ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. REMOVE ENGINE ROOM SIDE COVER

    Click here

  3. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  4. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. B0076WIC01
      B0076EM Areas to be held when lifting V-bank cover sub-assembly
      B0073AQ Front

      Hold the rear area of the V-bank cover sub-assembly shown in the illustration and detach the rear clip (1).

      Note

      If the V-bank cover sub-assembly is lifted rearward or forward and to the right or left at the same time, the V-bank cover sub-assembly may be damaged.

    2. Hold and lift both sides of the V-bank cover sub-assembly to detach the 2 front clips (2) and (3) to remove the V-bank cover sub-assembly.

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  6. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  7. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

    Click here

  8. SECURE STEERING WHEEL

    Click here

  9. REMOVE FRONT WHEELS

    Click here

  10. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  11. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. B007424

      Remove the 13 screws, 3 clips and No. 1 engine under cover assembly.

  12. REMOVE REAR ENGINE UNDER COVER LH


    1. B0072US

      Remove the screw and rear engine under cover LH.

  13. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  14. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. B0072WD

      Remove the 4 bolts, turn the clip to loosen it, and remove the front suspension member brace.

      Tech Tips

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

  15. REMOVE NO. 2 ENGINE UNDER COVER (w/ No.2 Engine Under Cover)


    1. B0072SX

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

  16. DRAIN ENGINE OIL

    Click here

  17. DRAIN ENGINE COOLANT

    Click here

  18. DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  19. REMOVE INLET NO. 1 AIR CLEANER


    1. B0077A8

      Remove the bolt and inlet No. 1 air cleaner.

  20. DISCONNECT NO. 2 VENTILATION HOSE

    Click here

  21. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary.

    Click here

  22. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary.


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary.


    1. B0074EXC01
      *a Air Cleaner Support

      Disconnect the wire harness clamp from the air cleaner case sub-assembly.

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

      Note

      Make sure the air cleaner support remains attached to the vehicle body.

  24. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B00780D

      Disconnect the mass air flow meter sub-assembly connector.

    2. Disconnect the 2 wire harness clamps from the air cleaner assembly with air cleaner hose.

    3. B0074KN

      Disconnect the No. 2 fuel vapor feed hose clamp from the air cleaner cap with air cleaner hose.

    4. B0074YL

      Disconnect the union to check valve hose from the air cleaner cap with air cleaner hose (for RHD).

    5. B0076XUC01
      *a Air Cleaner Support

      Remove the 2 bolts.

    6. Loosen the hose clamp and remove the air cleaner assembly with air cleaner hose.

      Note

      Make sure the air cleaner support remains attached to the vehicle body.

  25. DISCONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. B0075FK

      Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.

  26. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. B00776S

      Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.

  27. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. B0072O1

      Slide the clip and disconnect the No. 2 fuel vapor feed hose from the purge valve (purge VSV).

  28. DISCONNECT RADIATOR RESERVE TANK HOSE


    1. B0076X3

      Slide the clip and disconnect the radiator reserve tank hose from the water inlet sub-assembly.

  29. REMOVE NO. 1 RADIATOR HOSE

    Click here

  30. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  31. DISCONNECT INLET HEATER WATER HOSE A


    1. B0076K5

      Slide the clip and disconnect the inlet heater water hose A from the No. 3 heater water by-pass pipe.

  32. DISCONNECT OUTLET HEATER WATER HOSE A


    1. B0076DE

      Slide the clip and disconnect the outlet heater water hose A from the No. 3 heater water by-pass pipe.

  33. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  34. DISCONNECT SUCTION HOSE

    Click here

  35. REMOVE ENGINE ROOM ECU COVER

    Click here

  36. DISCONNECT WIRE HARNESS (for LHD)

    Tech Tips

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.


    1. B0073R6

      Engine room LH side:


      1. Disconnect the engine wire clamp.

      2. Disconnect the engine wire from the engine room ECU box.

        Click here

    2. Engine room RH side:


      1. B0073CL

        Separate the No. 1 center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

      2. B00777Z

        Disconnect the No. 2 engine wire clamp.

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

      4. Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.

      5. B0076TU

        Disconnect the 2 No. 4 engine wire clamps.

      6. Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.

      7. Disengage the 2 claws and disconnect the No. 4 engine wire from the No. 1 engine room relay block and No. 1 junction block assembly.

      8. B0077JI

        Disconnect the No. 3 engine wire clamp.

      9. Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.

  37. DISCONNECT WIRE HARNESS (for RHD)

    Tech Tips

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.


