ENGINE ASSEMBLY (w/o DPF) REMOVAL


  1. 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. 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 become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  4. REMOVE FRONT BUMPER LOWER COVER


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

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


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

  6. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  7. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


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

  8. 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.

      Tech Tips

      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. Loosen the cylinder block drain cock plug.

      A01DNO9E01
      Text in Illustration
      *1 Radiator Reservoir *2 Vent Plug
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

  9. 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.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  10. 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.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  11. 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.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  12. DRAIN POWER STEERING FLUID

  13. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator Click here.

  14. REMOVE BATTERY HOLD DOWN CLAMP


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

  15. REMOVE BATTERY

  16. REMOVE BATTERY TRAY

  17. REMOVE NO. 1 AIR CLEANER HOSE


    1. A01DNR2

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

  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    A01DTIXE02
    Text in Illustration
    *A except Cold Area Specification Vehicles
    *B for Cold Area Specification Vehicles

    1. except Cold Area Specification Vehicles:

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

    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.

  19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01DMCQ

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

  21. 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.

  22. 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.

  23. 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.

  24. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A01DR5G

      Disconnect the compressor connector.

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

  25. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body Click here.

  26. REMOVE FUEL FILTER ASSEMBLY


    1. Remove the fuel filter Click here.

  27. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY


    1. A01DUMX

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

  28. 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.

  29. DISCONNECT INLET HEATER WATER HOSE


    1. A01DRUA

      Disconnect the inlet heater water hose.

  30. DISCONNECT OUTLET HEATER WATER HOSE


    1. A01DRLI

      Disconnect the outlet heater water hose.

  31. DISCONNECT FUEL HOSE


    1. A01DPWC

      Disconnect the No. 1 fuel hose and No. 2 fuel hose.

  32. REMOVE GLOVE COMPARTMENT DOOR SUB-ASSEMBLY


    1. Remove the glove compartment door Click here.

  33. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. A01DMKM

      Remove the nut and detach the 2 claws.

    3. A01DQAJ

      Disconnect the 3 injection driver connectors and remove the bolt.

    4. A01DTAR

      Disconnect the connector and detach the clamp.

    5. A01DROE

      Remove the bolt.

    6. A01DTI2

      Remove the nut and disconnect the engine wire.

    7. A01DS5W

      Remove the bolt and disconnect the wire harness protector.

    8. A01DRBNE01
      Text in Illustration
      *A w/ KDSS
      *B w/o KDSS

      Remove the bolt and disconnect the engine wire.

    9. A01DQG8E01
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the clamp and disconnect the 9 connectors.

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

      Detach the grommet from the wire harness support.

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

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

  34. 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.

  35. 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.

  36. REMOVE STARTER ASSEMBLY (for 3.0 kW Type)


    1. Remove the terminal cap.

    2. A01DN7F

      Disconnect the starter connector.

    3. Remove the nut and disconnect the starter wire.

    4. A01DPF6

      Remove the bolt, 2 nuts and starter assembly.

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01DMT5E01
      Text in Illustration
      *A w/ EGR Cooler
      *B w/o EGR Cooler

      Remove the 3 nuts and front exhaust pipe.

    2. Remove the gasket.

  38. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. A01DTSDE07
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential.

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

    3. A01DNIAE10
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

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

  39. REMOVE PROPELLER SHAFT ASSEMBLY


    1. A01DNVME01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    2. Remove the 4 nuts and 4 washers.

    3. A01DOUDE01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential flange.

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

    5. Remove the propeller shaft.

  40. REMOVE OIL PAN INSULATOR


    1. A01DT0Z

      Remove the 2 bolts and oil pan insulator.

  41. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Remove the manual transmission Click here.

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

    A01DUUI

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

      Tech Tips

      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.

  43. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Remove the automatic transmission Click here.

  44. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    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.

  45. REMOVE ENGINE ASSEMBLY


    1. A01DSKBE01
      Text in Illustration
      *1 No. 1 engine hanger
      *2 No. 2 engine hanger

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

      Tech Tips

      Part No.

      No. 1 engine hanger 12284-30020
      No. 2 engine hanger 12282-67030
      Bolt 91552-81014 and 91642-81030
      Torque:
      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 }

      Note

      Install the engine hangers with new bolts.

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

    3. A01DQIKE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Remove the 4 bolts and 4 nuts.

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

  46. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    A01DRN0E01
    Text in Illustration
    *a Matchmark

    1. Place matchmarks on the clutch cover and flywheel.

    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.

  47. 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.

  48. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. A01DS4JE01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    2. Remove the 8 bolts and flywheel.

  49. REMOVE PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)


    1. A01DS4JE01

      Using SST, hold the crankshaft pulley.

      SST
      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.

  50. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  51. INSTALL ENGINE TO ENGINE STAND

  52. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  53. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01DQ9TE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disconnect the 2 hoses.

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