ENGINE ASSEMBLY REMOVAL

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.


  1. REMOVE ENGINE ROOM SIDE COVER


    1. A01FGMK

      Remove the 4 clips and engine room side cover.

  2. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A01FGF0

      Remove the 7 clips and cool air intake duct seal.

  3. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A01FIO6E01

      Place one hand on the rear of the cover as shown in the illustration and detach the clip near the rear. Then, place both hands on the sides of the cover and lift the cover to detach the 2 clips near the front in the order shown in the illustration to remove the cover.

      Text in Illustration
      A01FE8R Areas to place hands when lifting cover

      Note

      If the cover is lifted rearward or forward and to the right or left at the same time, the cover maybe damaged.

  4. DISCHARGE REFRIGERANT FROM REFRIGERATION 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.

  5. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  7. 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.

  8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

  9. REMOVE FRONT WHEEL

  10. REMOVE ENGINE UNDER COVER


    1. A01FF39

      Remove the 13 screws, 3 clips and engine under cover.

  11. REMOVE REAR ENGINE UNDER COVER LH


    1. A01FH08

      Remove the screw and rear engine under cover LH.

  12. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  13. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. A01FGRB

      Remove the 4 bolts, and then turn the clip and remove the front suspension member brace.

      Tech Tips

      Do not remove the clip from the front suspension member brace.

  14. REMOVE NO. 2 ENGINE UNDER COVER


    1. A01FGRO

      Remove the 4 screws, 2 grommets and No. 2 engine under cover.

  15. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the drain plug and gasket.

    3. Install a new gasket and the drain plug.

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

  16. DRAIN ENGINE COOLANT


    1. Loosen the radiator drain cock plug and drain the coolant.

      A01FIVGE02
      Text in Illustration
      *1 Radiator Cap *2 Radiator Drain Cock Plug
      *3 Cylinder Block Drain Cock Plug *4 Radiator Reservoir Tank

      CAUTION:

      Do not remove the radiator cap, cylinder block drain cock plugs and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

      Tech Tips

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

    2. Remove the radiator cap.

    3. Loosen the 2 cylinder block drain cock plugs.

  17. DRAIN AUTOMATIC TRANSMISSION FLUID


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

    2. Install a new gasket and the drain plug.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  18. REMOVE NO. 1 AIR CLEANER INLET


    1. A01FHG8

      Remove the bolt and No. 1 air cleaner inlet.

  19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE


    1. A01FEMK

      Disconnect the mass air flow meter connector.

    2. Disconnect the clamp from the air cleaner.

    3. A01FDGM

      Disconnect the VSV hose.

    4. A01FDVX

      for RHD:

      Disconnect the union to check valve hose.

    5. A01FF3K

      Disconnect the 4 clamps.

    6. Remove the hose clamp and air cleaner cap with air cleaner hose.

  20. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01FH2S

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

      Note

      When removing the air cleaner case sub-assembly, be careful not to lose the grommet on the underside of the air cleaner case.

  22. DISCONNECT UNION TO CHECK VALVE HOSE


    1. A01FG52E01
      Text in Illustration
      *A for LHD
      *B for RHD

      Slide the clip and disconnect the union to check valve hose.

  23. DISCONNECT PURGE LINE HOSE


    1. A01FGWH

      Slide the clip and disconnect the purge line hose.

  24. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01FH5Z

      Slide the clamp and disconnect the No. 1 radiator hose.

  25. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01FHKX

      Disconnect the No. 2 radiator hose from the water inlet with thermostat sub-assembly.

  26. DISCONNECT RADIATOR RESERVOIR TANK HOSE


    1. A01FFLZ

      Slide the clamp and disconnect the radiator reservoir tank hose.

  27. DISCONNECT INLET HEATER WATER HOSE


    1. A01FI1Y

      Slide the clip and disconnect the inlet heater water hose.

  28. DISCONNECT OUTLET HEATER WATER HOSE


    1. A01FHQD

      Slide the clip and disconnect the outlet heater water hose.

  29. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    A01FIQH

    1. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the cooler compressor assembly.

    2. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

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

  30. DISCONNECT SUCTION HOSE

    A01FFPG

    1. Remove the bolt and disconnect the suction hose from the cooler compressor assembly.

    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.

  31. REMOVE ECM COVER


    1. A01FHIK

      Remove the 3 bolts and ECM cover.

