ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  3. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B003TFCC01
      B003V9P Areas to be Held when Lifting No. 1 Engine Cover Sub-assembly

      Hold the areas of the No. 1 engine cover sub-assembly shown in the illustration and lift the No. 1 engine cover sub-assembly to disengage the front clips (1) and (2).

    2. With the No. 1 engine cover sub-assembly raised, disengage the rear clip (3) and remove the No. 1 engine cover sub-assembly.

  4. REMOVE INLET NO. 1 AIR CLEANER


    1. B003UTG

      Remove the bolt and inlet No. 1 air cleaner.

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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  6. DISCHARGE FUEL SYSTEM PRESSURE

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  7. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

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  8. SECURE STEERING WHEEL

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  9. REMOVE FRONT WHEELS

  10. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

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  11. REMOVE ENGINE UNDER COVER


    1. B003VZE

      Remove the 13 screws, 3 clips and engine under cover.

  12. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. B003U7R

      Remove the 4 bolts, turn the clip to loosen it, and remove the front suspension member brace.

      Tech Tips

      Do not remove the clip from the front suspension member brace.

  13. REMOVE NO. 2 ENGINE UNDER COVER


    1. B003W5M

      Remove the 4 screws and No. 2 engine under cover.

  14. REMOVE REAR ENGINE UNDER COVER LH


    1. B003T89

      Remove the screw and rear engine under cover LH.

  15. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  16. DRAIN ENGINE OIL

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  17. DRAIN ENGINE COOLANT

    Click here

  18. DRAIN COOLANT (for Intercooler)

    Click here

  19. DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  20. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary.


    1. B003WLI

      Slide the hose clamp and disconnect the No. 1 ventilation hose from the air cleaner hose assembly.

    2. Disengage the wire harness clamp and disconnect the connector from the intake mass air flow meter sub-assembly.

    3. Remove the bolt.

    4. Loosen the hose clamp, disengage the 4 clamps and remove the air cleaner cap sub-assembly with air cleaner hose assembly.

  21. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary.


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  22. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary.


    1. B003T58C02
      *1 Air Cleaner Support

      Disengage the wire harness clamp and disconnect the air cleaner case sub-assembly.

    2. Remove the 2 bolts and air cleaner case sub-assembly.

      Note

      Make sure the air cleaner support is attached to the vehicle body.

  23. REMOVE AIR CLEANER ASSEMBLY WITH NO. 2 AIR CLEANER HOSE


    1. B003W6NC01
      *1 Air Cleaner Support

      Slide the hose clamp and disconnect the No. 1 ventilation hose from the air cleaner hose assembly.

    2. Disengage the 2 wire harness clamps and disconnect the connector from the intake mass air flow meter sub-assembly.

    3. Remove the 3 bolts.

    4. Loosen the hose clamp and remove the air cleaner cap sub-assembly with air cleaner assembly with No. 2 air cleaner hose.

      Note

      Make sure the air cleaner support is attached to the vehicle body.

  24. REMOVE RADIATOR HOSE SUB-ASSEMBLY

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  25. DISCONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY


    1. B003WPY

      Slide the clip and disconnect the No. 2 radiator hose sub-assembly from water inlet.

  26. REMOVE INTERCOOLER RESERVE TANK ASSEMBLY

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  27. REMOVE V-RIBBED BELT

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  28. DISCONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. B003X9U

      Slide the clip and disconnect the union to check valve hose from the vacuum pump assembly.

    2. Remove the bolt and disconnect the union to check valve hose.

  29. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. B003VQY

      Slide the clip and disconnect the union to check valve hose from the vacuum pump assembly.

    2. Disengage the clamp to disconnect the union to check valve hose from the vacuum hose clamp.

  30. DISCONNECT INLET HEATER WATER HOSE A


    1. B003W1M

      Remove the water hose set from the inlet heater water hose A.

    2. B003UAE

      Slide the clip and disconnect the inlet heater water hose A from the No. 5 water by-pass pipe.

  31. DISCONNECT OUTLET HEATER WATER HOSE A


    1. B003UGB

      Remove the water hose set from the outlet heater water hose A.

    2. B003X1U

      Slide the clip and disconnect the outlet heater water hose A from the No. 5 water by-pass pipe.

  32. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B003W9P

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).

  33. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B003WPFC01
      *1 No. 1 Fuel Tube Clamp

      Remove the No. 1 fuel tube clamp from the wire harness clamp bracket.

    2. Disconnect the fuel tube sub-assembly from the fuel pump assembly.

      Click here

    3. Disconnect the fuel tube sub-assembly from the fuel delivery pipe and fuel pump assembly.

      Click here

  34. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  35. DISCONNECT SUCTION HOSE

    Click here

  36. REMOVE ENGINE ROOM ECU COVER

    Click here

  37. DISCONNECT ENGINE WIRE (for LHD)

    Tech Tips

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.


    1. for LH side:


      1. B003TDM

        Remove the nut and disconnect the No. 2 engine wire from the positive (+) battery terminal.

      2. Disengage the clamp.

      3. Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.

      4. B003UJ5

        Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.

      5. Disengage the 2 claws and disconnect the No. 4 engine wire from the No. 1 engine room relay block.

      6. Disengage the 2 No. 4 engine wire clamps.

      7. B003WNU

        Remove the bolt and disconnect the No. 3 engine wire from the engine wire bracket.

      8. Disengage the No. 3 engine wire clamp from the engine wire bracket.

    2. for RH side:


      1. B003WR6

        Disconnect the 4 engine wire harness connectors.

      2. B003WLG

        While pushing the lock on the lever, pull up the lock lever to disconnect the ECM connector.

      3. B003TGE

        Remove the nut and disconnect the engine wire.

