ENGINE(for AWD) REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. REMOVE COWL TOP VENTILATOR LOUVER RH

    Click here

  5. PRECAUTION

    Note

    After turning the engine 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.

  6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    Note

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

  7. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  8. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY

    Click here

  9. REMOVE NO. 1 AIR CLEANER INLET

    Click here

  10. REMOVE ENGINE ROOM SIDE COVER RH

    Click here

  11. REMOVE ENGINE ROOM SIDE COVER LH

    Click here

  12. REMOVE FRONT CENTER FLOOR COVER


    1. A001EGD

      Remove the 3 screws, 2 bolts, clip and front center floor cover.

  13. REMOVE NO. 2 ENGINE UNDER COVER


    1. A0018VJ

      Remove the 4 screws, 2 clips and No. 2 engine under cover.

  14. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

    Click here

  15. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

    Click here

  16. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  17. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER


    1. A0019ZJ

      Remove the 9 bolts and front suspension member protector lower.

  18. DRAIN ENGINE OIL

    Click here

  19. DRAIN ENGINE COOLANT

    Click here

  20. DRAIN FRONT DIFFERENTIAL OIL

    Click here

  21. DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  22. DISCONNECT NO. 1 OIL COOLER INLET HOSE

    Click here

  23. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE

    Click here

  24. REMOVE FRONT BUMPER COVER

    Click here

  25. REMOVE FRONT SUSPENSION LOWER CROSSMEMBER

    Click here

  26. REMOVE REAR FRAME SIDE RAIL


    1. A001EPD

      Remove the 6 bolts, 4 nuts and 2 rear frame side rails.

  27. REMOVE INTAKE AIR CONNECTOR PIPE

    Click here

  28. REMOVE AIR CLEANER ASSEMBLY LH

    Click here

  29. REMOVE AIR CLEANER ASSEMBLY RH

    Click here

  30. REMOVE RADIATOR RESERVOIR ASSEMBLY

    Click here

  31. REMOVE ENGINE ROOM ECU OUTLET DUCT


    1. A001952

      Remove the engine room ECU outlet duct from the fan shroud and ECU box.

  32. DISCONNECT NO. 1 RADIATOR HOSE

  33. DISCONNECT NO. 2 RADIATOR HOSE

  34. REMOVE RESONATOR BRACKET SUB-ASSEMBLY

    Click here

  35. REMOVE V-RIBBED BELT

    Click here

  36. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  37. REMOVE OIL TEMPERATURE SENSOR

    Click here

  38. DISCONNECT NO. 3 FUEL HOSE

    Click here

  39. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  40. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  41. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  42. DISCONNECT HOSES AND CONNECTORS


    1. A001B2G

      Remove the 3 bolts and engine room ECU cover.

    2. A001AMOE01

      Disconnect the 4 TCM connectors and 2 wiring harness support connectors.

    3. Detach the 2 wiring harness support clamps, and then detach the clamp of connector A from the ECU box.

      Tech Tips

      It is not necessary to disconnect the connection at A in the illustration.

    4. A001A8K

      Lift up the wiring harness support and disconnect the 4 ECM connectors.

    5. A001DCU

      Detach the 2 clamps. Then remove the 2 nuts and disconnect the wires with No. 1 engine room junction block.

    6. A001A27

      Detach the clamp and disconnect the 3 connectors with front controller.

    7. A001BRIE03
      *1 Lock

      Release the locks of the power steering ECU connector A and disconnect the connectors B.

    8. Detach the 2 clamps.

    9. A001FBT

      Remove the bolt and disconnect the ground wire.

    10. A001B3W

      Disconnect the 2 connectors and detach the 5 clamps.

    11. A0018XL

      Disconnect the 2 heater hoses.

    12. A001AZW

      Disconnect the purge line hose.

  43. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Click here.

  44. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY


    1. A001FXU

      Detach the 2 claws, and remove the bolt and No. 1 air duct sub-assembly.

      Note

      Be careful not to damage the air duct as its connection to the vehicle is very tight.

