ENGINE ASSEMBLY REMOVAL

PROCEDURE

1. Click here

   DISCHARGE FUEL SYSTEM PRESSURE

   Click here

2. Click here

   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).

3. Click here

   DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note:

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

4. Click here

   REMOVE FRONT BUMPER COVER

   
   

   • for Standard (Click here)

   • w/ Winch (Click here)

5. Click here

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

   Click here

6. Click here

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

   Click here

7. Click here

   REMOVE RADIATOR SIDE DEFLECTOR LH

   Click here

8. Click here

   REMOVE HOOD SUB-ASSEMBLY

   
   
   1. 

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

      CAUTION:

      Remove the hood support assembly while supporting the hood by hand.

   2. Remove the 4 bolts and hood.

9. Click here

   REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

   (Click here)

10. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING B

    Click here

11. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING D

    Click here

12. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING A

    Click here

13. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING C

    Click here

14. Click here

    REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

    
    
    1. 

       Remove the 10 bolts and No. 1 engine under cover sub-assembly.

15. Click here

    REMOVE NO. 2 ENGINE UNDER COVER

    
    
    1. 

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

16. Click here

    REMOVE OIL PAN PROTECTOR ASSEMBLY

    
    
    1. 

       Remove the 4 bolts and oil pan protector assembly.

17. Click here

    REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

18. Click here

    DRAIN ENGINE OIL

    Click here

19. Click here

    DRAIN ENGINE COOLANT

    Click here

20. Click here

    DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

21. Click here

    REMOVE BATTERY

    
    

    1. Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp from the battery bracket, and then remove the battery clamp.

    3. Remove the battery.

22. Click here

    REMOVE AIR CLEANER AND HOSE

    Click here

23. Click here

    REMOVE NO. 1 RADIATOR HOSE

    Click here

24. Click here

    REMOVE FAN SHROUD

    Click here

25. Click here

    REMOVE NO. 2 RADIATOR HOSE

    Click here

26. Click here

    REMOVE RADIATOR ASSEMBLY

    Click here

27. Click here

    DISCONNECT NO. 3 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

    
    
    1. 

       Disconnect the No. 3 air injection system hose from the air tube sub-assembly.

28. Click here

    REMOVE NO. 5 WATER BY-PASS PIPE

    Click here

29. Click here

    REMOVE EGR VALVE BRACKET

    Click here

30. Click here

    REMOVE PCV HOSE ASSEMBLY

    Click here

31. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY (w/ Secondary Air Injection System)

    Click here

32. Click here

    REMOVE INTAKE MANIFOLD

    Click here

33. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

34. Click here

    DISCONNECT SUCTION HOSE

    Click here

35. Click here

    DISCONNECT PRESSURE FEED TUBE

    Click here

36. Click here

    REMOVE VANE PUMP ASSEMBLY

    Click here

37. Click here

    REMOVE GENERATOR ASSEMBLY

    
    

    • for 130A, 150A Type:

      (Click here)

    • for 180A Type:

      (Click here)

38. Click here

    DISCONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

39. Click here

    REMOVE PROPELLER SHAFT HEAT INSULATOR

    Click here

40. Click here

    DISCONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

41. Click here

    DISCONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

    Click here

42. Click here

    REMOVE TAILPIPE ASSEMBLY

    Click here

43. Click here

    REMOVE CENTER EXHAUST PIPE ASSEMBLY

    Click here

44. Click here

    REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

45. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

46. Click here

    REMOVE NO. 2 MANIFOLD STAY

    Click here

47. Click here

    REMOVE MANIFOLD STAY

    Click here

48. Click here

    REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

49. Click here

    REMOVE EXHAUST MANIFOLD ASSEMBLY LH

    Click here

50. Click here

    REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

51. Click here

    REMOVE EXHAUST MANIFOLD ASSEMBLY RH

    Click here

52. Click here

    REMOVE STARTER COVER

    Click here

53. Click here

    REMOVE STARTER ASSEMBLY

    Click here

54. Click here

    DISCONNECT FUEL HOSE AND FUEL TUBE SUB-ASSEMBLY

    
    
    1. 

       Remove the fuel pipe clamp from the fuel tube connector.

    2. Disconnect the fuel hose and fuel tube sub-assembly (Click here).

55. Click here

    DISCONNECT ENGINE WIRE

    
    
    1. 

       Disconnect the clamp and ECM connector.

       Tip:

       Refer to the following procedures to disconnect the ECM connector (Click here).

    2. 

       Disconnect the 4 connectors and 2 clamps from the connector holder block.

    3. 

       Remove the bolt and disconnect the ground wire.

    4. 

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

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

    6. w/ Secondary Air Injection System:

       Disconnect the 2 air injection control driver connectors.

    7. Remove the bolt, disconnect the clamp and ground wire.

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

    9. 

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

    10. 

        w/ Secondary Air Injection System:

        Disconnect the connector and clamp.

56. Click here

    DISCONNECT TRANSMISSION OIL COOLER HOSE

    Click here

57. Click here

    REMOVE OIL COOLER TUBE

    Click here

58. Click here

    REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    (Click here)

59. Click here

    REMOVE PROPELLER SHAFT ASSEMBLY

    (Click here)

60. Click here

    REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

61. Click here

    REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    (Click here)

62. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE (w/ ATF Warmer)

    
    
    1. 

       w/ Rear Heater:

       Disconnect the 6 water hoses.

    2. 

       Remove the 2 bolts and No. 1 water by-pass pipe.

    3. 

       w/o Rear Heater:

       Disconnect the 4 water hoses.

    4. 

       Remove the 2 bolts and No. 1 water by-pass pipe.

63. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE (w/o ATF Warmer)

    
    
    1. 

       Disconnect the hose.

    2. Remove the 2 bolts and No. 1 water by-pass pipe.

64. Click here

    REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Click here

65. Click here

    REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    
    
    1. 

       Using SST, hold the crankshaft.

       09213-70011	09213-70020
       09330-00021

    2. 

       Remove the 10 bolts, the rear drive plate spacer, the drive plate and ring gear, and the crankshaft angle sensor rotor.

66. Click here

    INSTALL ENGINE HANGER

    
    
    1. 

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

       43 N*m

       438 kgf*cm

       32 ft.*lbf

       Tip:

       Engine Hanger	12281-38150
       Bolt	90119-14120

67. Click here

    REMOVE ENGINE ASSEMBLY

    
    
    1. 

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

       Table 1. Text in Illustration

       *1	Engine Hanger
       *2	Engine
       *a	50° or less

       Note:

       When hanging the engine, make sure to hang the engine with the angle of the sling device at 50° or less. Otherwise, the engine or engine hangers may be damaged.

    2. 

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

       Table 2. Text in Illustration

       *A	for LH Side
       *B	for RH Side

    3. Lift the engine out of the vehicle carefully.

       Note:
       

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

       • 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 workbench.

68. Click here

    INSTALL ENGINE STAND

    
    

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

    2. Remove the 2 bolts and 2 engine hangers.

69. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR LH

    
    
    1. 

       Remove the nut and mounting insulator.

70. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR RH

    
    
    1. 

       Remove the nut and mounting insulator.

71. Click here

    REMOVE NO. 2 FRONT ENGINE MOUNTING BRACKET LH

    
    
    1. 

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