ENGINE ASSEMBLY REMOVAL


  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM (w/ Air Conditioning System)


    1. Start the engine.

    2. Operate the cooler compressor under the conditions shown below:

      Item Condition
      Engine Speed Idling
      Operating Time 3 minutes or more
      A/C Switch Status On
      Blower Switch Status HI
      Set Temperature MAX COOL

      This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

      Note

      It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock, etc.

    3. Stop the engine.

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

      Tech Tips

      Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

  2. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge the fuel system pressure Click here.

  3. DISCONNECT CABLE FROM 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.

  4. REMOVE HOOD SUB-ASSEMBLY


    1. Disconnect the washer nozzle hose.

    2. A00K1ME

      Remove the 8 bolts and hood.

      Note

      If the hood support is detached from the ball joint, it become non-reusable. Therefore, do not detach the hood support from the ball joint unless replacing it.

  5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


    1. Remove the cowl top ventilator louver Click here.

  6. REMOVE FRONT BUMPER COVER LOWER


    1. Remove the clip, 5 bolts and front bumper cover lower.

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


    1. Remove the 4 bolts.

    2. A00JXIF

      Unhook the engine under cover from the vehicle body as shown in the illustration.

  8. REMOVE TRANSMISSION UNDER COVER


    1. Remove the 2 bolts and transmission under cover.

  9. REMOVE REAR ENGINE UNDER COVER ASSEMBLY


    1. Remove the 4 bolts and rear engine under cover.

  10. REMOVE FRONT FENDER APRON SEAL LH


    1. Remove the 5 clips and front fender apron seal.

  11. REMOVE FRONT FENDER APRON SEAL RH


    1. Remove the 5 clips and front fender apron seal.

  12. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL LH


    1. Remove the 5 clips and front No. 1 fender apron to frame seal.

  13. REMOVE FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Remove the 5 clips and front No. 1 fender apron to frame seal.

  14. REMOVE UPPER RADIATOR SUPPORT SEAL


    1. Remove the 13 clips and upper radiator support seal.

  15. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and drain the engine oil into a container.

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

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

  16. 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.

    A00XEOUE01
    Text in Illustration
    *1 Reservoir Cap *2 Radiator Cap
    *3 Radiator Drain Cock Plug *4 Cylinder Block Drain Cock Plug

    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap and drain the coolant.

      Tech Tips

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

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

  17. DISCONNECT CABLE FROM POSITIVE BATTERY TERMINAL

  18. REMOVE BATTERY HOLD DOWN CLAMP


    1. A00O9H8

      Loosen the 2 nuts and remove the battery hold down clamp.

  19. REMOVE BATTERY

  20. REMOVE BATTERY TRAY

  21. REMOVE V-BANK COVER


    1. A00OAQRE01
      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.

  22. REMOVE FRONT BUMPER COVER


    1. Remove the front bumper cover Click here.

  23. REMOVE AIR CLEANER CAP AND HOSE


    1. A0097JZ

      Remove the air cleaner cap and hose.


      1. Disconnect the mass air flow meter connector, vacuum hose and ventilation hose and detach the 4 clamps.

      2. Loosen the clamp.

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

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. Remove the air cleaner filter element.

    2. A009AWN

      Detach the wire harness clamp.

    3. Remove the 3 bolts and air cleaner case.

  25. REMOVE UPPER FRONT BUMPER RETAINER


    1. A009AXY

      Remove the 3 bolts and retainer.

  26. REMOVE RADIATOR SIDE DEFLECTOR RH


    1. A0097OL

      Using a clip remover, detach the 3 claws and remove the clip. Then move the side deflector so that the radiator can be removed in the step below.

  27. REMOVE RADIATOR SIDE DEFLECTOR LH


    1. A009A5U

      Using a clip remover, detach the 3 claws and remove the clip. Then move the side deflector so that the radiator can be removed in the step below.

  28. REMOVE NO. 1 RADIATOR HOSE

    A00960H

  29. REMOVE NO. 2 RADIATOR HOSE


    1. A0099VX

      Disconnect the radiator hose from the water inlet.

    2. A009BHB

      Detach the clamp and remove the radiator hose.

  30. REMOVE RADIATOR RESERVOIR


    1. A0097EH

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

    2. Remove the 3 bolts and radiator reservoir.

  31. DISCONNECT OIL COOLER TUBE (w/ Warmer)


    1. A0094UA

      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.

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


    1. A00969N

      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.

