ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. SET HOOD SUB-ASSEMBLY

    A004I60E04

    1. Change the front hood stay position from A to B, and support the hood sub-assembly at position B.

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


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Click here

  5. REMOVE FRONT SUSPENSION UPPER TO COWL BRACE SUB-ASSEMBLY LH

    Click here

  6. REMOVE FRONT SUSPENSION UPPER TO COWL BRACE SUB-ASSEMBLY RH

    Click here

  7. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE


    1. A004H1D

      Disconnect the hose.

    2. A004IES

      Remove the 2 bolts and disconnect the chamber.

    3. A004HHK

      Loosen the hose clamp and disconnect the No. 2 ventilation hose.

    4. A004HO0

      Disconnect the mass air flow meter connector.

    5. Disengage the clamp and separate the wire harness from the air cleaner cap.

    6. A004JGL

      Loosen the hose clamp.

    7. A004ID8

      Remove the 3 bolts and air cleaner cap with air cleaner hose.

    8. A004I6K

      Remove the bolt and stay from the body.

  8. DRAIN ENGINE OIL

    Click here

  9. DRAIN ENGINE COOLANT

    Click here

  10. REMOVE RADIATOR RESERVE TANK ASSEMBLY

    Click here

  11. REMOVE WATER FILLER SUB-ASSEMBLY

    A004HJV

    1. Remove the 2 bolts and disconnect the water filler sub-assembly.

    2. Remove the 2 clamps and water filler sub-assembly.

  12. REMOVE INJECTOR DRIVER

    Click here

  13. DISCONNECT ENGINE WIRE (for RHD)

    Tech Tips

    Fix the disconnected harness components with tape to keep them out of the way.


    1. for Automatic Transmission:


      1. A004KO4E03

        Release the lock of connector (A) and disconnect the connector.

      2. Disconnect the connector (B).

      3. Disconnect the 2 wire harness clamps.

      4. A004IYL

        Slide the connector in the direction shown in the illustration, and disconnect the wire harness.

    2. A004K4IE01

      Remove the 2 bolts and the wire harness bracket from the No. 2 engine hanger.

    3. Release the lock of connector (A) and disconnect the connector.

    4. Disconnect the connector (B).

    5. A004J2L

      Disconnect the wire harness clamp and wire harness from the No. 2 engine hanger.

    6. A004KXC

      Disconnect the 2 wire harness clamps.

    7. Remove the 2 bolts and 2 wire harness clamp brackets.

    8. A004HJW

      Disconnect the 5 wire harness clamps.

    9. A004KNO

      Disconnect the terminal cap.

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

    11. Disconnect the generator connector and disengage the clamp.

  14. DISCONNECT ENGINE WIRE (for LHD)

    Tech Tips

    Fix the disconnected harness components with tape to keep them out of the way.


    1. A004K4IE01

      Remove the 2 bolts and the wire harness clamp bracket from the No. 2 engine hanger.

    2. Release the lock of connector (A) and disconnect the connector.

    3. Disconnect the connector (B).

    4. A004JES

      Disconnect the connector.

    5. A004J2L

      Disconnect the wire harness clamp and wire harness from the No. 2 engine hanger.

    6. A004IJO

      Disconnect the 3 wire harness clamps.

    7. for Automatic Transmission:


      1. A004JLQE03

        Release the lock of connector (A) and disconnect the connector.

      2. Disconnect the connector (B).

      3. A004HOA

        Slide the connector in the direction shown in the illustration, and disconnect the wire harness.

      4. A004IVF

        Disconnect the 4 wire harness clamps.

      5. Remove the bolt and wire harness clamp bracket.

    8. A004KNO

      Disconnect the terminal cap.

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

    10. Disconnect the generator connector and disengage the clamp.

  15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    for Resin Intake Manifold:

    Click here

  16. DISCONNECT VACUUM TUBE CONNECTOR HOSE (for Automatic Transmission)


    1. for LHD:


      1. A004JD6

        Loosen the hose clamp and disconnect the vacuum tube connector hose.

      2. A004IWQ

        Remove the 2 bolts and disconnect the vacuum tube connector hose.

    2. for RHD:


      1. A004I7J

        Loosen the hose clamp and disconnect the union to check valve hose.

  17. DISCONNECT VACUUM TUBE CONNECTOR HOSE (for Manual Transmission)


    1. A004K88E02
      Text in Illustration
      *A for LHD
      *B for RHD

      Loosen the hose clamp and disconnect the union to check valve hose from the intake manifold.

  18. REMOVE EXHAUST MANIFOLD

    Click here

  19. FIX FRONT EXHAUST PIPE SUB-ASSEMBLY (for Manual Transmission)


    1. A004HGD

      Tie the front exhaust pipe sub-assembly to the front cross member sub-assembly with rope.