    1. Engine room LH side:


      1. B00761D

        Separate the No. 1 center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

      2. B0073B2

        Disconnect the No. 2 engine wire clamp.

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

      4. Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.

      5. B00748L

        Disconnect the No. 4 engine wire clamp.

      6. Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.

      7. Disengage the 2 claws and disconnect the No. 4 engine wire from the No. 1 engine room relay block and No. 1 junction block assembly.

      8. B0072LJ

        Disconnect the engine wire clamp.

      9. Disconnect the engine wire from the engine room ECU box.

        Click here

    2. Engine room RH side:


      1. B00770A

        Disconnect the No. 3 engine wire clamp.

      2. Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.

  38. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B0075ZA

      Remove the fuel pipe clamp.

    2. B00776M

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

      Click here

  39. DISCONNECT NO. 3 FUEL HOSE


    1. B0075JQ

      Slide the clip and disconnect the No. 3 fuel hose from the No. 1 fuel pipe sub-assembly.

  40. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. B0074PL

      Remove the fuel pipe clamp.

    2. B0077ZS

      Disconnect the No. 2 fuel tube sub-assembly from the fuel pipe.

      Click here

  41. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  42. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

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

    Click here

  44. SEPARATE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  45. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. B0073PP

      Remove the bolt and nut, and disconnect the front shock absorber assembly LH from the front suspension lower arm assembly LH.

      Note

      Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut secured.

  46. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  47. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  48. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  49. DISCONNECT WIRE HARNESS


    1. B00770C

      Disconnect the 2 wire harness clamps and 3 wire harness connectors from the power steering link assembly.

      Tech Tips

      For the connector with lock lever, pull up the lock lever to disengage the lock.

  50. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  51. REMOVE SUSPENSION TOWER DAMPER

    Click here

  52. REMOVE FRONT UPPER NO. 2 SUSPENSION MEMBER


    1. B00742A

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

  53. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. B0076MH

      Remove the 4 bolts and front lower suspension member protector from the front suspension crossmember sub-assembly.

  54. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. B0077PD

      Remove the nut and disconnect the No. 2 earth wire from the vehicle body.

    2. B0075AGC01
      B0076EM Attachment Installation Position

      Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transmission.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transmission horizontal.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

    3. B0076X2

      Remove the 4 bolts, and separate the rear engine mounting member from the vehicle body.

    4. B0076Y2C01
      B0073AQ Bolt
      B0077IM Nut

      Remove the 4 bolts and disconnect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH.

    5. Remove the 6 bolts, 2 nuts and strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.

    6. Operate the engine lifter and remove the engine assembly with transmission from the vehicle.

      Note


      • Make sure that the engine assembly with transmission is clear of all wiring, hoses and the steering sliding with shaft yoke sub-assembly.

      • After removing the engine assembly with transmission, hang the steering sliding with shaft yoke sub-assembly with rope or equivalent.

  55. INSTALL NO. 1 ENGINE HANGER


    1. B007644C01
      *a RH Side
      *b LH Side

      Install the 2 No. 1 engine hangers with the 4 bolts 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
    2. Attach an engine sling device and hang the engine assembly with transmission with a chain block.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hangers may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

  56. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B00752S

      Disconnect the wire harness clamp from the engine oil level dipstick guide.

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

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

  57. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

    Click here

  58. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

    Click here

  59. REMOVE STARTER ASSEMBLY

    Click here

  60. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  61. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  62. DISCONNECT WIRE HARNESS

    Click here

  63. DISCONNECT WATER BY-PASS HOSE

    Click here

  64. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  65. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  66. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B0072SAC01
      *a LH Side
      *b RH Side

      Remove the 2 bolts and front suspension crossmember sub-assembly from the engine assembly.

  67. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.


    1. B0076A9C01
      *a LH Side
      *b RH Side

      Remove the 2 nuts and 2 front engine mounting insulators from the front suspension crossmember sub-assembly.

  68. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. B0076XP

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

  69. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. B00754U

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

    2. B0073OJ

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

  70. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hangers may be damaged or deformed if the angle is incorrect.

      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

    2. Remove the 4 bolts and 2 No. 1 engine hangers.

  71. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY (TWC: Front Catalyst)


    1. B0073GV

      Using a precision straightedge and feeler gauge, measure the warpage of the surface which contacts the cylinder head sub-assembly.

      Maximum Warpage
      0.70 mm (0.02756 in.)

      Tech Tips

      If the warpage is more than the maximum, replace the exhaust manifold sub-assembly.