01DS5W

      Remove the bolt and disconnect the wire harness protector.

    8. A01DRBNE01

      Remove the bolt and disconnect the engine wire.

      Table 4. Text in Illustration
      *A w/ KDSS
      *B w/o KDSS
    9. A01DQG8E01

      Detach the clamp and disconnect the 9 connectors.

      Table 5. Text in Illustration
      *A for LHD
      *B for RHD
    10. A01DOF2E01

      Detach the grommet from the wire harness support.

      Table 6. Text in Illustration
      *A for LHD
      *B for RHD
    11. A01DQAWE01

      Detach the 4 claws and remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

      Table 7. Text in Illustration
      *A for LHD
      *B for RHD
  42. Click here

    REMOVE STARTER ASSEMBLY (for 2.2 kW Type)


    1. Remove the terminal cap.

    2. A01DMUX

      Remove the nut and disconnect the starter wire.

    3. Disconnect the starter connector.

    4. A01DOP0

      for Automatic Transmission:

      Remove the bolt, 2 nuts and starter assembly.

    5. A01DLTW

      for Manual Transmission:

      Remove the bolt, nut and starter assembly.

  43. Click here

    REMOVE STARTER ASSEMBLY (for 2.7 kW Type)


    1. Remove the terminal cap.

    2. A01DN7F

      Remove the nut and disconnect the starter wire.

    3. Disconnect the starter connector.

    4. A01DOTE

      for Automatic Transmission:

      Remove the bolt, 2 nuts and starter assembly.

    5. A01DP3K

      for Manual Transmission:

      Remove the bolt, nut and starter assembly.

  44. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY

    (Click here)

  45. Click here

    REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. A01DTSDE07

      Place matchmarks on the propeller shaft flange and differential.

      Table 8. Text in Illustration
      *a Matchmark

    2. Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly.

    3. A01DNIAE10

      Place matchmarks on the propeller shaft flange and transfer flange.

      Table 9. Text in Illustration
      *a Matchmark

    4. Remove the 4 nuts, 4 washers and front propeller shaft assembly.

  46. Click here

    REMOVE PROPELLER SHAFT ASSEMBLY


    1. A01DNVME01

      Place matchmarks on the propeller shaft flange and transfer flange.

      Table 10. Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

    2. Remove the 4 nuts and 4 washers.

    3. A01DOUDE01

      Place matchmarks on the propeller shaft flange and differential flange.

      Table 11. Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. Remove the propeller shaft.

  47. Click here

    REMOVE OIL PAN INSULATOR


    1. A01DT0Z

      Remove the 2 bolts and oil pan insulator.

  48. Click here

    REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    (Click here)

  49. Click here

    REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transmission)


    1. Turn the crankshaft to gain access to the 6 bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

      Tip:

      If it is difficult to reach the setting bolts with the wrench, raise or lower the transmission jack until there is sufficient space for the wrench.

  50. Click here

    REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    (Click here)

  51. Click here

    REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tip:

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. A01DNFY

      Remove the 4 bolts and rear No. 1 engine mounting insulator.

  52. Click here

    REMOVE ENGINE ASSEMBLY


    1. A01DSKBE01

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

      for No. 1 engine hanger
      25 N*m 255 kgf*cm 18 ft.*lbf
      for No. 2 engine hanger
      60 N*m 612 kgf*cm 44 ft.*lbf
      Table 12. Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      Tip:

      Part No.

      No. 1 Engine Hanger 12284-30020
      No. 2 Engine Hanger 12282-67030
      Bolt 91552-81014 and 91642-81030
      Note:

      Install the engine hangers with new bolts.

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

    3. A01DQIKE01

      Remove the 4 bolts and 4 nuts.

      Table 13. Text in Illustration
      *A for LH Side
      *B for RH Side

    4. Remove the engine by operating the engine sling device and chain block.

  53. Click here

    REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. Place matchmarks on the clutch cover and flywheel.

      Table 14. Text in Illustration
      *a Matchmark

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

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note:

      Do not drop the clutch disc.

  54. Click here

    REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note:

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

  55. Click here

    REMOVE CRANKSHAFT PULLEY COVER


    1. A01DPSQ

      Remove the 2 bolts and crankshaft pulley cover.

  56. Click here

    REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. A01DS4JE01

      Using SST, hold the crankshaft pulley.

      09213-58014
      09330-00021

    2. Remove the 8 bolts and flywheel.

  57. Click here

    REMOVE PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)


    1. A01DS4JE01

      Using SST, hold the crankshaft pulley.

      09213-58014
      09330-00021
    2. A01DPUA

      Remove the 8 bolts, the rear drive plate spacer, the pump impeller drive plate and the flywheel and ring gear.

  58. Click here

    REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  59. Click here

    INSTALL ENGINE TO ENGINE STAND

  60. Click here

    REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  61. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01DQZEE01

      Detach the clamp and disconnect the 2 hoses.

      Table 15. Text in Illustration
      *A for LH Side
      *B for RH Side

    2. Remove the 2 nuts and 2 front engine mounting insulators.