ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  4. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. B001ETN

      Remove the 8 bolts and hood.

      Note

      If the hood support is detached from the ball joint, it become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  6. REMOVE FRONT BUMPER COVER LOWER


    1. Remove the clip, 5 bolts and front bumper cover lower.

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


    1. Remove the 4 bolts.

    2. B001IJW

      Unhook the engine under cover from the vehicle body as shown in the illustration.

  8. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  9. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


    1. Remove the 4 bolts and rear engine under cover.

  10. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 5 clips and front fender apron seal.

  11. REMOVE FRONT FENDER APRON SEAL RH


    1. Remove the 5 clips and front fender apron seal.

  12. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL LH


    1. Remove the 5 clips and front No. 1 fender apron to frame seal.

  13. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Remove the 5 clips and front No. 1 fender apron to frame seal.

  14. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  15. DRAIN ENGINE OIL

    Click here

  16. DRAIN ENGINE COOLANT

    Click here

  17. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  18. REMOVE BATTERY HOLD DOWN CLAMP

    Click here

  19. REMOVE BATTERY

  20. REMOVE BATTERY TRAY

  21. REMOVE V-BANK COVER

    Click here

  22. REMOVE FRONT BUMPER COVER


    1. Remove the front bumper cover Click here.

  23. REMOVE AIR CLEANER CAP AND HOSE

    Click here

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  25. REMOVE FRONT BUMPER CENTER UPPER RETAINER

    Click here

  26. REMOVE RADIATOR SIDE DEFLECTOR RH

    Click here

  27. REMOVE RADIATOR SIDE DEFLECTOR LH

    Click here

  28. REMOVE NO. 1 RADIATOR HOSE

    Click here

  29. REMOVE NO. 2 RADIATOR HOSE

    Click here

  30. REMOVE RADIATOR RESERVOIR

    Click here

  31. DISCONNECT OIL COOLER TUBE (w/ Warmer)

    Click here

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

    Click here

  33. REMOVE FAN SHROUD

    Click here

  34. REMOVE RADIATOR ASSEMBLY

    Click here

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

    Click here

  36. REMOVE INTAKE AIR SURGE TANK

    Click here

  37. REMOVE FAN AND GENERATOR V BELT

    Click here

  38. DISCONNECT VANE PUMP ASSEMBLY

    Click here

  39. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  40. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  41. REMOVE COOLER COMPRESSOR ASSEMBLY

    Click here

  42. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the front exhaust pipe Click here.

  43. REMOVE MANIFOLD STAY

    Click here

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

    Click here

  45. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)


    1. for Manual tilt and manual telescopic steering column:

      Disconnect the No. 2 steering intermediate shaft Click here.

    2. for Power tilt and power telescopic steering column:

      Disconnect the No. 2 steering intermediate shaft Click here.

  46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  48. REMOVE NO. 2 MANIFOLD STAY

    Click here

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

    Click here

  50. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  51. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  52. REMOVE WIRING HARNESS CLAMP BRACKET

    Click here

  53. REMOVE GENERATOR ASSEMBLY

    Click here

  54. REMOVE STARTER ASSEMBLY

    Click here

  55. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

    Click here

  56. DISCONNECT ENGINE WIRE


    1. B001E9V

      Remove the bolt and disconnect the connector.

    2. Remove the glove compartment door Click here.

    3. Disconnect the ECM connector.


      1. B001F1OE01
        Text in Illustration
        *A for LHD
        *B for RHD

        Detach the clamp and disconnect the 9 connectors.

      2. B001F3ME05
        Text in Illustration
        *A for LHD
        *B for RHD

        Detach the grommet from the wire harness support.

      3. B001EUKE05
        Text in Illustration
        *A for LHD
        *B for RHD

        Detach the 4 claws to remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

  57. DISCONNECT HEATER WATER HOSE ASSEMBLY


    1. B001FANE03
      Text in Illustration
      *A w/o Rear Heater
      *B w/ Rear Heater

      w/o Rear heater:

      Disconnect the 2 hoses and heater water hose.

    2. w/ Rear heater:

      Disconnect the 4 hoses and heater water hose.

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


    1. Remove the No. 2 fuel pipe clamp from the fuel tube connector.

    2. B001EB9

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

  59. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  60. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  61. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Remove the manual transmission from the vehicle Click here.

  62. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Remove the automatic transmission from the vehicle Click here.

  63. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for Automatic Transmission)

    Click here

  64. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for Manual Transmission)

    Click here

  65. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. B001FAI

      Remove the bolt and disconnect the suction hose.

  66. DISCONNECT OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. B001GSGE01
      Text in Illustration
      *A w/o Air Cooled Transmission Oil Cooler
      *B w/ Air Cooled Transmission Oil Cooler

      Remove the bolt and disconnect the oil cooler tube.

  67. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  68. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

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


    1. B001EMIE06

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. B001DMS

      Remove the 8 bolts and flywheel.

      Note

      Do not reuse the bolts.

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


    1. B001EMIE07

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. B001H86

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

  71. REMOVE ENGINE ASSEMBLY


    1. B001FK2E05
      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

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

    3. B001CEZ

      Remove the 6 nuts from the front engine mounting insulator LH and RH.

    4. Lift the engine out of the vehicle carefully.

      Note

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

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

    6. Place the engine onto a work bench.

  72. INSTALL ENGINE STAND


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