ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. PRECAUTION

    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.

    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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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  3. DISCHARGE FUEL SYSTEM PRESSURE

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  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. SECURE STEERING WHEEL

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  6. 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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  7. REMOVE FRONT WHEELS

  8. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 8 bolts, 6 screws, 3 clips and No. 1 engine under cover.

  9. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 2 bolts, 2 screws, clip and No. 2 engine under cover.

  10. REMOVE FRONT FLOOR COVER LH

    Click here

  11. SEPARATE FRONT FENDER LINER LH


    1. Remove the 3 screws and 3 clips and separate the front fender liner LH.

  12. SEPARATE FRONT FENDER LINER RH


    1. Remove the 3 screws and 3 clips and separate the front fender liner RH.

  13. REMOVE FRONT FENDER APRON SEAL LH


    1. A002AEW

      Remove the 2 bolts, clip and front fender apron seal LH.

  14. REMOVE FRONT FENDER APRON SEAL RH


    1. A0027LJ

      Remove the 2 bolts, clip and front fender apron seal RH.

  15. DRAIN ENGINE OIL

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  16. DRAIN ENGINE COOLANT

    Click here

  17. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD)

    Click here

  18. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD)

    Click here

  19. DRAIN TRANSFER OIL (for AWD)

    Click here

  20. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  21. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  22. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  23. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH

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  24. REMOVE RADIATOR SIDE SEAL RH

    Click here

  25. REMOVE COOL AIR INTAKE DUCT SEAL

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  26. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A002BDT

      Hold the rear of the V-bank cover sub-assembly and raise it to disengage the 2 front retainers.

    2. Raise the V-bank cover sub-assembly to disengage the rear retainer to remove the V-bank cover sub-assembly.

      Note

      Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

  27. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A0029DP

      Remove the 2 bolts and inlet air cleaner assembly.

    2. Separate the air hose from the 2 hose clamps.

  28. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A002AEU

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

  31. REMOVE BATTERY


    1. A002A42

      Disconnect the cable from the positive (+) battery terminal.

    2. Remove the nut and bolt.

    3. Remove the battery clamp, battery clamp bolt, battery and battery tray.

  32. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)


    1. B003ZWVC01
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Disconnect the reservoir level switch connector and remove the bolt from the brake master cylinder reservoir assembly.

    2. Move the brake master cylinder reservoir assembly as shown in the illustration to disengage the 2 claws, and separate it.

  33. REMOVE RESERVOIR BRACKET (for LHD)

    Click here

  34. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for RHD)


    1. B00409SC01
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket

      Disconnect the reservoir level switch connector and remove the bolt from the brake master cylinder reservoir assembly.

    2. Move the brake master cylinder reservoir assembly as shown in the illustration to disengage the 2 claws, and separate it.

  35. REMOVE RESERVOIR BRACKET (for RHD)

    Click here

  36. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A002BJ2

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

  37. REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. B003Z75

      Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.

  38. REMOVE ENGINE MOVING CONTROL ROD

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.


    1. B003Z59

      Remove the 2 bolts, engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket.

  39. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A0028W4

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve.

  40. DISCONNECT UNION TO CHECK VALVE HOSE


    1. B003ZHGC02
      *A for LHD
      *B for RHD

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

  41. DISCONNECT NO. 1 RADIATOR HOSE


    1. A0027F8

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

    2. Separate the No. 1 radiator hose from the radiator pipe clamp.

  42. DISCONNECT NO. 2 RADIATOR HOSE


    1. A002AS1

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

  43. DISCONNECT INLET HEATER WATER HOSE


    1. A002AUM

      Slide the clip and disconnect the inlet heater water hose from the water inlet.

  44. DISCONNECT OUTLET HEATER WATER HOSE


    1. A002CGR

      Slide the clip and disconnect the outlet heater water hose from the water outlet.

  45. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A002AQU

      Remove the No. 1 fuel pipe clamp.

    2. B004071C04
      B003ZIE Push
      B003Z8F Pull

      Disconnect the connector from the fuel main tube by hand. When the connector and the fuel main tube are stuck, push and pull the connector to release it. Pull the connector off of the fuel main tube carefully.

      Note


      • Check for any dirt and foreign matter in the fuel main tube and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel main tube and connector.

      • Do not use any tools to separate the fuel main tube and connector.

      • Do not forcibly bend or twist the nylon tube.

      • Check for any dirt and foreign matter on the tube seal surface. Clean if necessary.

      • Cover the fuel main tube and connector ends with plastic bags to prevent damage and contamination.

      • If the fuel main tube and connector are stuck together, pinch the fuel main tube between your fingers and turn it carefully to free it. Then disconnect the fuel main tube.

