ENGINE ASSEMBLY REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


    1. Start the engine.

    2. Turn the A/C switch on.

    3. Operate the cooler compressor while the engine speed is approximately 1000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.

    4. Stop the engine.

    5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice 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. REMOVE HOOD SUB-ASSEMBLY


    1. A015AM6

      Remove the 2 hood support bolts and disconnect the hood supports.

    2. Remove the 4 bolts and hood.

  6. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. A01588F

      Remove the 3 bolts and screw.

    2. Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly LH.

  8. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. A0159SG

      Remove the 3 bolts and 2 screws.

    2. Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly RH.

  9. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover.

  10. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 2 bolts and No. 2 engine under cover.

  11. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 7 clips and radiator support seal.

      A015BVKE02

  12. REMOVE RADIATOR GRILLE


    1. A0157G3E01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the radiator grille assembly.

    2. Remove the 3 screws.

    3. Detach the 2 clips and 8 claws, and remove the radiator grille assembly.

    4. w/ Wide View Front Monitor System:


      1. Disconnect the connector.

  13. REMOVE FRONT BUMPER COVER


  14. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    A01554XE01
    Text in Illustration
    *1 Radiator Reservoir *2 Radiator Cap
    *3 Radiator Drain Cock Plug *4 Cylinder Block Water Drain Cock Plug
    *a for Type A *b for Type B

    1. for Type A:

      Loosen the radiator drain cock plug and 2 cylinder block water drain cock plugs.

    2. for Type B:

      Loosen the radiator drain cock plug and cylinder block water drain cock plug.

    3. Remove the radiator cap. Then drain the coolant.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    4. for Type A:

      Tighten the 2 cylinder block water drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    5. for Type B:

      Tighten the cylinder block water drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    6. Tighten the radiator drain cock plug by hand.

  15. REMOVE V-BANK COVER


    1. A0159TNE01
      Text in Illustration
      *1 Pin
      *2 Hook

      Raise the front of the V-bank cover to detach the 2 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

  16. REMOVE TRANSMISSION OIL COOLER AIR DUCT (w/ Air Cooled Transmission Oil Cooler)


    1. A0156YA

      Remove the 4 bolts and oil cooler air duct.

  17. REMOVE RADIATOR SIDE DEFLECTOR RH (w/o Air Cooled Transmission Oil Cooler)


    1. A015DCW

      Using a clip remover, remove the 4 clips and move the side deflector so that the radiator can be removed in a later step.

  18. REMOVE RADIATOR SIDE DEFLECTOR LH


    1. A015D00

      Using a clip remover, remove the 4 clips and move the side deflector so that the radiator can be removed in a later step.

  19. REMOVE NO. 1 RADIATOR HOSE

  20. REMOVE NO. 2 RADIATOR HOSE


    1. A015907

      Detach the clamp and remove the No. 2 radiator hose.

  21. DISCONNECT OIL COOLER TUBE (w/ Air Cooled Transmission Oil Cooler)


    1. A015B72

      Detach the claw to open the flexible hose clamp, and then remove the 2 bolts to disconnect the oil cooler tube from the fan shroud.

  22. REMOVE FAN SHROUD


    1. Loosen the 4 nuts holding the fluid coupling fan.

    2. Remove the fan and generator V-belt Click here.

    3. A0158CS

      Disconnect the reservoir hose from the upper side of the radiator tank.

    4. Remove the 2 bolts holding the fan shroud.

    5. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    6. Remove the fan pulley from the water pump.

  23. DISCONNECT INLET OIL COOLER HOSE (for Automatic Transmission)


    1. A01557V

      Disconnect the oil cooler hose.

  24. DISCONNECT OUTLET OIL COOLER HOSE (for Automatic Transmission)


    1. Disconnect the oil cooler hose.

  25. REMOVE RADIATOR ASSEMBLY


    1. A01585J

      Remove the 4 bolts and radiator.

  26. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the 2 bolts and No. 2 engine under cover seal.

    3. Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

    4. Install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    5. Install the No. 2 engine under cover seal with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  27. REMOVE AIR CLEANER CAP AND HOSE


    1. A0159Q2

      Remove the air cleaner cap and hose.


      1. Disconnect the mass air flow meter connector, vacuum hose and ventilation hose and detach the clamp.

      2. Loosen the clamp.

      3. Unfasten the 4 hook clamps, and then remove the bolt and the air cleaner cap and hose.

  28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. Remove the air cleaner filter element.

    2. A015DSS

      Remove the 3 bolts and air cleaner case.

