ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. 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.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  3. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. B001CM8

      Remove the 8 bolts and hood sub-assembly.

      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.

  4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  5. REMOVE FRONT BUMPER LOWER COVER


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

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


    1. B001IJW

      Remove the 4 bolts and No. 1 engine under cover sub-assembly.

  7. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  8. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


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

  9. DRAIN ENGINE COOLANT

    Click here

  10. DRAIN ENGINE OIL

    Click here

  11. DRAIN MANUAL TRANSMISSION OIL (for Manual Transmission)

    Click here

  12. DRAIN AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

    Click here

  13. REMOVE RADIATOR ASSEMBLY

    Click here

  14. DISCONNECT ENGINE WIRE


    1. Remove the ECM Click here.

    2. B001G8U

      Detach the clamp and disconnect the engine wire from the bracket.

    3. B001F3ME07
      Text in Illustration
      *A for LHD
      *B for RHD

      Detach the grommet from the wire harness support.

    4. B001EUKE03
      Text in Illustration
      *A for LHD
      *B for RHD

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

  15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  16. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  17. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  18. REMOVE AIR CLEANER CASE

    Click here

  19. REMOVE NO. 2 INTERCOOLER AIR HOSE

    Click here

  20. REMOVE AIR TUBE ASSEMBLY

    Click here

  21. DISCONNECT UREA TANK FILLER PIPE ASSEMBLY (w/ Urea SCR System)

    Click here

  22. DISCONNECT VANE PUMP OIL RESERVOIR SUB-ASSEMBLY

    Click here

  23. DISCONNECT NO. 1 FUEL HOSE


    1. B001IH6

      Disconnect the clamp from the No. 1 fuel hose.

    2. Slide the clamp and disconnect the No. 1 fuel hose from the No. 2 fuel pipe.

  24. DISCONNECT NO. 2 FUEL HOSE


    1. B001GB1

      Disconnect the 2 clamps from the No. 2 fuel hose.

    2. Slide the clamp and disconnect the No. 2 fuel hose from the No. 3 nozzle leakage pipe.

  25. DISCONNECT ENGINE WIRE


    1. B001GUB

      Detach the 3 claws and remove the No. 1 relay block cover upper from the engine room relay block.

    2. B001H03

      Remove the nut and detach 2 claws.

    3. B001DGW

      Remove the bolt.

    4. Detach the clamp and disconnect the No. 2 engine wire.

    5. B001DYS

      Remove the nut and disconnect the engine room main wire from the battery.

  26. REMOVE BATTERY HOLD DOWN CLAMP


    1. Loosen the 2 nuts and remove the battery hold down clamp from the body.

  27. REMOVE BATTERY

  28. REMOVE BATTERY TRAY

  29. REMOVE WATER HOSE SUB-ASSEMBLY

    Click here

  30. DISCONNECT VANE PUMP ASSEMBLY


    1. B001HTM

      Disconnect the 2 connectors from the vane pump assembly.

    2. B001HON

      Remove the 2 bolt and disconnect the vane pump assembly from the generator bracket.

  31. REMOVE GENERATOR ASSEMBLY

    Click here

  32. DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. B001DI4

      Disconnect the connector from the cooler compressor assembly.

    2. Remove the 3 bolts and nut.

    3. B001HN0

      Using an E8 "TORX" socket wrench, remove the stud bolt and disconnect the cooler compressor assembly from the compressor mounting bracket.

  33. REMOVE WATER HOSE SUB-ASSEMBLY B (w/ Viscous Heater)


    1. B001DDT

      Remove the bolt and disconnect the water hose sub-assembly B from the water inlet.

    2. B001HHX

      Slide the 4 clamps and remove the water hose sub-assembly B from the No. 2 water pipe and water outlet sub-assembly.

  34. REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous Heater)


    1. Disconnect the connector from the viscous heater with magnet clutch assembly.

    2. B001HAY

      Remove the 2 bolts and viscous heater with magnet clutch assembly from No. 1 viscous heater bracket.

  35. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  36. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  37. REMOVE PROPELLER SHAFT ASSEMBLY

    Click here

  38. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Click here

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

    Click here

  40. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  41. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  42. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  43. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. B001ICX

      w/ Viscous Heater:

      Remove the 4 bolts, viscous heater crankshaft pulley and crankshaft pulley cover from the crankshaft pulley.

    2. B001DK3

      w/o Viscous Heater:

      Remove the 4 bolts and crankshaft pulley cover from the crankshaft pulley.

    3. B001GE8E01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014
      09330-00021
    4. B001H3K

      for Manual Transmission:

      Remove the 8 bolts and flywheel sub-assembly from the crankshaft.

    5. B001CIY

      for Automatic Transmission:

      Remove the 8 bolts, rear drive plate spacer, pump impeller drive plate and flywheel sub-assembly from the crankshaft.

  44. REMOVE REAR END PLATE


    1. B001HGG

      Remove the bolt and rear end plate from the cylinder block sub-assembly.

  45. INSTALL ENGINE HANGER


    1. B001CYSE01
      Text in Illustration
      *1 No. 1 Engine Hanger Upper
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger upper and No. 2 engine hanger with the 3 bolts as shown in the illustration.

      Torque:
      for No. 1 engine hanger upper
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      for No. 2 engine hanger
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger Upper 12284-11010
      No. 2 Engine Hanger 12282-11080
      Bolt 91671-80835 or 90119-08474 and 91552-81025

  46. REMOVE ENGINE ASSEMBLY


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

    2. B001G9E

      Remove the 4 bolts and 4 nuts from the body.

    3. Lift the engine assembly out from the vehicle slowly and carefully.

      Note


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

      • While lowering the engine assembly from the vehicle, do not allow it to contact the vehicle.

  47. INSTALL ENGINE ASSEMBLY TO ENGINE STAND

    Note


    • 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.

    • 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 assembly while it is suspended, as doing so is dangerous.


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

    2. Remove the 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.

  48. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  49. REMOVE FRONT ENGINE MOUNTING INSULATOR (for LH Side)


    1. B001F12

      Disconnect the vacuum hose from the front engine mounting insulator.

    2. Remove the nut and front engine mounting insulator from the front engine mounting bracket.