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 V-BANK COVER SUB-ASSEMBLY


    1. B003SYEC02
      B003V9P Areas to be held when lifting V-bank cover sub-assembly
      B003WAF Front

      Hold the rear area of the V-bank cover sub-assembly shown in the illustration and detach the rear clip (1).

      Note

      If the V-bank cover sub-assembly is lifted rearward or forward and to the right or left at the same time, the V-bank cover sub-assembly may be damaged.

    2. Hold both sides of the V-bank cover sub-assembly and lift it to detach the 2 front clips (2) and (3) to remove the V-bank cover sub-assembly.

  4. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  5. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  7. SECURE STEERING WHEEL

    Click here

  8. REMOVE FRONT WHEELS

  9. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  10. REMOVE ENGINE UNDER COVER


    1. A01MYMZ

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

  11. REMOVE REAR ENGINE UNDER COVER LH


    1. B003W7X

      Remove the screw and rear engine under cover LH.

  12. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  13. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. A01MX33

      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.

  14. REMOVE NO. 2 ENGINE UNDER COVER (for Full Cover Type)


    1. B003WCGC01
      *1 Grommet

      Remove the 4 screws, turn the 2 grommets to loosen them, and remove the No. 2 engine under cover.

  15. REMOVE NO. 2 ENGINE UNDER COVER (for Half Cover Type)


    1. B003V0S

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

  16. DRAIN ENGINE OIL

    Click here

  17. DRAIN ENGINE COOLANT

    Click here

  18. DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  19. REMOVE INLET NO. 1 AIR CLEANER


    1. B003WWP

      Remove the bolt and inlet No. 1 air cleaner.

  20. DISCONNECT NO. 2 VENTILATION HOSE

    Click here

  21. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Tech Tips

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

    Click here

  22. 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.

  23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

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


    1. B003VPBC03
      *1 Air Cleaner Support

      Disconnect the wire harness clamp from 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.

  24. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B003USY

      Disconnect the mass air flow meter sub-assembly connector.

    2. Disconnect the 2 wire harness clamps from the air cleaner assembly with air cleaner hose.

    3. B003W9Q

      Disconnect the No. 2 fuel vapor feed hose clamp from the air cleaner cap with air cleaner hose.

    4. B003T4O

      Disconnect the union to check valve hose from the air cleaner cap with air cleaner hose (for RHD).

    5. B003W0YC01
      *1 Air Cleaner Support

      Remove the 2 bolts.

    6. Loosen the hose clamp and remove the air cleaner assembly with air cleaner hose.

      Note

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

  25. DISCONNECT UNION TO CHECK VALVE HOSE


    1. B003W48C02
      *A for LHD
      *B for RHD

      Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.

  26. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. B003UXP

      Slide the clip and disconnect the No. 2 fuel vapor feed hose from the purge valve (purge VSV).

  27. DISCONNECT RADIATOR RESERVE TANK HOSE


    1. B003V00

      Slide the clip and disconnect the radiator reserve tank hose from the water inlet sub-assembly.

  28. REMOVE NO. 1 RADIATOR HOSE

    Click here

  29. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  30. DISCONNECT HEATER INLET WATER HOSE


    1. B003TU2

      Slide the clip and disconnect the heater inlet water hose from the No. 3 heater water by-pass pipe.

  31. DISCONNECT HEATER OUTLET WATER HOSE


    1. B003U6U

      Slide the clip and disconnect the heater outlet water hose from the No. 3 heater water by-pass pipe.

  32. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  33. DISCONNECT SUCTION HOSE

    Click here

  34. REMOVE ENGINE ROOM ECU COVER

    Click here

  35. DISCONNECT WIRE HARNESS (for LHD)

    Tech Tips

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


    1. B003STJ

      Engine room LH side:


      1. Disconnect the engine wire clamp.

      2. Disconnect the engine wire from the engine room ECU box.

        Click here

    2. B003UCL

      Engine room RH side:


      1. Disconnect the No. 2 engine wire clamp.

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

      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. B003W7F

        Disconnect the 2 No. 4 engine wire clamps.

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

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

      7. B003WL3

        Disconnect the No. 3 engine wire clamp.

      8. Remove the bolt and disconnect the No. 3 engine wire from the body.

  36. DISCONNECT WIRE HARNESS (for RHD)

    Tech Tips

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


    1. B003VKW

      Engine room LH side:


      1. Disconnect the No. 2 engine wire clamp.

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

      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. B003VS4

        Disconnect the No. 4 engine wire clamp.

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

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

      7. B003STJ

        Disconnect the engine wire clamp.

      8. Disconnect the engine wire from the engine room ECU box.

        Click here

    2. B003VSV

      Engine room RH side:


      1. Disconnect the No. 3 engine wire clamp.

      2. Remove the bolt and disconnect the No. 3 engine wire from the body.

  37. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B003VZW

      Remove the fuel pipe clamp.

    2. B003W6V

      Disconnect the fuel tube sub-assembly from the fuel pipe.

      Click here

  38. DISCONNECT NO.3 FUEL HOSE


    1. B003WSV

      Slide the clip and disconnect the No. 3 fuel hose from the No. 1 fuel pipe sub-assembly.

  39. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  40. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

    Click here

  41. REMOVE ENGINE UNDER BRACE SUB-ASSEMBLY


    1. A01MULH

      Remove the 4 bolts and engine under brace sub-assembly.

  42. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  43. SEPARATE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  44. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. B003V18

      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.

  45. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  46. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  47. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  48. DISCONNECT WIRE HARNESS


    1. B003TZD

      Disconnect 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.

  49. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  50. REMOVE FRONT UPPER NO. 2 SUSPENSION MEMBER


    1. A01MYJ5

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

  51. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. B003UOP

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

  52. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. A01MYSR

      Remove the nut and disconnect the No. 2 earth wire from the body.

    2. B003UJMC01
      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. A01MZ25

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

    4. B003SUTC02
      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 and strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.

    6. Operate the engine lifter, then 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 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 NO. 1 ENGINE HANGER


    1. B003WDHC02
      *a RH Side
      *b LH Side

      Install the 2 No. 1 engine hangers with the 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-31070
      Bolt 91671-F0822

    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 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.

  54. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01MZ9E

      Disconnect the wire harness clamp from the engine oil level dipstick guide.

    2. Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  55. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

    Click here

  56. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

    Click here

  57. REMOVE STARTER ASSEMBLY

    Click here

  58. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  59. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  60. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  61. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  62. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B003V4HC01
      *a LH Side
      *b RH Side

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

  63. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B003TE7C01
      *a LH Side
      *b RH Side

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

  64. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

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


    1. A01MVW0

      Remove the 4 nuts and rear engine mounting member from the rear engine mounting insulator.

  65. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01MW8W

      Remove the 4 bolts and rear engine mounting insulator from the automatic transmission assembly.

  66. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 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 4 bolts and 2 No. 1 engine hangers.

  67. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY


    1. B003WRI

      Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head.

      Maximum warpage
      0.70 mm (0.02756 in.)

      If the warpage is more than the maximum, replace the exhaust manifold sub-assembly.