      4. Disengage the claw and disconnect the engine wire.

  38. DISCONNECT ENGINE WIRE (for RHD)

    Tech Tips

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.


    1. for LH side:


      1. B003WNU

        Remove the bolt and disconnect the No. 3 engine wire from the engine wire bracket.

      2. Disengage the No. 3 engine wire clamp from the engine wire bracket.

    2. for RH side:


      1. B003UJC

        Remove the nut and disconnect the No. 2 engine wire from the positive (+) battery terminal.

      2. Disengage the No. 2 engine wire clamp.

      3. B003WR6

        Disconnect the 4 engine wire harness connectors.

      4. B003WLG

        While pushing the lock on the lever, pull up the lock lever to disconnect the ECM connector.

      5. B003TGE

        Remove the nut and disconnect the engine wire.

      6. Disengage the claw and disconnect the engine wire.

      7. Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.

      8. B003TGI

        Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.

      9. Disengage the 2 claws and disconnect the No. 4 engine wire from the No. 1 engine room relay block.

      10. Disengage the No. 4 engine wire clamp.

  39. DISCONNECT NO. 3 ENGINE WIRE (for LHD)


    1. B003SXN

      Disengage the 2 wire harness clamps and 3 wire harness connectors from the power steering link assembly.

      Tech Tips

      For the connector with lock lever, pull up the lock lever to disengage the lock.

  40. DISCONNECT NO. 3 ENGINE WIRE (for RHD)


    1. B003UMI

      Disengage the 2 wire harness clamps and 3 wire harness connectors from the power steering link assembly.

      Tech Tips

      For the connector with lock lever, pull up the lock lever to disengage the lock.

  41. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

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  42. DISCONNECT HEATER ACCESSORY ASSEMBLY


    1. B003SXU

      Remove the 2 bolts and disconnect the heater accessory assembly from the vehicle body.

  43. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. B003TG7

      Remove the bolt and nut, and disconnect the front shock absorber assembly LH from the front suspension lower arm assembly LH.

      Note

      When removing the bolt, keep the nut from rotating.

  44. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  45. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

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  46. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  47. REMOVE SUSPENSION TOWER DAMPER

    Click here

  48. REMOVE FRONT UPPER NO. 2 SUSPENSION MEMBER


    1. B003UE6

      Remove the 6 bolts and 2 front upper No. 2 suspension members.

  49. SEPARATE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

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  50. SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  51. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. B003SVH

      Remove the 4 bolts and front lower suspension member protector from the front suspension crossmember sub-assembly.

  52. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. B003VCZ

      Remove the bolt and disconnect the No. 2 earth wire from the automatic transmission assembly.

    2. B003TQ0C01
      B003V9P Attachment Installation Position

      Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transmission.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

    3. B003TZE

      Remove the 4 bolts, and separate the rear engine mounting member from the vehicle body.

    4. B003VAAC01
      B003WAF Bolt
      B003U82 Nut

      Remove the 4 bolts and disconnect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH.

    5. Remove the 6 bolts, 2 nuts, strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.

    6. Operate the engine lifter and remove the engine assembly with transmission from the vehicle.

      Note


      • Make sure that the engine assembly with transmission is clear of all wiring, hoses and the steering sliding with shaft yoke sub-assembly.

      • After removing the engine assembly with transmission, hang the steering sliding with shaft yoke sub-assembly with rope or equivalent.

  53. INSTALL ENGINE HANGER


    1. B003U7TC01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *a Bolt

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

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

      Tech Tips

      Item Part No.
      No. 1 Engine Hanger 12281-36100
      No. 2 Engine Hanger 12282-36140
      Bolt (No. 1 engine hanger) 91552-81050
      Bolt (No. 2 engine hanger) 90119-12285

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

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

  54. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly with transmission.

  55. REMOVE NO. 3 VENTILATION HOSE


    1. B003VY6

      Slide the 2 clips and disconnect the No. 3 ventilation hose from the cylinder head cover sub-assembly and air tube.

    2. Disengage the clamp to remove the No. 3 ventilation hose.

  56. REMOVE AIR TUBE


    1. B003WDM

      Loosen the 2 hose clamps and remove the 2 bolts and air tube.

  57. REMOVE NO. 1 AIR HOSE


    1. B003VQ0

      Loosen the hose clamp and remove the No. 1 air hose.

  58. REMOVE NO. 2 AIR HOSE


    1. B003TU3

      Loosen the hose clamp and remove the No. 2 air hose.

  59. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  60. REMOVE NO. 4 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  61. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front and Rear Catalyst)

    Click here

  62. DISCONNECT WIRE HARNESS

    Click here

  63. DISCONNECT WATER BY-PASS HOSE

    Click here

  64. REMOVE STARTER ASSEMBLY


  65. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  66. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  67. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  68. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  69. DISCONNECT NO. 13 WATER BY-PASS HOSE


    1. B003V3E

      Slide the clip and disconnect the No. 13 water by-pass hose from the No. 1 water by-pass pipe.

  70. REMOVE REAR END PLATE


    1. B003VS3

      Remove the 2 bolts and rear end plate.

  71. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B003T3SC01
      *A for RH Side
      *B for LH Side

      Remove the 2 bolts and front suspension crossmember sub-assembly from the engine assembly.

  72. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.


    1. B003VFWC01
      *A LH Side
      *B RH Side

      Remove the 2 nuts and 2 front engine mounting insulators from the front suspension crossmember sub-assembly.

  73. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

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


    1. B003WVF

      Remove the 4 nuts and rear engine mounting member from the rear No. 1 engine mounting insulator.

  74. 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. B003UNI

      Remove the 4 bolts and rear No. 1 engine mounting insulator from the automatic transmission assembly.

  75. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine to an 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.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

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