      Note


      • Remove all water on and around the ECM cover.

      • Perform the inspection indoors to avoid rain.

      • Be sure to prevent water intrusion to the ECM (connectors and screw parts).

  32. DISCONNECT ENGINE WIRE (for LHD)


    1. Engine Room LH Side:


      1. A01FH7Q

        Disconnect the wire harness clamp and engine wire from the ECM box Click here.

    2. Engine Room RH Side:


      1. A01FIO0

        Remove the nut and disconnect the No. 2 engine wire and engine room main wire from the positive (+) battery terminal.

      2. Disconnect the clamp.

      3. Remove the No. 1 engine room relay block cover.

      4. A01FI9Q

        Remove the nut and disconnect the No. 4 engine wire from the No. 1 engine room junction block.

      5. Disconnect the 2 wire harness clamps.

      6. A01FFR3

        Remove the bolt, clamp and No. 3 engine wire.

  33. DISCONNECT ENGINE WIRE (for RHD)


    1. Engine Room LH Side:


      1. A01FIOV

        Remove the nut and disconnect the No. 2 engine wire and engine room main wire from the positive (+) battery terminal.

      2. Disconnect the clamp.

      3. Remove the No. 1 engine room relay block cover.

      4. A01FFHW

        Remove the nut and disconnect the No. 4 engine wire from the No. 1 engine room junction block.

      5. Disconnect the wire harness clamp.

      6. A01FH7Q

        Disconnect the wire harness clamp and engine wire from the ECM box Click here.

    2. Engine Room RH Side:


      1. A01FFR3

        Remove the bolt, clamp and No. 3 engine wire.

  34. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01FGOI

      Remove the fuel pipe clamp.

    2. A01FDYE

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

  35. DISCONNECT NO. 2 FUEL HOSE


    1. A01FDW5

      Slide the clamp and disconnect the No. 2 fuel hose.

  36. REMOVE NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY


    1. A01FIXV

      Remove the 4 grommets, 7 clips and No. 1 rear floor board sub-assembly.

  37. REMOVE NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY


    1. A01FG9R

      Remove the 4 grommets, 7 clips and No. 2 rear floor board sub-assembly.

  38. REMOVE FRONT CENTER FLOOR BRACE


    1. A01FE0M

      Remove the 6 bolts, 2 nuts, 2 clips and front center floor brace.

  39. DISCONNECT HEATED OXYGEN SENSOR


    1. for Bank 1 Sensor 2:


      1. A01FECSE01
        Text in Illustration
        *1 Grommet

        Disconnect the grommet of the heated oxygen sensor.

      2. A01FENTE01

        Using SST, disconnect the heated oxygen sensor.

        SST
        09224-00010

    2. for Bank 2 Sensor 2:


      1. A01FD99E01
        Text in Illustration
        *1 Grommet

        Disconnect the grommet of the heated oxygen sensor.

      2. A01FGR0E01

        Using SST, disconnect the heated oxygen sensor.

        SST
        09224-00010

  40. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. A01FDFD

      Remove the 4 nuts, 8 bolts, 4 compression springs and front exhaust pipe assembly.

    2. Remove the 4 gaskets.

    3. w/ Protector:

      Tech Tips

      Only perform this procedure when replacement of the front No. 1 exhaust pipe protector is necessary.

      A01FE6G

      1. Remove the bolt and clamp.

      2. Remove the 2 bolts, 2 nuts, exhaust pipe protector stay and front No. 1 exhaust pipe protector.

  41. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. A01FFX1

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

  42. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY


    1. A01FHFX

      Remove the 4 bolts and front center floor brace sub-assembly.

  43. REMOVE NO. 1 FUEL TANK PROTECTOR


    1. A01FIHE

      Remove the 4 nuts and No. 1 fuel tank protector.

  44. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR


    1. A01FFA3

      Remove the 4 nuts and front No. 1 floor heat insulator.

  45. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY


    1. A01FIAAE01
      Text in Illustration
      *a Matchmark

      Put matchmarks on the propeller shaft flange and differential flange.

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

      Tech Tips

      If the flange connection is hard to separate, temporarily install 1 nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.

    3. A01FHEK

      Remove the 2 bolts and 2 washers.

      Tech Tips

      Some vehicles are not equipped with the washers.

