ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. 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

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  6. SECURE STEERING WHEEL

    Click here

  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. B003ZNR

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

  14. REMOVE FRONT FENDER APRON SEAL RH


    1. B003ZL6

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

  15. DRAIN ENGINE OIL

    Click here

  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

    Click here

  21. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  22. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH

    Click here

  23. REMOVE RADIATOR SIDE SEAL RH

    Click here

  24. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  25. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. B003ZAV

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

    2. Raise the V-bank cover sub-assembly to disengage the 2 front clips and remove the V-bank cover sub-assembly.

      Note

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

  26. REMOVE BATTERY


    1. B003Z52

      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.

  27. REMOVE INLET AIR CLEANER ASSEMBLY


    1. B003ZP6

      Remove the 2 bolts and inlet air cleaner assembly.

  28. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B003Z7Y

      Disconnect the mass air flow meter sub-assembly connector.

    2. Disengage the wire harness clamp.

    3. B003Z04C02
      *1 No. 1 Fuel Vapor Feed Hose
      *2 No. 2 Ventilation Hose

      Disengage the No. 1 fuel vapor feed hose from the air cleaner hose assembly.

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

    5. B003Z7P

      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.

  29. 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.

  30. REMOVE RESERVOIR BRACKET (for LHD)

    Click here

  31. 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.

  32. REMOVE RESERVOIR BRACKET (for RHD)

    Click here

  33. REMOVE AIR CLEANER BRACKET


    1. B003ZQU

      Disengage the clamp.

    2. Remove the 2 bolts and air cleaner bracket from the vehicle body.

  34. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. B003Z5SC01
      B003ZIE Bolt
      B003Z8F Nut

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine mounting insulator sub-assembly RH.

  35. REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. B003ZI0

      Remove the 4 bolts and engine moving control rod bracket with engine moving control rod from the front No. 1 engine mounting bracket LH and vehicle body.

  36. 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.

  37. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Disconnect the purge VSV (purge valve) connector.

    2. B003Z8M

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

  38. DISCONNECT UNION TO CHECK VALVE HOSE


    1. B003ZDUC01
      *A for LHD
      *B for RHD

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

    2. for LHD


      1. Disengage the clamp from the union to check valve hose.

  39. DISCONNECT NO. 1 RADIATOR HOSE


    1. B003ZCC

      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.

  40. DISCONNECT NO. 2 RADIATOR HOSE


    1. B003ZRM

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

  41. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. B003ZY4

      Slide the 2 clips and disconnect the 2 water hose sub-assemblies.

    2. Disengage the clamp from the water hose sub-assembly.

  42. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. B003ZHO

      Slide the clip and disconnect the No. 3 water by-pass hose from the radiator pipe assembly.

  43. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B003Z0B

      Slide the clip and disconnect the No. 4 water by-pass hose from the radiator pipe assembly.

  44. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B003ZDZC02
      *A Fuel Pipe Camp Type A
      *B Fuel Pipe Camp Type B

      Remove the No. 2 fuel pipe clamp from the No. 1 fuel pipe clamp.

    2. B00401EC01
      *A Fuel Pipe Camp Type A
      *B Fuel Pipe Camp Type B

      Remove the No. 1 fuel pipe clamp from the fuel tube connector.

    3. Disconnect the No. 2 fuel tube sub-assembly (for Direct Injection).


      1. B00402S

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

        Click here

    4. Disconnect the fuel tube sub-assembly (for Port Injection).


      1. B003ZER

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

        Click here

  45. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE


    1. B003ZL1

      Slide the clip and disconnect the No. 1 transmission oil cooler hose from the transmission oil thermostat.

  46. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE


    1. B003Z09

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

  47. DISCONNECT TRANSMISSION OIL THERMOSTAT


    1. B003ZMY

      Remove the bolt and disconnect the transmission oil thermostat from the oil cooler stay.

  48. REMOVE STARTER ASSEMBLY

    Click here

  49. DISCONNECT ENGINE WIRE


    1. B003ZX5

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

    2. B00401I

      Remove the bolt and separate the earth wire.

