ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    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.

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

  2. 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.

  3. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  4. REMOVE FRONT BUMPER LOWER COVER


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

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


    1. Remove the 4 bolts and No. 1 engine under cover.

  6. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  7. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


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

  8. DRAIN ENGINE COOLANT

    Click here

  9. DRAIN ENGINE OIL

    Click here

  10. DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)

    Click here

  11. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

    Click here

  12. DRAIN POWER STEERING FLUID

  13. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator Click here.

  14. REMOVE BATTERY HOLD DOWN CLAMP


    1. Remove the 2 nuts and battery hold down clamp.

  15. REMOVE BATTERY

  16. REMOVE BATTERY TRAY

  17. REMOVE NO. 1 AIR CLEANER HOSE

    Click here

  18. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  19. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  21. REMOVE COMPRESSOR OUTLET ELBOW

    Click here

  22. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (for Cold Area Specification Vehicles)


    1. Disconnect the viscous heater connector.

    2. B001EJM

      Disconnect the water by-pass hose and water hose.

    3. B001C82

      Remove the 2 bolts and viscous heater with magnet clutch.

  23. REMOVE NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)


    1. B001ELT

      Remove the 4 bolts and No. 1 viscous heater bracket.

  24. DISCONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. B001HGA

      Disconnect the compressor connector.

    2. Remove the 4 bolts and disconnect the cooler compressor.

  25. REMOVE DIESEL THROTTLE BODY ASSEMBLY


    1. Remove the diesel throttle body Click here.

  26. REMOVE FUEL FILTER ASSEMBLY


    1. Remove the fuel filter Click here.

  27. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY


    1. B001EZV

      Remove the 3 bolts and disconnect the vane pump oil reservoir.

  28. DISCONNECT PRESSURE FEED TUBE ASSEMBLY


    1. B001GDA

      Disconnect the power steering oil pressure switch connector.

    2. B001F2V

      Remove the union bolt and gasket and disconnect the pressure feed tube.

  29. DISCONNECT INLET HEATER WATER HOSE


    1. B001FYM

      Disconnect the inlet heater water hose.

  30. DISCONNECT OUTLET HEATER WATER HOSE


    1. B001EI8

      Disconnect the outlet heater water hose.

  31. DISCONNECT FUEL HOSE


    1. B001HQB

      Disconnect the No. 1 fuel hose and No. 2 fuel hose.

  32. REMOVE GLOVE COMPARTMENT DOOR SUB-ASSEMBLY


    1. Remove the glove compartment door Click here.

  33. DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. B001ER8

      Remove the nut and detach the 2 claws.

    3. B001DVU

      Disconnect the 3 injection driver connectors and remove the bolt.

    4. B001EUU

      Disconnect the connector and detach the clamp.

    5. B001FKG

      Remove the bolt.

    6. B001HFS

      Remove the nut and disconnect the engine wire.

    7. B001FCP

      Remove the bolt and disconnect the wire harness protector.

    8. B001G0XE01
      Text in Illustration
      *A w/ KDSS
      *B w/o KDSS

      Remove the bolt and disconnect the engine wire.

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

      Detach the clamp and disconnect the 9 connectors.

    10. B001F3ME04
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the grommet from the wire harness support.

    11. B001EUKE01
      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.

  34. REMOVE STARTER ASSEMBLY (for 2.2 kW Type)

    Click here

  35. REMOVE STARTER ASSEMBLY (for 2.7 kW Type)

    Click here

  36. REMOVE STARTER ASSEMBLY (for 3.0 kW Type)

    Click here

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  38. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  39. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  40. REMOVE OIL PAN INSULATOR


    1. B001GHZ

      Remove the 2 bolts and oil pan insulator.

  41. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Remove the manual transmission Click here.

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

    Click here

  43. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Remove the automatic transmission Click here.

  44. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. B001DO7

      Remove the 4 bolts and rear No. 1 engine mounting insulator.

  45. REMOVE ENGINE ASSEMBLY


    1. B001HGME01
      Text in Illustration
      *1 No. 1 engine hanger
      *2 No. 2 engine hanger

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

      Tech Tips

      Part No.

      No. 1 engine hanger 12284-30020
      No. 2 engine hanger 12282-67030
      Bolt 91552-81014 and 91642-81030
      Torque:
      for No. 1 engine hanger
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      for No. 2 engine hanger
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Install the engine hangers with new bolts.

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

    3. B001FODE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Remove the 4 bolts and 4 nuts.

    4. Remove the engine by operating the engine sling device and chain block.

  46. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  47. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

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


    1. B001HZ4E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021

    2. Remove the 8 bolts and flywheel.

  49. REMOVE PUMP IMPELLER DRIVE PLATE (for Automatic Transmission)


    1. B001HZ4E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021
    2. B001D2I

      Remove the 8 bolts, the rear drive plate spacer, the pump impeller drive plate, and the flywheel and ring gear.

  50. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  51. INSTALL ENGINE TO ENGINE STAND

  52. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine.

  53. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B001FFTE01
      Text in Illustration
      *A for LH Side
      *B for RH Side

      Disconnect the 2 hoses.

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