    4. Pull out the propeller shaft.

    5. A01FI13E01

      Insert SST in the transmission to prevent oil leakage.

      SST
      09325-40010

      Note

      Be careful not to damage the oil seal.

  46. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY


    1. A01FIYHE01

      Loosen the bolt labeled A, remove the bolt labeled B.

      Note

      Do not remove the bolt labeled A, only loosen it.

    2. A01FHGCJ10
      Text in Illustration
      *a Matchmarks
      *b Slide

      Slide the steering sliding with shaft yoke in the direction of the arrow and place matchmarks.

    3. Disconnect the steering sliding with shaft yoke from the steering link.

  47. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH


    1. A01FF5A

      Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.

      Note

      Support the steering knuckle using a rubber attachment or other similar object to prevent excessive force from being applied to the flexible hose.

  48. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  49. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH


    1. A01FG3W

      Remove the 2 bolts and steering knuckle from the lower ball joint.

  50. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  51. DISCONNECT POWER STEERING LINK WIRE HARNESS


    1. A01FH3HE01

      Disconnect the 2 wire harness clamps from the bracket.

    2. Disconnect the 2 connectors (A) and (B) from the power steering link assembly.

    3. Release the lock of connector (C) and disconnect the connector from the power steering link assembly.

  52. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY


    1. Move the shift lever to N.

    2. A01FEVC

      Remove the nut, and disconnect the floor shift gear shifting rod sub-assembly.

    3. A01FELG

      Remove the clip and pin, and disconnect the floor shift gear shifting rod sub-assembly from the transmission control shaft lever RH.

  53. REMOVE FRONT NO. 2 UPPER SUSPENSION MEMBER


    1. A01FI17

      Remove the 6 bolts and front No. 2 upper suspension member.

  54. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A01FEWR

      Remove the 4 bolts and suspension member protector.

  55. INSTALL ENGINE HANGER


    1. A01FHSN

      Install the 2 No. 1 engine hangers 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 - 31070
      Bolt 91671 - F0822

  56. REMOVE ENGINE AND TRANSMISSION ASSEMBLY


    1. A01FDVG

      Remove the nut and disconnect the wire harness.

    2. A01FDPAE01
      Text in Illustration
      *a Place Wooden Block or Plate Attachments

      Set the engine on an engine lifter.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • 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.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    3. A01FERO

      Remove the 4 bolts, and then separate the rear engine mounting member.

    4. A01FFDI

      Remove the 10 bolts and 2 nuts shown in the illustration.

    5. Operate the engine lifter, then slowly remove the engine from the vehicle.

      Note


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

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

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

      Note

      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.

  57. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01FF1R

      Remove the oil level dipstick.

    2. Remove the bolt and No. 2 oil level dipstick guide.

    3. Remove the O-ring from the No. 2 oil level dipstick guide.

  58. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01FIUP

      Remove the bolt and clamp, then remove the engine oil level dipstick guide.

    2. Remove the bolt, then remove the engine oil level dipstick guide.

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

  59. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH


    1. Remove the engine under cover sub-assembly LH.

  60. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH


    1. Remove the engine under cover sub-assembly RH.

  61. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01FIKJE01
      Text in Illustration
      *a Front

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

  62. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01FEX7E01
      Text in Illustration
      *a Front

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

  63. REMOVE STARTER ASSEMBLY


    1. A01FEL4E03

      Disconnect the starter connector.

    2. Detach the terminal cap.

    3. Remove the nut and disconnect the starter cable.

    4. Remove the 2 bolts and starter.

  64. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. A01FDDW

      Remove the flywheel housing side cover from the engine assembly.

  65. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT


    1. A01FJ22E04

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01FFMX

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

  66. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  67. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY


    1. A01FJ22E03

      Using SST, hold the crankshaft pulley.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A01FHAX

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

  68. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01FDUZE02
      Text in Illustration
      *a LH Side
      *b RH Side

      Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.

  69. INSTALL ENGINE ON ENGINE STAND


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

      Note


      • 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.

      • 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.

    2. Remove the 4 bolts and 2 engine hangers.

  70. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01FIUQE01
      Text in Illustration
      *a LH Side
      *b RH Side

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

  71. REMOVE REAR ENGINE MOUNTING MEMBER


    1. A01FHC6

      Remove the 4 nuts and rear engine mounting member from the rear No. 1 engine mounting insulator.

  72. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01FE0Y

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