  29. REMOVE AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)


    1. A015D4X

      Disconnect the No. 3 air hose.

    2. A0155QA

      for Bank 1 Side:

      Remove the bolt and disconnect the air tube assembly from the emission control valve set.

    3. A0159YF

      for Bank 2 Side:

      Remove the 2 bolts and disconnect the air tube assembly from the No. 2 emission control valve set.

  30. REMOVE INTAKE AIR SURGE TANK


    1. A01566J

      Disconnect the throttle body connector.

    2. Disconnect the No. 4 water by-pass hose.

    3. Disconnect the No. 5 water by-pass hose.

    4. A0159CO

      Disconnect the purge line hose.

    5. Disconnect the No. 1 vacuum switching valve connector.

    6. Disconnect the No. 1 PCV hose.

    7. A015AZX

      Remove the 2 bolts and throttle body bracket.

    8. A01571A

      Detach the 2 wire harness clamps and remove the bolt and bracket.

    9. A015972

      Detach the wire harness clamp.

    10. A0156DO

      Remove the 2 bolts and No. 1 surge tank stay.

    11. A015BXZ

      for Manual Transmission:

      Remove the nut and disconnect the clutch flexible hose bracket.

    12. A0157OA

      Remove the 2 bolts and No. 2 surge tank stay.

    13. A0157O8

      Remove the 2 nuts, 4 bolts and intake air surge tank.

    14. Remove the gasket.

  31. DISCONNECT ENGINE WIRE


    1. Remove the junction block cover.

    2. A015BSF

      Disconnect the ECM connector Click here.

    3. Detach the wire harness clamp.

    4. Disconnect the 4 connectors from the junction block.

    5. Remove the engine room relay block cover.

    6. A015704

      Remove the bolt and disconnect the ground wire from the bracket.

    7. w/ Secondary Air Injection System:

      Disconnect the 2 air injection control driver connectors and detach the clamp.

    8. Disconnect the 2 connectors and 2 clips from the engine room junction block.

    9. Remove the nut and disconnect the wire and 2 clips from the engine room junction block.

    10. Remove the nut and disconnect the wire from the positive (+) battery cable.

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

    12. Remove the bolt and detach the wire harness clamp, and then disconnect the ground wire from the body.

    13. A0158UB

      Disconnect the connector and detach the 2 clamps.

    14. A015DSI

      w/ Winch:

      Remove the 2 bolts and winch ground wire.

    15. A0156YV

      Disconnect the power steering switch connector and detach the clamp.

    16. A0159CG

      w/ Secondary Air Injection System:

      Disconnect the air pump connector and detach the clamp.

  32. REMOVE HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)


    1. A01582IE01

      Disconnect the sensor connector.

    2. A0157CKE01

      Using SST, remove the sensor.

      SST
      09224-00010

  33. REMOVE TAILPIPE ASSEMBLY


    1. Remove the bolt, clamp and gasket.

    2. Remove the tailpipe from the 2 exhaust pipe supports.

  34. REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. Remove the 4 bolts and 2 compression springs.

    2. Remove the center exhaust pipe from the 3 exhaust pipe supports.

    3. Remove the 2 gaskets from the front exhaust pipe and front No. 2 exhaust pipe.

  35. REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY


    1. Disconnect the heated oxygen sensor connector.

    2. Remove the 2 nuts and front exhaust pipe.

    3. Remove the gasket from the front exhaust pipe.

  36. REMOVE HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)


    1. A015DWXE01

      Using SST, remove the sensor.

      SST
      09224-00010

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Disconnect the heated oxygen sensor connector.

    2. Remove the 2 nuts and front exhaust pipe.

    3. Remove the gasket from the front exhaust pipe.

  38. REMOVE FRONT FENDER APRON TRIM PACKING A


    1. A015AN4

      Remove the 3 clips and front fender apron trim packing A.

  39. REMOVE FRONT FENDER APRON TRIM PACKING B


    1. A015CC0

      w/ KDSS:

      Remove the 3 clips and front fender apron trim packing B.

    2. A015BDJ

      w/o KDSS:

      Remove the 4 clips and front fender apron trim packing B.

  40. REMOVE FRONT FENDER APRON TRIM PACKING C


    1. A015D4I

      Remove the 4 clips and front fender apron trim packing C.

  41. REMOVE FRONT FENDER APRON TRIM PACKING D


    1. A0155AV

      Remove the 4 clips and front fender apron trim packing D.

