ENGINE ASSEMBLY REMOVAL


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start up the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

    4. Stop the engine.

    5. Using SST, let the refrigerant gas out.

      SST
      07110-58060   ( 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080 )

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. DRAIN ENGINE COOLANT

    CAUTION:

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


    1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the radiator drain cock.

    2. Loosen the radiator drain cock plug.

      A003DK2E03
      Text in Illustration
      *1 Bleeder Plug *2 Radiator Cap Sub-assembly
      *3 Radiator Reserve Tank Assembly *4 Cylinder Block Drain Cock Plug
      *5 Radiator Drain Cock Plug - -

    3. Remove the radiator cap sub-assembly.

    4. Loosen the cylinder block drain cock plug, and drain the engine coolant.

    5. Tighten the radiator drain cock plug.

    6. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    7. Disconnect the hose from the radiator drain cock.

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap sub-assembly.

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

    3. Clean and install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  6. DRAIN AUTOMATIC TRANSMISSION FLUID


    1. A003CX5

      Remove the drain plug and gasket from the automatic transmission assembly and drain the ATF.

    2. Install a new gasket and the drain plug to the automatic transmission assembly.

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

  7. REMOVE SEAT TRACK COVER LH


    1. A003B84

      Using a clip remover, remove the clip.

    2. Detach the claw and remove the seat track cover LH.

  8. REMOVE FRONT SEAT ASSEMBLY RH


    1. A003GD3

      Move the front seat assembly fully forward.

    2. Remove the 2 bolts on the rear side of the seat.

    3. Move the front seat assembly to the rearmost position.

    4. Remove the 2 bolts on the front side of the seat.

    5. Move the front seat assembly to the center of the seat slide rail. Set the seatback in the upright position.

    6. Disconnect the front seat inner belt assembly connector.

    7. Remove the front seat assembly.

  9. REMOVE FRONT DOOR SCUFF PLATE RH

  10. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Fold back the floor carpet.

    2. Remove the 5 bolts and engine service hole sub cover sub-assembly.

  11. REMOVE TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY


    1. Remove the 2 seat belt anchor covers.

    2. A003GMV

      Remove the 2 bolts and disconnect the front center seat belt assembly RH and front center seat lap type belt assembly.

    3. Detach the clips and fold back the carpet.

    4. A003ANJ

      Remove the 4 bolts and transmission service hole cover sub-assembly from the body.

  12. REMOVE GENERATOR ASSEMBLY

    Click here

  13. REMOVE STARTER ASSEMBLY

    Click here

  14. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  15. DISCONNECT ENGINE WIRE


    1. Remove the ECM Click here.

    2. A003FC0

      Detach the 4 claw and remove the wiring harness protector cover from the wiring harness protector.

    3. A003H73

      Detach the 2 clamp and disconnect engine wire from the wiring harness protector.

    4. A003E8G

      Disconnect the 2 connectors from the engine room main wire.

    5. A003IFH

      Disconnect the connector.

    6. A003D33

      Remove the bolt.

    7. Detach the clamp and disconnect the engine wire from the body.

  16. DISCONNECT AIR CLEANER HOSE ASSEMBLY


    1. A003DCU

      Lift up the retainer of air cleaner hose assembly as shown in the illustration.

    2. Disconnect the air cleaner hose assembly from the compressor inlet elbow.

  17. DISCONNECT NO. 1 AIR HOSE


    1. A003E8I

      Slide the clamp and disconnect the No. 1 air hose from the No. 1 air tube.

  18. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. A003C4P

      Slide the clamp and disconnect the water hose sub-assembly from the water by-pass pipe assembly.

    2. A003GAW

      Slide the clamp and disconnect the water hose sub-assembly from the water by-pass pipe.

  19. DISCONNECT NO. 4 RADIATOR HOSE


    1. A003HNE

      Slide the clip and disconnect the No. 4 radiator hose from the water outlet sub-assembly.

  20. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A003D4Y

      Remove the 2 nuts and disconnect the vane pump oil reservoir assembly from the body.

  21. DISCONNECT VANE PUMP ASSEMBLY


    1. A003AFP

      Remove the 2 bolt and disconnect the vane pump assembly from the generator bracket.

