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ENGINE ASSEMBLY REMOVAL

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  1. Click here

    DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:

    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.

    • After discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.


    1. Disconnect the fuel pump ECU connector (Click here).

    2. Start the engine. After the engine stops, turn the engine switch off.

      Tip:

      DTC P0171/0174 (system too lean) may be stored.

    3. Crank the engine again, and then check that the engine does not start.

    4. Loosen the fuel tank cap, and then discharge the pressure in the fuel tank completely.

    5. Disconnect the cable from the negative (-) battery terminal.

      Note:

      • After turning the engine 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).

      • When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

    6. Connect the fuel pump ECU connector (Click here).

  2. Click here

    PRECAUTION

    Note:

    After turning the engine 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).

  3. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  4. Click here

    REMOVE FRONT BUMPER COVER


  5. Click here

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


    1. A0156YA

      Remove the 4 bolts and oil cooler air duct.

  6. Click here

    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.

  7. Click here

    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.

  8. Click here

    REMOVE HOOD SUB-ASSEMBLY


    1. A015ABJ

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

      CAUTION:

      Remove the hood support assembly while supporting the hood by hand.

    2. Remove the 4 bolts and hood.

  9. Click here

    REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    (Click here)

  10. Click here

    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.

  11. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING D


    1. A0155AV

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

  12. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING A


    1. A015AN4

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

  13. Click here

    REMOVE FRONT FENDER APRON TRIM PACKING C


    1. A015D4I

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

  14. Click here

    REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. A0157XJ

      Remove the 10 bolts and No. 1 engine under cover sub-assembly.

  15. Click here

    REMOVE NO. 2 ENGINE UNDER COVER


    1. A015A78

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

  16. Click here

    REMOVE OIL PAN PROTECTOR ASSEMBLY


    1. A015AER

      Remove the 4 bolts and oil pan protector assembly.

  17. Click here

    REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A0158H7E01

      Raise the front of the V-bank cover to detach the 3 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

      Table 1. Text in Illustration
      *1 Grommet
      *2 Pin
      *3 Hook
      *4 Bracket
  18. Click here

    DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. A0159J6

      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.

      40 N*m 408 kgf*cm 30 ft.*lbf

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

      10 N*m 102 kgf*cm 7 ft.*lbf
  19. Click here

    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.


    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap and drain the coolant.

      Tip:

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

    3. Loosen the 2 cylinder block drain cock plugs and drain the coolant from the engine.

    4. Tighten the 2 cylinder block drain cock plugs.

      13 N*m 130 kgf*cm 9 ft.*lbf
    5. A015AEQE01

      Tighten the radiator drain cock plug by hand.

      Table 2. Text in Illustration
      *1 Reservoir Cap *2 Radiator Cap
      *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug
  20. Click here

    DRAIN AUTOMATIC TRANSMISSION FLUID


    1. Remove the drain plug and gasket, and drain the ATF.

    2. Install a new gasket and the drain plug.

      20 N*m 204 kgf*cm 15 ft.*lbf
  21. Click here

    REMOVE BATTERY


    1. Remove the bolt and loosen the nut.

    2. Detach the hook of the battery clamp from the battery bracket, and then remove the battery clamp.

    3. Remove the battery.

  22. Click here

    REMOVE AIR CLEANER AND HOSE


    1. A0159Z0

      Disconnect the No. 2 PCV hose and No. 1 air hose.

    2. Disconnect the mass air flow meter connector and detach the clamp.

    3. Remove the 3 bolts and loosen the hose clamp, and then remove the air cleaner and hose.

  23. Click here

    REMOVE NO. 1 RADIATOR HOSE


    1. A015D8T

      Remove the No. 1 radiator hose.

  24. Click here

    REMOVE FAN SHROUD


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

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

    3. A0157LN

      Disconnect the reservoir hose from the upper radiator tank.

    4. w/ Air Cooled Transmission Oil Cooler:

      Detach the claw to open the flexible hose clamp.

    5. Remove the 2 bolts and disconnect the oil cooler tube from the fan shroud.

    6. Remove the 2 bolts holding the fan shroud.

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

      Note:

      Be careful not to damage the radiator core.

    8. Remove the fan pulley from the engine water pump.

  25. Click here

    REMOVE NO. 2 RADIATOR HOSE


    1. A0158YI

      Remove the No. 2 radiator hose.

  26. Click here

    REMOVE RADIATOR ASSEMBLY


    1. A0159M7

      Remove the 4 bolts and radiator.

  27. Click here

    DISCONNECT NO. 3 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)


    1. A0159DA

      Disconnect the No. 3 air injection system hose from the air tube sub-assembly.

  28. Click here

    REMOVE NO. 5 WATER BY-PASS PIPE


    1. A015C9F

      Disconnect the 2 water by-pass hoses and remove the 2 bolts and No. 5 water by-pass pipe.

  29. Click here

    REMOVE EGR VALVE BRACKET


    1. A015878

      Detach the 2 wire harness clamps and PCV hose clamp.

