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. B003SXBC02
      B003V9P Areas to be held when lifting the V-bank cover sub-assembly
      B003WAF Front of Engine

      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

    Click here

  7. SECURE STEERING WHEEL

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  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. B003TAS

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

  11. REMOVE REAR ENGINE UNDER COVER LH


    1. B003U9P

      Remove the screw and rear engine under cover LH.

  12. REMOVE REAR ENGINE UNDER COVER RH


    1. B003WYL

      Remove the screw and rear engine under cover RH.

  13. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. B003T52

      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


    1. B003SYJ

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

  15. DRAIN ENGINE OIL

    Click here

  16. DRAIN ENGINE COOLANT

    Click here

  17. DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  18. REMOVE INLET NO. 1 AIR CLEANER


    1. B003X9T

      Remove the bolt and inlet No. 1 air cleaner.

  19. 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.


    1. B003VBM

      Slide the clip and disconnect the No. 2 ventilation hose.

    2. B003V2N

      Disconnect the mass air flow meter sub-assembly connector.

    3. Disconnect the wire harness clamp from the air cleaner cap with air cleaner hose.

    4. B003WV1

      Disengage the clamp to disconnect the No. 1 fuel vapor feed hose from the air cleaner cap with air cleaner hose.

    5. B003VI6

      Release the 4 clamps.

    6. Loosen the hose clamp and remove the air cleaner cap with air cleaner hose from the throttle body with motor assembly.

  20. 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.

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

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


    1. B003WMMC02
      *a Pin
      *b 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.

  22. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B003UU8

      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. B003TML

      Disengage the clamp to disconnect the No. 1 fuel vapor feed hose from the air cleaner assembly with air cleaner hose.

    4. B003TV6C04
      *a Pin
      *b Air Cleaner Support

      Remove the 2 bolts.

    5. Slide the clip and disconnect the No. 2 ventilation hose from the air cleaner assembly with air cleaner hose.

    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.

  23. DISCONNECT UNION TO CONNECTOR TUBE HOSE (for LHD)


    1. B003TOV

      Slide the clip and disconnect the union to connector tube hose.

  24. DISCONNECT UNION TO CONNECTOR TUBE HOSE (for RHD)


    1. B003TAL

      Slide the clip and disconnect the union to connector tube hose.

  25. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B003WG5

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

  26. DISCONNECT NO. 1 RADIATOR HOSE


    1. B003U2V

      Slide the clip and disconnect the No. 1 radiator hose from the water inlet.

  27. DISCONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY

    Click here

  28. DISCONNECT INLET NO. 1 OIL COOLER HOSE (w/ Transmission Oil Cooler)

    Click here

  29. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE (w/ Transmission Oil Cooler)

    Click here

  30. DISCONNECT INLET HEATER WATER HOSE A


    1. B003TPZ

      Remove the water hose set.

    2. B003TIM

      Slide the clip and disconnect the inlet heater water hose A from the No. 2 water by-pass pipe.

  31. DISCONNECT OUTLET HEATER WATER HOSE A


    1. B003V4U

      Remove the water hose set.

    2. B003TQE

      Slide the clip and disconnect the outlet heater water hose A from the No. 2 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. Engine room LH side:


      1. B003V8N

        Disconnect the 3 connectors from the No. 2 connector holder.

      2. B003SXL

        Disconnect the clamp.

      3. Disengage the 3 claws and disconnect the No. 2 connector holder.

      4. B003V0R

        Disengage the lock, pull up the lever and disconnect the ECM connector.

    2. Engine room RH side:


      1. B003WBU

        Disconnect the 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. B003ULV

        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. B003TN5

        Disconnect the 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. Engine room LH side:


      1. B003U4X

        Disconnect the 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. B003W79

        Disconnect the 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. B003V8N

        Disconnect the 3 connectors from the No. 2 connector holder.

      8. B003SXL

        Disconnect the clamp.

      9. Disengage the 3 claws and disconnect the No. 2 connector holder.

      10. B003V0R

        Disengage the lock, pull up the lever and disconnect the ECM connector.

    2. B003TN5

      Engine room RH side:


      1. Disconnect the clamp.

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

  37. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for LHD)


    1. B003W4A

      Remove the fuel pipe clamp.

    2. B003V9Q

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

      Click here

  38. DISCONNECT FUEL TUBE SUB-ASSEMBLY (for RHD)


    1. B003T4Q

      Remove the fuel pipe clamp.

    2. B003U72

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

      Click here

  39. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. B003URK

      Remove the fuel pipe clamp as shown in the illustration.

    2. Disconnect the No. 2 fuel tube sub-assembly from the fuel pipe.

      Click here

  40. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

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

    Click here

  42. SEPARATE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  43. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. B003TJI

      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

    Perform the same procedure as for the LH side.

  45. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  46. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  47. DISCONNECT WIRE HARNESS (for LHD)


    1. B003WHEN02

      Disconnect the 2 wire harness clamps from the bracket.

    2. Disconnect the 2 connectors (A) and (B) from the power steering link assembly.

    3. Release the lock of connector (C) and disconnect the connector from the power steering link assembly.

  48. DISCONNECT WIRE HARNESS (for RHD)


    1. B003V9MN02

      Disconnect the 2 wire harness clamps from the bracket.

    2. Disconnect the 2 connectors (A) and (B) from the power steering link assembly.

    3. Release the lock of connector (C) and disconnect the connector from the power steering link assembly.

  49. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  50. REMOVE SUSPENSION TOWER DAMPER

    Click here

  51. REMOVE FRONT UPPER NO. 2 SUSPENSION MEMBER


    1. B003TRJ

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

  52. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. B003WYP

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

  53. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. B003WXI

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

    2. B003TX2C02
      *a 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. B003TMN

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

    4. B003WQEC04
      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 the 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.

  54. INSTALL ENGINE HANGERS


    1. B003UF5C04
      *a No. 1 Engine Hanger
      *b No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger 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
      No. 2 Engine Hanger 12282 - 31160
      Bolt 91671-10825

    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.

  55. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  56. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B003WK5

      Disconnect the 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.

  57. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH


    1. B003U8W

      Remove the 2 clamps and engine under cover sub-assembly LH.

  58. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH


    1. B003VEM

      Remove the 2 clamps and engine under cover sub-assembly RH.

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

    Click here

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

    Click here

  61. REMOVE STARTER COVER

    Click here

  62. REMOVE STARTER ASSEMBLY

    Click here

  63. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  64. REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

  65. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  66. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  67. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B003XA5C02
      *a LH Side
      *b RH Side

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

  68. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B003V8XC02
      *a LH Side
      *b RH Side

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

  69. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

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


    1. B003WON

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

  70. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B003XAA

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

  71. REMOVE REAR ENGINE MOUNTING BRACKET

    Tech Tips

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


    1. B003X49

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

  72. INSTALL ENGINE ASSEMBLY 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, No. 1 engine hanger and No. 2 engine hanger.