  46. DISCONNECT NO. 1 OUTLET OIL COOLER HOSE


    1. A002BM4

      Slide the clip and disconnect the No. 1 outlet oil cooler hose.

  47. DISCONNECT NO. 1 INLET OIL COOLER HOSE


    1. A0028CU

      Slide the clip and disconnect the No. 1 inlet oil cooler hose.

  48. REMOVE STARTER ASSEMBLY

    Click here

  49. DISCONNECT ENGINE WIRE


    1. A002AKZ

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

    2. A0027IC

      Remove the bolt and separate the earth wire.

    3. Remove the nut from the engine room relay block assembly.

    4. Disconnect the 3 wire clamps.

    5. A002A8Z

      Disconnect the 4 connectors from the engine room relay block assembly.

    6. Using a screwdriver, disengage the claw and separate the engine wire from the engine room relay block assembly.

    7. A00279J

      Pull up the lock lever while pushing the lock on the lever to disconnect the ECM connector.

      Note

      After disconnecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting part of the ECM connector.

    8. Disengage the 2 wire harness clamps.

  50. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A002C44

      Remove the nut from the transmission control shaft lever.

    2. A0029GD

      Using a screwdriver, disengage the 4 claws, separate the transmission control cable assembly with clip from the No. 1 transmission control cable bracket.

    3. Remove the clip from the transmission control cable assembly.

  51. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

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  52. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  53. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

    Click here

  54. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  56. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD)

    Click here

  57. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD)

    Click here

  58. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  59. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  60. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)


    1. A002BP0

      Remove the 2 bolts and No. 1 exhaust pipe support bracket.

  61. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A002CAD

      Remove the 2 bolts and flywheel housing under cover.

  62. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for 2WD)

    Click here

  63. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for AWD)

    Click here

  64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A0027DD

      Set an engine lifter.

      Note


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

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

    2. B003Z3TC04
      B003ZIE Bolt
      B003Z8F Nut

      Remove the 6 bolts, 2 nuts and frame side plate RH and frame side plate LH.

    3. Remove the 6 bolts, 2 nuts and front suspension member rear brace RH and front suspension member rear brace LH.

    4. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

      Note


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

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

  65. INSTALL ENGINE HANGERS


    1. B003Z50C05
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger (Part No. 12281-31120)
      *2 No. 2 Engine Hanger (Part No. 12282-31100)
      *3 Bolt (Part No. 91671-10825) or (Part No. 90119-A0117)

      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 }

    2. Attach the engine sling device and hang the engine assembly with transaxle with the 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 with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.

  66. REMOVE V-RIBBED BELT

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  67. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

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  68. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for AWD)

    Click here

  69. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (for AWD)

    Tech Tips

    Perform the same procedure as for the LH side.

  70. REMOVE FRONT STABILIZER BAR (for AWD)

    Click here

  71. REMOVE STEERING LINK ASSEMBLY (for AWD)

    Click here

  72. REMOVE FRONT FRAME ASSEMBLY


    1. A0028LE

      Disconnect the 2 clamps.

    2. A002CNM

      Remove the bolt and disconnect the front engine mounting insulator assembly.

    3. A0029ZN

      Remove the nut and disconnect the engine mounting insulator LH.

    4. A002AB0

      Remove the nut and disconnect the engine mounting insulator RH.

    5. A002CEK

      Remove the 2 bolts and disconnect the rear engine mounting insulator assembly.

    6. Remove the front frame assembly.

  73. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

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


    1. A00293Z

      Remove the hole plug from the front frame assembly.

    2. A0027WP

      Remove the 3 nuts and front engine mounting insulator assembly.

  74. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B003Z7K

      Remove the 2 hole plugs from the front frame assembly.

    2. A0027NN

      Remove the 3 nuts and engine mounting insulator LH.

  75. REMOVE ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. B003Z2Z

      Remove the 2 hole plugs from the front frame assembly.

    2. A002B6V

      Remove the 3 nuts and engine mounting insulator RH.

  76. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

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


    1. B004060

      Remove the 2 hole plugs from the front frame assembly.

    2. A00291Z

      Remove the 2 nuts and rear engine mounting insulator assembly.

  77. REMOVE MANIFOLD STAY

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  78. REMOVE ENGINE WIRE


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

  79. REMOVE RADIATOR PIPE CLAMP (for 2WD)

    Click here

  80. REMOVE RADIATOR PIPE CLAMP (for AWD)

    Click here

  81. REMOVE TRANSFER STIFFENER PLATE RH (for AWD)

    Click here

  82. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)

    Click here

  83. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD)

    Click here

  84. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  85. 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 hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

  86. REMOVE ENGINE HANGERS


    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.