    2. Remove the 3 bolts and EGR valve bracket.

  30. Click here

    REMOVE PCV HOSE ASSEMBLY


    1. A0157B6

      Disconnect the PCV hose from the PCV pipe of the cylinder head cover LH and RH.

    2. Remove the bolt and PCV hose.

  31. Click here

    REMOVE AIR TUBE SUB-ASSEMBLY (w/ Secondary Air Injection System)


    1. A0157J8

      Disconnect the No. 2 air injection system hose from the air switching valve.

    2. A0157HJ

      Disconnect the manifold absolute pressure sensor connector and detach the clamp.

    3. Remove the 2 bolts and bracket.

    4. A01561L

      Remove the bolt and air tube.

  32. Click here

    REMOVE INTAKE MANIFOLD


    1. w/o Secondary Air Injection System:


      1. A0155IQ

        Disconnect the manifold absolute pressure sensor connector and detach the clamp.

      2. Remove the 2 bolts and bracket.

    2. A015BVJ

      Disconnect the No. 4 water by-pass hose.

    3. Disconnect the throttle position sensor and throttle control motor connector.

    4. Disconnect the PCV valve hose.

    5. A015AH1

      Disconnect the purge VSV connector.

    6. Disconnect the purge line hose from the purge VSV.

    7. Disconnect the vacuum switching valve connector (for ACIS).

    8. A015DDM

      Remove the bolt.

    9. Detach the 3 wire harness clamps from the 3 wire harness brackets.

    10. A015BTH

      Disconnect the fuel tube from the fuel delivery pipe (Click here).

    11. A015CID

      Disconnect the fuel tube from the No. 2 fuel delivery pipe (Click here).

    12. A0159NP

      Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets.

      Table 3. Text in Illustration
      A015DIT Bolt
      A015CC1 Nut
  33. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0156O2

      Remove the engine oil level dipstick.

    2. Detach the engine wire clamp.

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

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

  34. Click here

    DISCONNECT SUCTION HOSE


    1. A015C28

      Slide the clip and disconnect the suction hose from the vane pump.

  35. Click here

    DISCONNECT PRESSURE FEED TUBE


    1. A0155AEE03

      Remove the bolt and disconnect the pressure feed tube.

      Table 4. Text in Illustration
      *1 Pressure Feed Tube

    2. Remove the gasket.

  36. Click here

    REMOVE VANE PUMP ASSEMBLY


    1. A0158UP

      Remove the 2 bolts and vane pump.

  37. Click here

    REMOVE GENERATOR ASSEMBLY


  38. Click here

    DISCONNECT COOLER COMPRESSOR ASSEMBLY


    1. A0158V3

      Remove the 3 bolts, nut and stud bolt, and then disconnect the cooler compressor.

      Tip:

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  39. Click here

    REMOVE PROPELLER SHAFT HEAT INSULATOR


    1. A0156MYE01

      Remove the 2 bolts and insulator.

  40. Click here

    DISCONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)


    1. A015DBE

      Disconnect the heated oxygen sensor connector.

    2. A0159SJE01

      Using SST, remove the heated oxygen sensor from the front No. 2 exhaust pipe.

      09224-00010
  41. Click here

    DISCONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)


    1. A015ANS

      Detach the clamp and disconnect the heated oxygen sensor connector.

    2. A015BLME01

      Using SST, remove the heated oxygen sensor from the front exhaust pipe.

      09224-00010
  42. Click here

    REMOVE TAILPIPE ASSEMBLY


    1. A015A6R

      Remove the bolt and exhaust tailpipe clamp.

    2. Remove the 2 exhaust pipe supports, gasket and tailpipe.

  43. Click here

    REMOVE CENTER EXHAUST PIPE ASSEMBLY


    1. Remove the 4 bolts and disconnect the center exhaust pipe.

    2. Remove the 3 exhaust pipe supports, 2 gaskets and center exhaust pipe.

  44. Click here

    REMOVE FRONT NO. 2 EXHAUST PIPE ASSEMBLY


    1. A0159VB

      Remove the 2 nuts and front No. 2 exhaust pipe.

    2. Remove the gasket.

  45. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A015CGH

      Remove the 2 nuts and front exhaust pipe.

    2. Remove the gasket.

  46. Click here

    REMOVE NO. 2 MANIFOLD STAY


    1. A0159NE

      Remove the 3 bolts and No. 2 manifold stay.

  47. Click here

    REMOVE MANIFOLD STAY


    1. A015C7Z

      Remove the 3 bolts and manifold stay.

  48. Click here

    REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A0158BI

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  49. Click here

    REMOVE EXHAUST MANIFOLD ASSEMBLY LH


    1. A015E59

      Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

    2. A015DP5E01

      w/ Secondary Air Injection System:

      Remove the 9 nuts, exhaust manifold and 2 gaskets.

      Table 5. Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

    3. w/o Secondary Air Injection System:

      Remove the 7 nuts, exhaust manifold and gasket.

