ENGINE ASSEMBLY REMOVAL


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

    Click here

  3. SEPARATE BATTERY NEGATIVE CABLE

  4. REMOVE FRONT WHEELS

  5. REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

  6. REMOVE ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)

  7. REMOVE ENGINE SIDE UNDER COVER LH (w/ Engine Side Under Cover LH)

  8. REMOVE ENGINE SIDE UNDER COVER RH (w/ Engine Side Under Cover RH)

  9. DRAIN ENGINE COOLANT

    CAUTION:

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

    Tech Tips

    Collect the engine coolant in a container and dispose of it according to local regulations.


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

      A003AWAE01
      Text in Illustration
      *A w/ Dual VVT-i *B w/o Dual VVT-i
      *1 Radiator Reservoir Cap Sub-assembly *2 Radiator Reservoir Assembly
      *3 Radiator Drain Cock Plug *4 Cylinder Block Water Drain Cock Plug
      *5 2-Way - -

    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block water drain cock plug and drain the engine coolant from the engine.

  10. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug and drain the engine oil from the oil pan sub-assembly.

      Note

      Collect the oil in a disposable oil container.

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

      Torque:
      38 N*m  { 382 kgf*cm, 28 ft.*lbf }

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

    Tech Tips

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

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

    Tech Tips

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

  13. REMOVE FRONT DOOR SCUFF PLATE

  14. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the 5 bolts and engine service hole sub cover.

  15. REMOVE FAN & GENERATOR V BELT


    1. A003GP7E01

      Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the drive belt. Then remove the drive belt.

      Note

      When removing the drive belt, do not use the idle pulley's bolt.

      Tech Tips

      After removing the drive belt, move the tensioner upward to the maximum amount.

  16. DISCONNECT RADIATOR HOSE INLET


    1. Remove the clamp, and disconnect the radiator hose inlet from the engine.

  17. DISCONNECT RADIATOR HOSE OUTLET


    1. Remove the clamp, and disconnect the radiator hose outlet from the engine.

  18. DISCONNECT HEATER WATER HOSE INLET A


    1. Disconnect the heater water inlet hose A from the heater unit.

  19. DISCONNECT HEATER WATER HOSE OUTLET B


    1. Disconnect the heater water outlet hose B from the heater unit.

  20. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. A003F6O

      Disconnect the fuel vapor feed hose from the VSV.

  21. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. Disconnect the union to connector tube hose from the intake manifold.

  22. REMOVE AIR PRESSURE SENSOR (w/ Manifold Absolute Pressure Sensor)


    1. A003F7L

      Disconnect the connector.

    2. Disconnect the vacuum hose and clamp.

    3. Detach the wire harness clamp

    4. Remove the 2 bolts and air pressure sensor together with the bracket.

    5. A003BTJ

      Remove the bolt and air pressure sensor.

  23. REMOVE INTAKE AIR CONNECTOR


    1. A003DHQ

      Slide the clamp and disconnect the No. 2 ventilation hose from the cylinder head cover sub-assembly.

    2. Disconnect the vacuum hose from the intake air connector.

    3. Loosen the 2 hose clamps.

    4. Remove the 2 bolts and intake air connector.

  24. DISCONNECT AIR HOSE NO.5 (w/ Secondary Air Injection System)


    1. Disconnect the air hose No.5 from the air switching valve.

  25. DISCONNECT FUEL HOSE


    1. A003DS3

      Disconnect the No. 1 fuel hose from the fuel pressure pulsation damper assembly Click here.

  26. DISCONNECT FUEL HOSE NO.2


    1. Remove the clamp, and disconnect the fuel hose No.2 from the delivery pipe.

  27. DISCONNECT VANE PUMP ASSEMBLY


    1. A003HW8E01

      Disconnect the PS fluid pressure switch connector.

    2. Remove the 2 bolts and disconnect the pump from the engine.

    3. Support the vane pump securely.

  28. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

  29. REMOVE OIL LEVEL GAUGE GUIDE


    1. A003EFGE01

      Remove the bolt and gauge guide.