  20. DISCONNECT HEATER WATER HOSE


    1. A004KAL

      Loosen the 2 hose clamps and disconnect the 2 heater water hoses.

  21. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE (for Automatic Transmission)


    1. A004IUQ

      Loosen the clip and disconnect the No. 1 transmission oil cooler hose.

  22. REMOVE SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)


    1. A004JWF

      Remove the bolt and disconnect the suction hose sub-assembly from the compressor assembly with pulley.

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

      Note

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

    3. for LHD:


      1. A004JAZ

        Remove the bolt and slide the hook connector.

      2. Remove the nut and suction pipe sub-assembly.

      3. Remove the O-ring from the suction pipe sub-assembly.

        Note

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

    4. for RHD:


      1. A004JPQ

        Remove the bolt and slide the hook connector.

      2. Disconnect the suction pipe sub-assembly.

      3. Remove the O-ring from the suction pipe sub-assembly.

        Note

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

  23. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

    Click here

  24. REMOVE STARTER ASSEMBLY (for Automatic Transmission)

    Click here

  25. REMOVE STARTER ASSEMBLY (for Manual Transmission)

    Click here

  26. DISCONNECT NO. 3 TRANSMISSION OIL COOLER HOSE (for Automatic Transmission)


    1. A004HS3

      Loosen the clip and disconnect the No. 3 transmission oil cooler hose.

  27. DISCONNECT RADIATOR OUTLET HOSE


    1. A004JYD

      Loosen the clip and disconnect the radiator outlet hose.

  28. DISCONNECT GROUNDED CABLE


    1. A004KBB

      Remove the 2 bolts and disconnect the 2 grounded cables.

  29. REMOVE REAR ENGINE UNDER COVER LH (w/ Floor Under Cover)


    1. A004I0R

      Remove the 3 bolts and 8 clips, then remove the rear engine under cover LH.

  30. REMOVE FRONT STABILIZER BAR (for Automatic Transmission)

    Click here

  31. FIX FRONT EXHAUST PIPE ASSEMBLY (for Automatic Transmission)


    1. A004HGD

      Tie the front exhaust pipe assembly to the front cross member sub-assembly with rope.

  32. SEPARATE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


    1. A004JWNE01

      Remove the 3 bolts and 2 nuts.

      Text in Illustration
      A004I9S Bolt
      A004KUZ Nut

      Note

      In order to prevent dropping, do not remove bolt B.

  33. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)


    1. A004J0QE01

      Remove the 3 bolts and 2 nuts.

      Text in Illustration
      A004I9S Bolt
      A004KUZ Nut

      Note

      In order to prevent dropping, do not remove bolt B.

  34. SEPARATE FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A004HPH

      Remove the 2 nuts from the front cross member sub-assembly.

  35. REMOVE FLYWHEEL HOUSING UNDER COVER

    Click here

  36. REMOVE DRIVE PLATE SETTING HEXAGON BOLT (for Automatic Transmission)

    Click here

  37. SEPARATE FUEL HOSE


    1. for Clamp Type:


      1. A004J57E01
        Text in Illustration
        *a matchmark

        Put matchmarks on the fuel hoses and fuel pipes.

      2. Remove the clamp and disconnect the fuel tube, No. 2 fuel tube and fuel tube from the fuel pipe.

    2. for Metal Type:


      1. A004J3V

        Using SST, disconnect the fuel tube and No. 2 fuel tube from the fuel pipe Click here.

        SST
        SU003-03936
      2. A004JFR

        Remove the clamp and disconnect the No. 2 fuel vapor feed hose from the fuel pipe.

  38. INSTALL ENGINE HANGER


    1. A004H1GE03
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the engine hanger with the bolt, as shown in the illustration.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-38030
      Bolt 90119-14120
    2. Use an engine sling device and a mini crane to hold the engine.

  39. SUPPORT TRANSMISSION ASSEMBLY


    1. A004JMO

      Support the transmission assembly clutch housing with a jack.

      Note

      Support the transmission assembly until the installation of the engine assembly is completed.

  40. REMOVE ENGINE ASSEMBLY


    1. A004HIGE01
      Text in Illustration
      *A for Automatic Transmission
      *B for Manual Transmission

      Remove the bolt from the transmission assembly.

    2. Hoist the engine assembly up with an engine sling device and a mini crane.

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

    Click here

  42. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  43. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

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

    Click here

  45. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  46. INSTALL ENGINE STAND


    1. Set the engine on an engine stand.

      Note

      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.

  47. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A004JKF

      Remove the 4 bolts and 2 front engine mounting brackets.