  33. REMOVE FAN SHROUD


    1. A0099DF

      Loosen the 4 nuts holding the fluid coupling fan.

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

    3. A009BQ0

      Remove the 2 bolts holding the fan shroud.

    4. 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.

    5. Remove the fan pulley from the water pump.

  34. REMOVE RADIATOR ASSEMBLY


    1. A00973KE01
      Text in Illustration
      *A w/ Warmer
      *B w/ Air Cooled Transmission Oil Cooler

      for Automatic Transmission:

      Disconnect the 2 oil cooler hoses.

    2. A0094UO

      Remove the 4 bolts and radiator.

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


    1. A00O3L9

      for Bank 1 Side:

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

    2. A00O7UT

      for Bank 2 Side:

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

  36. REMOVE INTAKE AIR SURGE TANK


    1. A00O8JD

      Disconnect the throttle body connector.

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

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

    4. A00O98Y

      Disconnect the No. 1 fuel vapor feed hose.

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

    6. Disconnect the No. 1 ventilation hose.

    7. A00O2WN

      Detach the 2 heater hose clamps.

    8. A00O441

      Remove the 2 bolts and throttle body bracket.

    9. A00O7DP

      Using a clip remover, detach the wire harness clamp.

    10. A00O8SL

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

    11. A00O452

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

    12. A00O6BF

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

    13. Remove the gasket.

  37. REMOVE FAN AND GENERATOR V BELT


    1. A0097XF

      While turning the belt tensioner counterclockwise, align the service hole for the belt tensioner and the belt tensioner fixing position, and then insert a bar of φ 6 mm (0.236 in.) into the service hole to fix the belt tensioner in place.

      Tech Tips

      The pulley bolt for the belt tensioner has a left-hand thread.

    2. Remove the V belt.

  38. DISCONNECT VANE PUMP ASSEMBLY


    1. A00JYYS

      Disconnect the 2 connectors.

    2. Detach the 2 wire harness clamps.

    3. A00JZXW

      Remove the 2 bolts and disconnect the vane pump.

  39. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A009BX0E02
      Text in Illustration
      *A except Model Code GRJ150L-GKFEKV, GRJ150L-GKAEKV
      *B Model Code GRJ150L-GKFEKV, GRJ150L-GKAEKV

      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.

  40. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A0097WAE02
      Text in Illustration
      *A except Model Code GRJ150L-GKFEKV, GRJ150L-GKAEKV
      *B Model Code GRJ150L-GKFEKV, GRJ150L-GKAEKV

      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.

  41. REMOVE COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. A00962A

      Disconnect the connector.

    2. Remove the 3 bolts, nut and the cooler compressor.

    3. Remove the stud bolt.

  42. REMOVE IDLER PULLEY ASSEMBLY (w/o Air Conditioning System)


    1. Remove the 3 bolts and idler pulley.

  43. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the front exhaust pipe Click here.

  44. REMOVE MANIFOLD STAY


    1. A00KYRM

      Remove the 3 bolts and manifold stay.

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


    1. A009AP7

      Remove the 2 bolts, 2 nuts and air tube.

    2. Remove the 2 gaskets from the air tube.

      Note

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

  46. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (for RHD)


    1. for Manual tilt and manual telescopic steering column:

      Disconnect the No. 2 steering intermediate shaft Click here.

    2. for Power tilt and power telescopic steering column:

      Disconnect the No. 2 steering intermediate shaft Click here.

  47. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A00L0B5

      Remove the 3 bolts and heat insulator.

  48. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A00KTIY

      w/ Secondary Air Injection System:


      1. Disconnect the air fuel ratio sensor connector.

      2. Remove the 6 nuts, manifold and gasket.

    2. A00KTZR

      w/o Secondary Air Injection System:


      1. Disconnect the air fuel ratio sensor connector.

      2. Remove the 6 nuts, manifold and gasket.

  49. REMOVE NO. 2 MANIFOLD STAY


    1. A00KY68

      Remove the 3 bolts and No. 2 manifold stay.

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


    1. A0096DQ

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

    2. Remove the 2 gaskets from the No. 2 air tube.

      Note

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

  51. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A00KWJM

      Remove the 3 bolts and heat insulator.

  52. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A00KU2V

      w/ Secondary Air Injection System:


      1. Disconnect the air fuel ratio sensor connector.

      2. Remove the 6 nuts, manifold and gasket.

    2. A00KYN7

      w/o Secondary Air Injection System:


      1. Disconnect the air fuel ratio sensor connector.

      2. Remove the 6 nuts, manifold and gasket.

  53. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A00O3VY

      Detach the clamp.