  30. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the compressor connector.

    2. A003DDVE02

      Remove the 4 bolts and disconnect the compressor from the engine.

      Tech Tips

      Disconnect the compressor with the low pressure hose and high pressure hose stuck by suspended from the rope.

    3. Support the cooler compressor securely.

  31. DISCONNECT ENGINE WIRE


    1. Disconnect the wire harness support of the ECM.

    2. Disconnect the connectors of the ECM.

    3. Disconnect the clamps of the engine wire and earth cable.

    4. Disconnect the +B terminal of the starter and connector from the generator.

    5. A003HGCE03

      Remove the nut and disconnect the cable from the engine room J/B.

  32. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for Super Long Wheelbase)


    1. w/ Secondary air injection system:


      1. Disconnect the fuel ratio sensor connector.

      2. Remove the fuel ratio sensor. Click here

    2. For unleaded gasoline engine:


      1. Disconnect the oxygen sensor connector.

      2. Remove the oxygen sensor. Click here

    3. Remove the 4 bolts, 2 nuts, and 2 compression springs.

    4. Remove the 2 gaskets from the exhaust pipe assembly front.

    5. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front.

  33. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for Long Wheelbase)


    1. w/ Secondary air infection system:


      1. Disconnect the fuel ratio sensor connector.

      2. Remove the fuel ratio sensor. Click here

    2. For unleaded gasoline engine:


      1. Disconnect the oxygen sensor connector.

      2. Remove the oxygen sensor. Click here

    3. Remove the 4 bolts, 2 nuts, and 2 compression springs.

    4. Remove the 2 gaskets from the exhaust pipe assembly front.

    5. Disconnect the exhaust pipe support, and remove the exhaust pipe assembly front.

  34. REMOVE EXHAUST PIPE ASSEMBLY CENTER (for Super Long Wheelbase)


    1. Remove the 2 bolts and gasket from the exhaust pipe assembly center.

    2. Disconnect the exhaust pipe supports, and remove the exhaust pipe assembly center.

  35. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for Super Long Wheelbase)


    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 with center bearing shaft assembly from the differential companion flange.

    3. A003C3U

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

    4. Remove the propeller with center bearing shaft assembly.

    5. 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

  36. REMOVE PROPELLER SHAFT ASSEMBLY (for Long Wheelbase)


    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

  37. REMOVE SPEED SENSOR FRONT LH (w/ ABS)


    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.

  38. REMOVE SPEED SENSOR FRONT RH (w/ ABS)

    Tech Tips

    Use the same procedures described for the LH side.

  39. REMOVE 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.

  40. REMOVE FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Use the same procedures described for the LH side.

  41. SEPARATE FRONT SUSPENSION 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.

  42. SEPARATE FRONT SUSPENSION SUB-ASSEMBLY UPPER RH

    Tech Tips

    Use the same procedures described for the LH side.

  43. SEPARATE SHOCK ABSORBER ASSEMBLY FRONT LH


    1. A003E46E02

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

  44. SEPARATE SHOCK ABSORBER ASSEMBLY FRONT RH

    Tech Tips

    Use the same procedures described for the LH side.

  45. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)


    1. A003H3DE01

      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. A003EGI

      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.

  46. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)


    1. A003DFI

      Remove the 2 bolts and separate the clutch release cylinder.

  47. REMOVE TRANSMISSION OIL LEVEL GAUGE SUB-ASSEMBLY (for Automatic Transmission)


    1. A003G8M

      Remove the transmission oil level gage sub assembly from the transmission oil filler tube.

  48. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A003EFYE01

      Remove the 2 bolts transmission oil filler tube sub-assembly.

    2. Remove the O-ring from the oil filler tube sub-assembly.

  49. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transmission)


    1. A003GA5E05

      Remove the nut and disconnect the transmission control cable assembly from the transmission control shaft lever assembly.