  42. REMOVE MANIFOLD STAY


    1. A015A0B

      Remove the 3 bolts and manifold stay.

  43. REMOVE AIR TUBE (w/ Secondary Air Injection System)


    1. A015BGZ

      Remove the 2 bolts, 2 nuts and air tube.

    2. Remove the 2 gaskets.

      Note

      Be careful not to damage the installation surface of the gaskets.

  44. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT


    • for Manual Tilt and Manual Telescopic Steering Column: Click here

    • for Power Tilt and Power Telescopic Steering Column: Click here

  45. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015BZC

      Remove the 3 bolts and heat insulator.

  46. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A015B0ZE01
      Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

      Disconnect the air fuel ratio sensor connector.

    2. Remove the 6 nuts, exhaust manifold sub-assembly RH and gasket.

  47. REMOVE NO. 2 MANIFOLD STAY


    1. A0157CN

      Remove the 3 bolts and No. 2 manifold stay.

  48. REMOVE NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A015D72

      Remove the 2 bolts, 2 nuts and No. 2 air tube.

    2. Remove the 2 gaskets.

      Note

      Be careful not to damage the installation surface of the gaskets.

  49. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015B2D

      Remove the 3 bolts and heat insulator.

  50. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A0156P3E01
      Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

      Disconnect the air fuel ratio sensor connector.

    2. Remove the 6 nuts, exhaust manifold sub-assembly LH and gasket.

  51. DISCONNECT WATER HOSE SUB-ASSEMBLY


    1. A0156A7E01
      Text in Illustration
      *A w/o Rear Heater
      *B w/ Rear Heater

      Disconnect the water hoses.

  52. DISCONNECT VANE PUMP ASSEMBLY


    1. A015904

      Disconnect the connector.

    2. Detach the wire harness clamp.

    3. A015A9Q

      Remove the 2 bolts and disconnect the vane pump.

  53. REMOVE GENERATOR ASSEMBLY


    1. A015C5L

      Disconnect the generator connector.

    2. Open the terminal cap.

    3. Remove the nut and disconnect the generator wire from terminal B.

    4. Remove the bolt and disconnect the wire harness clamp bracket.

    5. A015AA8

      Remove the bolt and disconnect the generator bracket.

    6. A0159AY

      Remove the 2 bolts and generator.

    7. A015BB0

      Remove the bolt and generator bracket.

  54. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. A015C1F

      Remove the bolt and disconnect the discharge hose from the cooler compressor.

    2. Remove the O-ring from the discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  55. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A01564I

      Remove the 2 bolts and disconnect the suction hose from the cooler compressor.

    2. Remove the O-ring from the suction hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  56. REMOVE COOLER COMPRESSOR ASSEMBLY


    1. A015DKA

      Disconnect the connector.

    2. Remove the 3 bolts and cooler compressor.

  57. DISCONNECT NO. 1 AND NO. 2 FUEL PIPES


    1. A015BCU

      Disconnect the No. 1 and No. 2 fuel pipes Click here.

  58. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    Click here

  59. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  60. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator is necessary.


    1. A015CRB

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

  61. DISCONNECT NO. 1 OIL COOLER HOSE TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A01566S

      Remove the 2 bolts and cooler hose tube.

  62. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    A0156YYE01

    1. Put matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts, and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  63. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note

    Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

  64. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. A015BDZE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A015CX6

      Remove the 8 bolts and flywheel.

      Note

      Do not reuse the bolts.

  65. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. A015BDZE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A0157VC

      Remove the 8 bolts, rear spacer, drive plate and front spacer.

      Note

      Do not reuse the bolts.

  66. INSTALL ENGINE HANGER


    1. A0156PZE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install 2 engine hangers with 4 bolts as shown in the illustration.

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

      Tech Tips

      No. 1 Engine Hanger 12281-31110
      No. 2 Engine Hanger 12282-31140
      Bolt 91671-C0830

  67. REMOVE ENGINE ASSEMBLY


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

    2. A015DOG

      Remove the 2 nuts and 4 bolts from the front engine mounting insulator LH and RH.

    3. Lift the engine out of the vehicle carefully.

      Note


      • Make sure the engine is clear of all wiring and hoses.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • 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.

    4. Remove the front engine mounting insulator LH and RH.

    5. Place the engine onto a work bench.

  68. INSTALL ENGINE STAND


    1. Install the engine onto an engine stand with bolts.

    2. Remove the 4 bolts and 2 engine hangers.

  69. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. Remove the bolt and front No. 2 engine mounting bracket LH.