  22. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A003AE3

      Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the cooler compressor assembly.

    2. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  23. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. A003B5I

      Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the cooler compressor assembly.

    2. Remove the O-ring from the No. 1 cooler refrigerant suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  24. DISCONNECT NO. 4 AIR HOSE


    1. A003H1C

      Disconnect the connector from the intake air temperature sensor.

    2. A003HDJ

      Slide the clamp and disconnect the oil return hose from the No. 4 air hose.

    3. A003ERA

      Disconnect the No. 4 air hose from the No. 3 air tube.

  25. REMOVE INTERCOOLER AIR TUBE


    1. A003BSB

      Remove the 2 bolts and air tube support bracket from the intercooler air tube and gas filter bracket.

    2. A003HO4

      Remove the intercooler air tube from the diesel throttle body assembly.

  26. DISCONNECT VACUUM TUBE CONNECTOR HOSE


    1. A003BIY

      Slide the clamp and disconnect the vacuum tube connector hose from the No. 1 hose to hose tube.

  27. DISCONNECT NO. 1 FUEL HOSE


    1. A003APH

      Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.

  28. DISCONNECT NO. 2 FUEL HOSE


    1. A003IA1

      Slide the clamp and disconnect the No. 2 fuel hose from the No. 3 nozzle leakage pipe assembly.

  29. DISCONNECT NO. 1 RADIATOR HOSE


    1. A003BDU

      Slide the clip and disconnect the No. 1 radiator hose from the water inlet.

  30. REMOVE PROPELLER SHAFT ASSEMBLY


    1. A003AD9E01

      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. A003BT1E01

      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

  31. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT


    1. A003CZO

      Turn the crankshaft to gain access to the 6 drive plate and torque converter setting bolts and remove each bolt while holding the crankshaft pulley bolt with a wrench.

  32. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  33. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A003AQV

      Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.

    2. A003DQ3E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    3. A003BG7

      Remove the 8 bolts, rear drive plate spacer, pump impeller drive plate and flywheel sub-assembly from the crankshaft.

  34. REMOVE REAR END PLATE


    1. A003FZC

      Remove the bolt and rear end plate from the cylinder block sub-assembly.

  35. DISCONNECT FRONT SPEED SENSOR LH


    1. A003ICLE01

      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.

  36. DISCONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  37. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH


    1. A003HGAE01

      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.

  38. DISCONNECT FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  39. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER LH


    1. A003AE0E01

      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.

  40. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedure described for the LH side.

  41. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. A003E46E02

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

  42. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  43. DISCONNECT STEERING TORQUE SHAFT ASSEMBLY


    1. A003FSCE01

      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. A003D4SE01

      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.

  44. REMOVE NO. 2 ENGINE COVER


    1. A003GPX

      Remove the No. 2 engine cover from the No. 1 engine hanger.

  45. REMOVE EGR PIPE INSULATOR

  46. REMOVE ENGINE ASSEMBLY


    1. Set an engine lifter in place.

    2. A003E2LJ06

      Remove the 16 bolts shown in the illustration.

    3. Operate the engine lifter and slowly remove the engine from the vehicle.

  47. INSTALL ENGINE HANGERS


    1. A003HJ6E01
      Text in Illustration
      *1 Upper No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the upper No. 1 engine hanger and No. 2 engine hanger with the 3 bolts as shown in the illustration.

      Torque:
      for upper No. 1 engine hanger
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for No. 2 engine hanger
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

      Tech Tips

      Upper No. 1 Engine Hanger 12284-11010 or 12284-11020
      No. 2 Engine Hanger 12282-11080 or 12282-11090
      Bolt 91552-81025 and 91672-80835

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

  48. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Remove the 4 bolts and front suspension crossmember sub-assembly from the engine assembly.

  49. REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. A003F7T

      Remove the nut and front engine mounting insulator RH from the engine mounting stabilizer.

  50. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A003AY5

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

  51. INSTALL 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 assembly while it is suspended, as doing so is dangerous.


    1. Install the engine assembly to an engine stand with the bolts.

    2. Remove the engine sling device and chain block.

    3. Remove the 3 bolts, upper No. 1 engine hanger, and No. 2 engine hanger from the engine assembly.

  52. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.