    2. Remove the clip and disconnect the transmission control cable assembly from the transmission control cable bracket.

  50. DISCONNECT OIL COOLER HOSE (for Automatic Transmission)


    1. Remove each clamp and disconnect the oil cooler inlet hose and oil cooler outlet hose from the oil cooler tube.

  51. SEPARATE 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.

  52. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


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

    2. A003E2LE04

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

    3. Remove the engine assembly w/ transmission out of the vehicle slowly and carefully.

  53. REMOVE STARTER ASSEMBLY (for 1.6 kW Type)


    1. A003F81E01

      Remove the 2 bolts, then remove the ground cable and bracket.

    2. A003BABE02

      Remove the nut and disconnect the wire harness from terminal 30.

    3. Disconnect the terminal 50 connector from the starter assembly.

    4. Remove the 2 bolts and the starter assembly.

  54. REMOVE STARTER ASSEMBLY (for 1.7 kW Type)


    1. A003G1W

      Remove the 2 bolts, then disconnect the ground cable and wiring harness clamp bracket.

    2. A003EOQ

      Open the terminal cap.

    3. Disconnect the starter connector.

    4. Remove the nut and disconnect the starter wire.

    5. A003AS9

      Remove the 2 bolts and starter assembly.

  55. REMOVE STARTER ASSEMBLY (for 2.0 kW Type)


    1. A003GTG

      Remove the 2 bolts, then disconnect the ground cable and wiring harness clamp bracket.

    2. A003FUE

      Open the terminal cap.

    3. Remove the nut, and then disconnect the starter wire harness.

    4. Disconnect the starter connector.

    5. A003B8D

      Remove the 2 bolts and starter assembly.

  56. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Click here

  57. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  58. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A003FS3E01

      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.

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

      Note

      Do not drop the clutch disc assembly.

  59. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    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.

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


    1. A003CAFE01

      Fix the crankshaft with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A003CI3E02

      Remove the 10 bolts and flywheel.

  61. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. A003CAFE01

      Fix the crankshaft with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A003BYKE01

      Remove the 10 bolts, spacer RR, drive plate and spacer FR.

  62. REMOVE REAR END PLATE


    1. Remove the 2 bolts and rear end plate.

  63. INSTALL ENGINE HANGERS


    1. A003HZUE02

      Install the engine hangers with the bolts.

      Torque:
      42 N*m  { 428 kgf*cm, 30 ft.*lbf }

      Tech Tips

      Engine Hangers 12281-75040
      Bolt 91552-A1020

      Note

      Use new bolts for the engine hangers.

  64. REMOVE FRONT SUSPENSION CROSS MEMBER SUB-ASSEMBLY


    1. Hold the engine with the engine sling device and chain block.

    2. Remove the 4 bolts from the engine mounting insulator.

    3. Remove the engine assembly by operating the engine sling device and chain block.

  65. INSTALL ENGINE STAND

  66. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  67. REMOVE VENTILATION PIPE


    1. Remove the bolt and ventilation pipe.

  68. REMOVE THROTTLE BODY ASSEMBLY


    1. A003ELPE01
      Text in Illustration
      *A w/ Dual VVT-i
      *B w/o Dual VVT-i

      Disconnect the throttle motor connector.

    2. Slide the clamp and disconnect the water by-pass hose from the throttle body assembly.

    3. Slide the clamp and disconnect the No. 2 water by-pass hose from the throttle body assembly.

    4. Remove the 4 bolts and throttle body assembly.

    5. A003DR5

      Remove the gasket from the intake manifold.

  69. REMOVE INTAKE MANIFOLD


    1. Disconnect the ventilation hose No.3.

    2. A003DMOE01

      Remove the 5 bolts, 2 nuts, intake manifold and gasket.

  70. REMOVE IGNITION COIL ASSEMBLY


    1. Remove the bolts and ignition coil assembly.

  71. REMOVE SPARK PLUG

  72. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

    Note

    Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.