  50. Click here

    REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01597T

      Remove the 3 bolts and heat insulator.

  51. Click here

    REMOVE EXHAUST MANIFOLD ASSEMBLY RH


    1. A015ALE

      Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

    2. A015DVWE01

      w/ Secondary Air Injection System:

      Remove the 9 nuts, exhaust manifold and 2 gaskets.

      Table 6. Text in Illustration
      *A w/ Secondary Air Injection System
      *B w/o Secondary Air Injection System

    3. w/o Secondary Air Injection System:

      Remove the 7 nuts, exhaust manifold and 2 gaskets.

  52. Click here

    REMOVE STARTER COVER


    1. A015B9D

      Remove the 3 bolts and starter cover.

  53. Click here

    REMOVE STARTER ASSEMBLY


    1. A0156WV

      Disconnect the starter connector.

    2. Remove the nut and disconnect the starter wire.

    3. A015E65

      Remove the 2 bolts and starter.

    4. A015E7L

      Remove the flywheel housing side cover.

  54. Click here

    DISCONNECT FUEL HOSE AND FUEL TUBE SUB-ASSEMBLY


    1. A015E3L

      Remove the fuel pipe clamp from the fuel tube connector.

    2. Disconnect the fuel hose and fuel tube sub-assembly (Click here).

  55. Click here

    DISCONNECT ENGINE WIRE


    1. A015CXX

      Disconnect the clamp and ECM connector.

      Tip:

      Refer to the following procedures to disconnect the ECM connector (Click here).

    2. A015APD

      Disconnect the 4 connectors and 2 clamps from the connector holder block.

    3. A0158YN

      Remove the bolt and disconnect the ground wire.

    4. A015D6I

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

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

    6. w/ Secondary Air Injection System:

      Disconnect the 2 air injection control driver connectors.

    7. Remove the bolt, disconnect the clamp and ground wire.

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

    9. A015ARC

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

    10. A0157S4

      w/ Secondary Air Injection System:

      Disconnect the connector and clamp.

  56. Click here

    DISCONNECT TRANSMISSION OIL COOLER HOSE


    1. Disconnect the 2 transmission oil cooler hoses from the oil cooler tube unions.

  57. Click here

    REMOVE OIL COOLER TUBE


    1. A0157D6

      Remove the 2 bolts and disconnect the oil cooler tube.

  58. Click here

    REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    (Click here)

  59. Click here

    REMOVE PROPELLER SHAFT ASSEMBLY

    (Click here)

  60. Click here

    REMOVE DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT


    1. A015DEC

      Turn the crankshaft to gain access to the 6 bolts and remove the bolts while holding the crankshaft pulley setting bolt with a wrench.

  61. Click here

    REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    (Click here)

  62. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE (w/ ATF Warmer)


    1. A015859

      w/ Rear Heater:

      Disconnect the 6 water hoses.

    2. A015AL3

      Remove the 2 bolts and No. 1 water by-pass pipe.

    3. A015868

      w/o Rear Heater:

      Disconnect the 4 water hoses.

    4. A0155GR

      Remove the 2 bolts and No. 1 water by-pass pipe.

  63. Click here

    REMOVE NO. 1 WATER BY-PASS PIPE (w/o ATF Warmer)


    1. A01568B

      Disconnect the hose.

    2. Remove the 2 bolts and No. 1 water by-pass pipe.

  64. Click here

    REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. Remove the 2 bolts and engine mounting heat insulator.

    2. Remove the 4 bolts and rear engine No. 1 mounting insulator from the transmission.

  65. Click here

    REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A015ARHE01

      Using SST, hold the crankshaft.

      09213-70011 09213-70020
      09330-00021
    2. A015CMP

      Remove the 10 bolts, the rear drive plate spacer, the drive plate and ring gear, and the crankshaft angle sensor rotor.

  66. Click here

    INSTALL ENGINE HANGER


    1. A01563S

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

      43 N*m 438 kgf*cm 32 ft.*lbf
      Tip:
      Engine Hanger 12281-38150
      Bolt 90119-14120
  67. Click here

    REMOVE ENGINE ASSEMBLY


    1. A015C2EE02

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

      Table 7. Text in Illustration
      *1 Engine Hanger
      *2 Engine
      *a 50° or less
      Note:

      When hanging the engine, make sure to hang the engine with the angle of the sling device at 50° or less. Otherwise, the engine or engine hangers may be damaged.

    2. A015COPE01

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

      Table 8. Text in Illustration
      *A for LH Side
      *B for RH Side

    3. Lift the engine out of the vehicle carefully.

      Note:

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

      • 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 workbench.

  68. Click here

    INSTALL ENGINE STAND


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

    2. Remove the 2 bolts and 2 engine hangers.

  69. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR LH


    1. A0156WK

      Remove the nut and mounting insulator.

  70. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR RH


    1. A015E7A

      Remove the nut and mounting insulator.

  71. Click here

    REMOVE NO. 2 FRONT ENGINE MOUNTING BRACKET LH


    1. A015CC5

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