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

    4. Disengage the 2 clamps to disconnect the engine wire.

    5. Disengage the 2 claws to disconnect the engine wire.

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

    7. B003Z4Y

      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 clamps.

    9. B003ZKK

      Remove the bolt and separate the No. 3 earth wire.

    10. B003YWO

      Disengage the clamp and disconnect the engine wire.

    11. Remove the nut and engine room main wire with engine wire from the positive (+) battery terminal.

    12. B003ZNH

      Disengage the 2 claws to disconnect the engine room main wire from the engine wire.

  50. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B003Z3C

      Remove the clip from the transmission control shaft lever as shown in the illustration.

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

    3. B00404L

      Using a screwdriver, disengage the 2 claws and disconnect the clip from the transmission control cable assembly.

    4. B003YZR

      Disengage the transmission control cable assembly from the No. 3 transmission control cable bracket.

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

    Click here

  52. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD)

    Click here

  53. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  54. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

  57. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  58. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. B003Z80

      Remove the 2 nuts and No. 1 exhaust pipe support bracket from the oil pan sub-assembly.

  59. REMOVE EXHAUST MANIFOLD

    Click here

  60. REMOVE FRONT AXLE SHAFT NUT

    Click here

  61. SEPARATE FRONT SPEED SENSOR LH

    Click here

  62. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure as for the LH side.

  63. SEPARATE TIE ROD ASSEMBLY LH

    for 2WD: Click here

    for AWD: Click here

  64. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  65. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  66. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  67. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  68. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  69. SEPARATE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  70. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  71. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)

    Click here

  72. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING (for LH Side)

    Click here

  73. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. B003ZPL

      Remove the 2 bolts and flywheel housing under cover.

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

    Click here

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

    Click here

  76. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Place height adjustment attachments and plate lift attachments, set an engine lifter underneath the engine assembly with transaxle.

      Note


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

      • Do not perform any procedures 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.

      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

    2. B003ZDAC01
      B003ZIE Bolt
      B003Z8F Nut

      Remove the 6 bolts, 2 nuts, frame side rail plate RH and frame side rail plate LH from the front frame assembly and vehicle body.

    3. Remove the 6 bolts, 2 nuts, front suspension member rear brace RH and front suspension member rear brace LH from the front frame assembly and vehicle body.

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

      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.

  77. INSTALL ENGINE HANGERS


    1. B003ZP1C02
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger
      *2 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 12281-31121
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825

    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.

      Note


      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.

      • Do not perform any procedures 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.

  78. REMOVE ENGINE WIRE


    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.

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

    Click here

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

    Tech Tips

    Perform the same procedure as for the LH side.

  81. REMOVE FRONT STABILIZER BAR (for AWD)

    Click here

  82. REMOVE STEERING LINK ASSEMBLY (for AWD)

    Click here

  83. REMOVE FRONT FRAME ASSEMBLY


    1. B003ZFK

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

    2. B003ZC8

      Remove the nut and disconnect the engine mounting insulator LH.

    3. B00401F

      Remove the nut and disconnect the engine mounting insulator RH.

    4. B003ZMLC01
      *A for 2WD
      *B for AWD

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

    5. Remove the front frame assembly.

  84. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for AWD)

    Click here

  85. REMOVE TRANSFER STIFFENER PLATE RH

    Click here

  86. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY

    for 2WD: Click here

    for AWD: Click here

  87. REMOVE ENGINE MOUNTING BRACKET RH


    1. B003ZL7

      Remove the 3 bolts and engine mounting bracket RH from the cylinder block sub-assembly.

  88. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  89. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

  90. REMOVE ENGINE HANGERS


    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and cylinder head LH.

  91. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

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


    1. B003ZX6

      Remove the hole plug from the front frame assembly.

    2. B003Z7E

      Remove the 3 nuts and front engine mounting insulator assembly.

  92. 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. B003YXJ

      Remove the 3 nuts and engine mounting insulator LH.

  93. 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. B003ZPY

      Remove the 3 nuts and engine mounting insulator RH.

  94. 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. B003ZPQC01
      *A for 2WD
      *B for AWD

      Remove the 2 nuts and rear engine mounting insulator assembly.