    1. Disconnect the vacuum hose from the fuel pressure regulator assembly.

    2. Slide the clamp and disconnect the No. 2 fuel hose from the fuel pressure regulator assembly.

    3. A003H4CE01
      Text in Illustration
      *A w/ Dual VVT-i
      *B w/o Dual VVT-i

      Disconnect the 4 fuel injector connectors.

    4. Remove the 2 bolts, fuel pulsation damper assembly and O-ring.

    5. Remove the 2 bolts and fuel delivery pipe sub-assembly together with the 4 fuel injector assemblies.

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

    6. Remove the 2 No. 1 delivery pipe spacers from the cylinder head sub-assembly.

    7. Remove the 4 injector vibration insulators.

    8. A003AY2E01
      Text in Illustration
      *A w/ Dual VVT-i
      *B w/o Dual VVT-i
      *a Protective Tape

      Using a screwdriver, pry out the 4 injector spacers and 4 O-rings from the cylinder head sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  73. REMOVE INJECTOR ASSEMBLY


    1. A003D73E01
      Text in Illustration
      *A w/ Dual VVT-i
      *B w/o Dual VVT-i
      A003DCD Pull Out

      Pull out the 4 fuel injector assemblies from the fuel delivery pipe sub-assembly.

    2. Remove the O-rings from the fuel injector assemblies.

  74. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A003H51

      Remove the 4 bolts and the heat insulator No.1.

  75. REMOVE INTAKE PIPE NO.4 (w/ Secondary Air Injection System)


    1. A003D55E02

      Remove the 4 nuts and intake pipe No.4.

    2. Remove the 2 gaskets.

  76. REMOVE AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection Ststem)


    1. A003BX0E01

      w/ Manifold Absolute Pressure Sensor:

      Disconnect the vacuum hose from the air switching valve assembly.

    2. A003B3VE02

      Disconnect the connector.

    3. Remove the 2 nuts and the switching valve.

  77. REMOVE EXHAUST MANIFOLD


    1. A003HEGE02

      w/o Secondary air injection system:


      1. Remove the 6 nuts, exhaust manifold and gasket.

    2. w/ Secondary air injection system:


      1. Remove the 8 nuts, exhaust manifold and gasket.

  78. REMOVE FAN PULLEY


    1. Remove the 4 nuts, fan pulley and fan spacer.

  79. REMOVE WATER BY-PASS PIPE NO.1


    1. Remove the bolt, 2 nuts, water by-pass pipe and gasket.

  80. REMOVE WATER INLET


    1. A003DQU

      Remove the 2 nuts, bolt, water inlet and gasket.

  81. REMOVE THERMOSTAT


    1. A003FA7J01

      Remove the thermostat.

  82. REMOVE GENERATOR ASSEMBLY


    1. A003H3N

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the 3 bolts and generator assembly.

  83. REMOVE IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A003CEV

      Loosen the bolt, and then remove the idle pulley assembly.

      Tech Tips

      The bolt in the illustration cannot be removed from the idle pulley assembly.

  84. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (w/ Air Conditioning System)


    1. A003EEI

      Remove the 5 bolts and compressor mounting bracket No.1.

  85. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1


    1. A003CXV

      Remove the bolt, pulley plate, collar, and idler pulley sub-assembly No.1.

  86. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A003HZ2

      Remove the 2 bolts and belt tensioner.

  87. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A003EP5

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

  88. REMOVE KNOCK CONTROL SENSOR


    1. A003GBRE01

      Disconnect the knock control sensor connector.

    2. Remove the bolt and the knock control sensor.

  89. REMOVE WATER TEMPERATURE SENSOR


    1. A003I9K

      Using a 19 mm deep socket wrench, remove the water temperature sensor.

  90. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH


    1. A003H9S

      Remove the 4 bolts and mounting bracket.

  91. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH


    1. A003DAL

      Remove the 4 bolts and mounting bracket.

  92. REMOVE ENGINE OIL LEVEL SENSOR


    1. Remove the 4 bolts and engine oil level sensor.