ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  2. 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. 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. REMOVE FRONT BUMPER COVER


  5. REMOVE FRONT BUMPER UPPER CENTER RETAINER (w/ Air Cooled Transmission Oil Cooler)


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

    Click here

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

    Click here

  8. REMOVE RADIATOR SIDE DEFLECTOR LH

    Click here

  9. REMOVE HOOD SUB-ASSEMBLY


    1. B001YEX

      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.

  10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  11. REMOVE FRONT FENDER APRON TRIM PACKING B

    Click here

  12. REMOVE FRONT FENDER APRON TRIM PACKING D

    Click here

  13. REMOVE FRONT FENDER APRON TRIM PACKING A

    Click here

  14. REMOVE FRONT FENDER APRON TRIM PACKING C

    Click here

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


    1. B001Z4U

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

  16. REMOVE NO. 2 ENGINE UNDER COVER


    1. B001ZL5

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

  17. REMOVE OIL PAN PROTECTOR ASSEMBLY


    1. B001VP9

      Remove the 4 bolts and oil pan protector assembly.

  18. REMOVE V-BANK COVER SUB-ASSEMBLY

    Click here

  19. DRAIN ENGINE OIL

    Click here

  20. DRAIN ENGINE COOLANT

    Click here

  21. DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  22. 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.

  23. REMOVE AIR CLEANER AND HOSE

    Click here

  24. REMOVE NO. 1 RADIATOR HOSE

    Click here

  25. REMOVE FAN SHROUD

    Click here

  26. REMOVE NO. 2 RADIATOR HOSE

    Click here

  27. REMOVE RADIATOR ASSEMBLY

    Click here

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


    1. B001ZJS

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

  29. REMOVE NO. 5 WATER BY-PASS PIPE

    Click here

  30. REMOVE EGR VALVE BRACKET

    Click here

  31. REMOVE PCV HOSE ASSEMBLY

    Click here

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

    Click here

  33. REMOVE INTAKE MANIFOLD

    Click here

  34. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  35. DISCONNECT SUCTION HOSE

    Click here

  36. DISCONNECT PRESSURE FEED TUBE

    Click here

  37. REMOVE VANE PUMP ASSEMBLY

    Click here

  38. REMOVE GENERATOR ASSEMBLY


  39. DISCONNECT COOLER COMPRESSOR ASSEMBLY

    Click here

  40. REMOVE PROPELLER SHAFT HEAT INSULATOR

    Click here

  41. DISCONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  42. DISCONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

    Click here

  43. REMOVE TAILPIPE ASSEMBLY

    Click here

  44. REMOVE CENTER EXHAUST PIPE ASSEMBLY

    Click here

  45. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY

    Click here

  46. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  47. REMOVE NO. 2 MANIFOLD STAY

    Click here

  48. REMOVE MANIFOLD STAY

    Click here

  49. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  50. REMOVE EXHAUST MANIFOLD ASSEMBLY LH

    Click here

  51. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  52. REMOVE EXHAUST MANIFOLD ASSEMBLY RH

    Click here

  53. REMOVE STARTER COVER

    Click here

  54. REMOVE STARTER ASSEMBLY

    Click here

  55. DISCONNECT FUEL HOSE AND FUEL TUBE SUB-ASSEMBLY


    1. B001Z5K

      Remove the fuel pipe clamp from the fuel tube connector.

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

  56. DISCONNECT ENGINE WIRE


    1. B001WLX

      Disconnect the clamp and ECM connector.

      Tech Tips

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

    2. B001YG5

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

    3. B001WBD

      Remove the bolt and disconnect the ground wire.

    4. B001WI8

      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. B001ZJ4

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

    10. B001XJ6

      w/ Secondary Air Injection System:

      Disconnect the connector and clamp.

    11. B001WXU

      w/ Winch:

      Detach the wire harness clamp, remove the nut and disconnect the ground wire from the wire harness clamp bracket.

  57. DISCONNECT TRANSMISSION OIL COOLER HOSE

    Click here

  58. REMOVE OIL COOLER TUBE

    Click here

  59. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  60. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  61. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

  62. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

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


    1. B001ZJM

      w/ Rear Heater:

      Disconnect the 6 water hoses.

    2. B001WCO

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

    3. B001ZK0

      w/o Rear Heater:

      Disconnect the 4 water hoses.

    4. B001ZO6

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

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


    1. B001ZZI

      Disconnect the hose.

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

  65. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Click here

  66. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. B001W55E01

      Using SST, hold the crankshaft.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. B001ZY8

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

  67. INSTALL ENGINE HANGER


    1. B001Y0I

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

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

      Tech Tips

      Engine Hanger 12281-38150
      Bolt 90119-14120

  68. REMOVE ENGINE ASSEMBLY


    1. B001WOBE02
      Text in Illustration
      *1 Engine Hanger
      *2 Engine
      *a 50° or less

      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 angle of the sling device at 50° or less. Otherwise, the engine or engine hangers may be damaged.

    2. B001XDGE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      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, 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.

  69. INSTALL ENGINE STAND


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

    2. Remove the 2 bolts and 2 engine hangers.

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR LH


    1. B00205M

      Remove the nut and mounting insulator.

  71. REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. B001WW2

      Remove the nut and mounting insulator.

  72. REMOVE NO. 2 FRONT ENGINE MOUNTING BRACKET LH


    1. B001Y96

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