ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. PRECAUTION

    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.

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  5. REMOVE HOOD SUB-ASSEMBLY


    1. B001ZVW

      Remove the 2 hood support bolts and disconnect the hood supports.

    2. Remove the 4 bolts and hood.

  6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

    Click here

  8. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

    Click here

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

    Click here

  10. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 2 bolts and No. 2 engine under cover.

  11. REMOVE UPPER RADIATOR SUPPORT SEAL

    Click here

  12. REMOVE RADIATOR GRILLE

    Click here

  13. REMOVE FRONT BUMPER COVER


  14. DRAIN ENGINE COOLANT

    Click here

  15. REMOVE V-BANK COVER

    Click here

  16. REMOVE TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)

    Click here

  17. REMOVE RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)

    Click here

  18. REMOVE RADIATOR SIDE DEFLECTOR LH

    Click here

  19. REMOVE NO. 1 RADIATOR HOSE

  20. REMOVE NO. 2 RADIATOR HOSE

    Click here

  21. DISCONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)

    Click here

  22. REMOVE FAN SHROUD

    Click here

  23. DISCONNECT INLET OIL COOLER HOSE (for Automatic Transmission)

    Click here

  24. DISCONNECT OUTLET OIL COOLER HOSE (for Automatic Transmission)

    Click here

  25. REMOVE RADIATOR ASSEMBLY

    Click here

  26. DRAIN ENGINE OIL

    Click here

  27. REMOVE AIR CLEANER CAP AND HOSE


    1. B001VPF

      Remove the air cleaner cap and hose.


      1. Disconnect the mass air flow meter connector, vacuum hose and ventilation hose and detach the clamp.

      2. Loosen the clamp.

      3. Unfasten the 4 hook clamps, and then remove the bolt and the air cleaner cap and hose.

  28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. Remove the air cleaner filter element.

    2. B001WFX

      Remove the 3 bolts and air cleaner case.

  29. REMOVE AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)

    Click here

  30. REMOVE INTAKE AIR SURGE TANK

    Click here

  31. DISCONNECT ENGINE WIRE


    1. Remove the junction block cover.

    2. B001ZNI

      Disconnect the ECM connector Click here.

    3. Detach the wire harness clamp.

    4. Disconnect the 4 connectors from the junction block.

    5. Remove the engine room relay block cover.

    6. B001VVN

      Remove the bolt and disconnect the ground wire from the bracket.

    7. w/ Secondary Air Injection System:

      Disconnect the 2 air injection control driver connectors and detach the clamp.

    8. Disconnect the 2 connectors and 2 clips from the engine room junction block.

    9. Remove the nut and disconnect the wire and 2 clips from the engine room junction block.

    10. Remove the nut and disconnect the wire from the positive (+) battery cable.

    11. Disconnect the cable from the positive (+) battery terminal.

    12. Remove the bolt and detach the wire harness clamp, and then disconnect the ground wire from the body.

    13. B001ZNE

      Disconnect the connector and detach the 2 clamps.

    14. B001YYJ

      w/ Winch:

      Remove the 2 bolts and winch ground wire.

    15. B001ZG3

      Disconnect the power steering switch connector and detach the clamp.

    16. B001Y3F

      w/ Secondary Air Injection System:

      Disconnect the air pump connector and detach the clamp.

  32. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  33. REMOVE TAILPIPE ASSEMBLY

    Click here

  34. REMOVE CENTER EXHAUST PIPE ASSEMBLY

    Click here

  35. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  36. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

    Click here

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  38. REMOVE FRONT FENDER APRON TRIM PACKING A

    Click here

  39. REMOVE FRONT FENDER APRON TRIM PACKING B

    Click here

  40. REMOVE FRONT FENDER APRON TRIM PACKING C

    Click here

  41. REMOVE FRONT FENDER APRON TRIM PACKING D

    Click here

  42. REMOVE MANIFOLD STAY

    Click here

  43. REMOVE AIR TUBE (w/ Secondary Air Injection System)

    Click here

  44. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT

    Click here

  45. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  46. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  47. REMOVE NO. 2 MANIFOLD STAY

    Click here

  48. REMOVE NO. 2 AIR TUBE (w/ Secondary Air Injection System)

    Click here

  49. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  50. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  51. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. B001XF5E02
      Text in Illustration
      *A w/o Rear Heater
      *B w/ Rear Heater

      Disconnect the water hoses.

  52. DISCONNECT VANE PUMP ASSEMBLY

    Click here

  53. REMOVE GENERATOR ASSEMBLY

    Click here

  54. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  55. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  56. REMOVE COOLER COMPRESSOR ASSEMBLY

    Click here

  57. DISCONNECT NO. 1 AND NO. 2 FUEL PIPES


    1. B001Y8D

      Disconnect the No. 1 and No. 2 fuel pipes Click here.

  58. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    Click here

  59. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  60. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator is necessary.


    1. B001Z54

      Remove the 4 bolts and rear engine mounting insulator from the transmission.

  61. DISCONNECT NO. 1 OIL COOLER HOSE TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. B001YOL

      Remove the 2 bolts and cooler hose tube.

  62. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  63. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

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


    1. B001YOVE05

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01XAEU

      Remove the 8 bolts and flywheel.

      Note

      Do not reuse the bolts.

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


    1. B001YOVE05

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. B001ZPQ

      Remove the 8 bolts, rear spacer, drive plate and front spacer.

      Note

      Do not reuse the bolts.

  66. INSTALL ENGINE HANGER


    1. B001X5GE04
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-31110
      No. 2 Engine Hanger 12282-31140
      Bolt 91671-C0830

  67. REMOVE ENGINE ASSEMBLY


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

    2. B001WER

      Remove the 2 nuts and 4 bolts from the front engine mounting insulator LH and RH.

    3. Lift the engine out of the vehicle carefully.

      Note


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

      • 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.

      • 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.

    4. Remove the front engine mounting insulator LH and RH.

    5. Place the engine onto a work bench.

  68. INSTALL ENGINE STAND


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

    2. Remove the 4 bolts and 2 engine hangers.

  69. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. Remove the bolt and front No. 2 engine mounting bracket LH.