    2. Remove the bolt and wiring harness clamp bracket.

  54. REMOVE GENERATOR ASSEMBLY


    1. A00O30W

      Open the terminal cap.

    2. Remove the nut and disconnect the wire harness from terminal B.

    3. Disconnect the generator connector from the generator assembly.

    4. A00O9WK

      Remove the 2 bolts and disconnect the wire harness.

    5. A00O3NO

      Disconnect the wire harness clamp.

    6. Remove the bolt and disconnect the generator bracket.

    7. A00OAUY

      Remove the 2 bolts and generator assembly.

    8. A00O4IN

      Remove the bolt and generator bracket.

  55. REMOVE STARTER ASSEMBLY


    1. A00XEG9

      Remove the bolt and disconnect the ground wire.

    2. Disconnect the starter connector.

    3. Open the terminal cap.

    4. Remove the nut and bolt, and then disconnect the starter wire.

    5. A00XF00

      Remove the 2 bolts and starter assembly.

  56. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)


    1. A00O5IYE01

      Remove the flywheel housing side cover.

    2. A00O68LE01

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

  57. DISCONNECT ENGINE WIRE


    1. A00JZCE

      Remove the bolt and disconnect the connector.

    2. Remove the glove compartment door Click here.

    3. Disconnect the ECM connector.


      1. A00K01FE01
        Text in Illustration
        *A for LHD
        *B for RHD

        Detach the clamp and disconnect the 9 connectors.

      2. A00JTN0E01
        Text in Illustration
        *A for LHD
        *B for RHD

        Detach the grommet from the wire harness support.

      3. A00JUF5E01
        Text in Illustration
        *A for LHD
        *B for RHD

        Detach the 4 claws to remove the wire harness support from the vehicle, and then pull out the ECM connector to remove it from the vehicle.

  58. DISCONNECT HEATER WATER HOSE ASSEMBLY


    1. A00JUMPE01
      Text in Illustration
      *A w/o Rear Heater
      *B w/ Rear Heater

      w/o Rear heater:

      Disconnect the 2 hoses and heater water hose.

    2. w/ Rear heater:

      Disconnect the 4 hoses and heater water hose.

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


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

    2. A00JYQ6

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

  60. REMOVE FRONT PROPELLER SHAFT ASSEMBLY


    1. A00XDITE07
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential.

    2. Remove the 4 nuts, 4 bolts, 4 washers and front propeller shaft assembly.

    3. A00XGE4E10
      Text in Illustration
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    4. Remove the 4 nuts, 4 washers and front propeller shaft assembly.

  61. REMOVE PROPELLER SHAFT ASSEMBLY


    1. A00XDCAE01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and transfer flange.

    2. Remove the 4 nuts and 4 washers.

    3. A00XGPFE01
      Text in Illustration
      *A for 3 Door
      *B for 5 Door
      *a Matchmark

      Place matchmarks on the propeller shaft flange and differential flange.

    4. Remove the 4 nuts, 4 bolts and 4 washers.

    5. Remove the propeller shaft.

  62. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. Remove the manual transmission from the vehicle Click here.

  63. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. Remove the automatic transmission from the vehicle Click here.

  64. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for Automatic Transmission)

    A00O50Q

    1. Remove the bolt and rear engine mounting heat insulator.

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

  65. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR (for Manual Transmission)


    1. A00O5XK

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

  66. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (for Automatic Transmission)


    1. A00K1TR

      Remove the bolt and disconnect the suction hose.

  67. DISCONNECT OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transmission)


    1. A00JWL2E01
      Text in Illustration
      *A w/o Air Cooled Transmission Oil Cooler
      *B w/ Air Cooled Transmission Oil Cooler

      Remove the bolt and disconnect the oil cooler tube.

  68. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)


    1. A009ASUE01
      Text in Illustration
      *a Matchmark

      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.

  69. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Note

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

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


    1. A00K0X2E01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00JW8Q

      Remove the 8 bolts and flywheel.

      Note

      Do not reuse the bolts.

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


    1. A00K0X2E01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A00JZJZ

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

  72. REMOVE ENGINE ASSEMBLY


    1. A00JVE9E01
      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

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

    3. A00JUB3

      Remove the 6 nuts from the front engine mounting insulator LH and RH.

    4. Lift the engine out of the vehicle carefully.

      Note

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

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

    6. Place the engine onto a work bench.

  73. INSTALL ENGINE STAND


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