  45. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  46. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  47. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  48. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  49. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  50. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH


    1. A001CJE

      Remove the bolt. Then disconnect the front lower shock absorber bracket sub-assembly RH.

  51. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH


    1. A001EJC

      Remove the bolt. Then disconnect the front lower shock absorber bracket sub-assembly LH.

  52. REMOVE ENGINE AND TRANSMISSION


    1. A001ASV

      Place a mark (with spray, etc.) over the rear right vehicle side attachment area of the front frame, which is indicated in the illustration.

    2. Place a mark (with spray, etc.) over the rear left vehicle side attachment area of the front frame.

    3. Set an engine lifter underneath the engine.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • 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 while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    4. A001B5J

      Remove the 4 rear engine mounting member's bolts.

    5. A001ADQ

      Remove the 4 bolts shown in the illustration.

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

      Note


      • Make sure that the engine is clear of all wiring and hose.

      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.

  53. INSTALL NO. 1 ENGINE HANGER


    1. A001B9C

      Install the 2 No. 1 engine hangers with the 2 bolts as shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 engine hanger 12281-38150
      Bolt 90119-14120
    2. A0019H5E01
      *1 50° or less
      *2 Engine Hanger
      *3 ENGINE

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

      Note

      When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or No. 1 engine hangers may be damaged.

  54. REMOVE FRONT FRAME ASSEMBLY


    1. A0018YBE01
      *1 for RH:
      *2 for LH:

      Remove the 4 nuts and front frame assembly.

  55. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A001FVME02
      *1 O-Ring
      *2 Pull

      Remove the engine oil level dipstick.

    2. Remove the 2 bolts and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  56. REMOVE GENERATOR ASSEMBLY

    Click here

  57. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  58. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  59. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A001EP7E02
      *1 for RH:
      *2 for LH:

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

  60. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A001AHI

      Remove the 5 bolts and front No. 1 engine mounting bracket RH.

  61. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A001E9J

      Remove the 5 bolts and front No. 1 engine mounting bracket LH.

  62. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  63. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  64. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET RH


    1. A001BFM

      Remove the 2 nuts and front No. 2 engine mounting bracket RH.

  65. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. A0019BO

      Remove the 2 nuts and front No. 2 engine mounting bracket LH.

  66. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  67. REMOVE STARTER ASSEMBLY

    Click here

  68. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  69. REMOVE NO. 1 OIL COOLER TUBE

    Click here

  70. REMOVE NO. 3 COVER SUB-ASSEMBLY

    Click here

  71. DISCONNECT WIRE HARNESS AND CONNECTOR

    Click here

  72. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

  73. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  74. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A001FZKE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
    2. A001ARC

      Remove the 10 bolts, rear spacer plate, drive plate and ring gear sub-assembly and crankshaft position sensor rotor.

  75. INSTALL ENGINE ON ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 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 while it is suspended, as doing so is dangerous.

    2. Remove the 2 bolts and 2 No. 1 engine hangers.

  76. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. A001C90

      Remove the 2 bolts, 2 nuts, 2 stud bolts and cooler compressor assembly.

  77. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY

    Click here

  78. REMOVE NO. 5 ENGINE COVER SUB-ASSEMBLY

    Click here

  79. REMOVE NO. 6 ENGINE COVER SUB-ASSEMBLY

    Click here

  80. REMOVE ENGINE WIRE


    1. for Engine LH Side:


      1. A0019R5

        Disconnect the camshaft timing control valve connector.

      2. Disconnect the 4 ignition coil connectors.

      3. Disconnect the 2 VVT sensor connectors.

      4. Disconnect the fuel pump connector (for high pressure).

      5. Disconnect the No. 8 engine wire connector.

      6. Disconnect the 4 wire harness clamps.

    2. for Engine Front Side:


      1. A001CMR

        Disconnect the engine coolant temperature sensor connector.

      2. Disconnect the 2 camshaft timing control motor connectors (for Bank 1).

      3. Disconnect the 2 camshaft timing control motor connectors (for Bank 2).

      4. Remove the 3 bolts and disconnect the clamp and ground wire.

      5. Remove the bolt and clamp bracket.

    3. for Engine RH Side:


      1. A001DVR

        Disconnect the camshaft timing control valve connector.

      2. Disconnect the 4 ignition coil connectors.

      3. Disconnect the 2 VVT sensor connectors.

      4. Disconnect the fuel pump connector (for high pressure).

      5. Disconnect the camshaft position sensor connector.

      6. Detach the 4 wire harness clamps.

      7. Disconnect the crankshaft position sensor connector.

      8. Remove the 2 bolts and disconnect the engine oil level sensor connector.

    4. for Engine Rear Side:


      1. A0019QE

        Disconnect the engine wire connector.

      2. Disconnect the fuel relief valve connector.

      3. Detach the 8 wire harness clamps.

      4. Remove the 2 bolts and disconnect the ground wire.

    5. Disconnect the throttle body connector.

    6. A001BYKE01
      *1 Move
      *2 Lock Lever
      *3 Release

      Disconnect the 8 injector driver connectors and detach the 2 clips as shown in the illustration.

    7. A001DER

      Disconnect the purge VSV connector.

    8. Disconnect the intake air control valve actuator connector.

    9. Remove the 2 bolts and disconnect the 2 clamp brackets and 2 clamps.

    10. Remove the 4 nuts and engine wire.

  81. REMOVE INJECTOR DRIVER

    Click here

  82. REMOVE NO. 1 ENGINE COVER


    1. A001DQD

      Remove the No. 1 engine cover.

  83. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  84. REMOVE PURGE VSV

    Click here

  85. REMOVE VENTILATION HOSE

  86. REMOVE THROTTLE BODY ASSEMBLY

    Click here

  87. REMOVE INTAKE MANIFOLD

    Click here

  88. REMOVE FUEL TUBE SUB-ASSEMBLY

    Click here

  89. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

    Click here

  90. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  91. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  92. REMOVE ENGINE COVER SUB-ASSEMBLY (for Bank 1)

    Click here

  93. REMOVE ENGINE COVER SUB-ASSEMBLY (for Bank 2)

    Click here

  94. REMOVE FUEL PUMP ASSEMBLY (for Bank 1)

    Click here

  95. REMOVE FUEL PUMP ASSEMBLY (for Bank 2)

    Click here

  96. REMOVE FUEL DELIVERY PIPE (for Port Injection)

    Click here

  97. REMOVE FUEL INJECTOR ASSEMBLY (for Port Injection)

    Click here

  98. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  99. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY

    Click here

  100. REMOVE NO. 2 ENGINE COVER SUB-ASSEMBLY LH

    Click here

  101. REMOVE NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  102. REMOVE FUEL DELIVERY PIPE (for Direct Injection)

    Click here

  103. REMOVE NO. 2 FUEL DELIVERY PIPE (for Direct Injection)

    Click here

  104. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)

    Click here

  105. REMOVE FUEL INJECTOR SEAL (for Direct Injection)

    Click here

  106. REMOVE SEPARATOR CASE

    Click here

  107. REMOVE ENGINE WIRE


    1. A001FQI

      Detach the 5 clamps and remove the 2 bolts and engine wire.

    2. Disconnect the 4 knock sensor connectors.

  108. REMOVE NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. A001FHM

      Remove the No. 4 engine cover sub-assembly.

  109. REMOVE KNOCK SENSOR

    Click here

  110. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A0019UK

      Remove the bolt and No. 2 idler pulley sub-assembly.

  111. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A001C1Z

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

  112. REMOVE WATER PUMP PULLEY

    Click here

  113. REMOVE WATER INLET HOUSING


    1. A001ENP

      Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the water by-pass hose and water inlet hose.

    2. A001BXB

      Remove the 3 bolts, water inlet housing and gasket.

  114. REMOVE ENGINE OIL LEVEL SENSOR

    Click here

  115. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  116. REMOVE IGNITION COIL ASSEMBLY

    Click here