CAUTION / NOTICE / HINT
*1 | thermostat (thermostat housing assembly) | *2 | oil cooler hose sub-assembly |
*3 | oil cooler assembly (for air cooled type) | - | - |
When the oil cooler assembly (for air cooled type) has been removed/installed or the oil cooler hose sub-assembly has been disconnected/reconnected, check the engine oil level after warming up the engine oil to between 100°C and 120°C to open the thermostat between the engine and oil cooler assembly (for air cooled type).
Enter the following menus: Powertrain / Engine / Data List / Engine Oil Temperature.
Tester Display |
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Engine Oil Temperature |
CAUTION / NOTICE / HINT
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
PRECAUTION
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.
REMOVE V-BANK COVER SUB-ASSEMBLY
Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 front clips. Continue to raise the V-bank cover sub-assembly to disengage the 2 rear clips to remove the V-bank cover sub-assembly.
Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.
REMOVE COOL AIR INTAKE DUCT SEAL
ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
for HFC-134a (R134a)
for HFO-1234yf (R1234 yf)
DISCHARGE FUEL SYSTEM PRESSURE
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
SECURE STEERING WHEEL
REMOVE FRONT WHEELS
REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY
Remove the 13 screws, 3 clips and No. 1 engine under cover assembly.
REMOVE REAR ENGINE UNDER COVER LH
Remove the screw and rear engine under cover LH.
REMOVE REAR ENGINE UNDER COVER RH
Perform the same procedure as for the LH side.
SEPARATE FRONT FENDER LINER LH
Remove the 2 screws and separate the front fender liner LH.
SEPARATE FRONT FENDER LINER RH
Remove the 2 screws and separate the front fender liner RH.
REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY
Remove the 6 bolts, 4 nuts and front suspension member brace sub-assembly.
REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR
Remove the 4 bolts and front lower suspension member protector.
REMOVE NO. 2 ENGINE UNDER COVER
Remove the 2 screws and No. 2 engine under cover.
REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
DRAIN ENGINE OIL
DRAIN ENGINE COOLANT
DRAIN AUTOMATIC TRANSMISSION FLUID
REMOVE INLET NO. 1 AIR CLEANER
DISCONNECT VENTILATION HOSE
REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
Disengage the 2 clamps and disconnect the vacuum hose assembly.
Disengage the clamp and disconnect the vacuum switching valve connector.
Remove the 2 bolts and air cleaner case sub-assembly.
REMOVE RADIATOR RESERVE TANK ASSEMBLY
DISCONNECT NO. 1 RADIATOR HOSE
Slide the clip and disconnect the No. 1 radiator hose from the front water by-pass joint.
DISCONNECT NO. 2 RADIATOR HOSE
Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
DISCONNECT NO. 2 OIL COOLER INLET HOSE
Slide the clip and disconnect the No. 2 oil cooler inlet hose from the oil cooler assembly.
DISCONNECT NO. 2 OIL COOLER OUTLET HOSE
Slide the clip and disconnect the No. 2 oil cooler outlet hose from the oil cooler assembly.
DISCONNECT OIL COOLER HOSE SUB-ASSEMBLY
Remove the 2 bolts and disconnect the oil cooler hose sub-assembly.
Remove the 2 O-rings from the oil cooler hose sub-assembly.
REMOVE FRONT SUSPENSION UPPER TO COWL BRACE LH
Remove the bolt, 3 nuts and front suspension upper to cowl brace LH.
REMOVE FRONT SUSPENSION UPPER TO COWL BRACE RH
Remove the bolt, 3 nuts and front suspension upper to cowl brace RH.
DISCONNECT HEATER WATER OUTLET HOSE
Remove the water hose set.
Slide the clip and disconnect the heater water outlet hose from the No. 3 water by-pass pipe.
DISCONNECT HEATER WATER INLET HOSE
Remove the water hose set.
Slide the clip and disconnect the heater water inlet hose from the No. 3 water by-pass pipe.
DISCONNECT UNION TO CHECK VALVE HOSE (for LHD)
Disengage the union to check valve hose from the clamp.
Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.
DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)
Disengage the union to check valve hose from the clamp.
Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.
DISCONNECT NO. 1 FUEL VAPOR FEED HOSE
Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).
DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY
Remove the fuel pipe clamp.
Pinch the fuel tube connector and then pull off the No. 2 fuel tube sub-assembly.
Check for any dirt and foreign matter in the fuel pipe and around the fuel tube connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel pipe and fuel tube connector.
Do not use any tools to separate the fuel pipe and fuel tube connector.
Do not forcibly bend or twist the nylon tube.
Put the fuel pipe and fuel tube connector ends in plastic bags to prevent damage and contamination.
If the fuel pipe and fuel pipe connector are stuck together, pinch the fuel pipe between your fingers and turn it carefully to free it. Then disconnect the No. 2 fuel tube sub-assembly.
DISCONNECT FUEL TUBE SUB-ASSEMBLY
Remove the fuel pipe clamp.
Pinch the fuel tube connector and then pull off the fuel tube sub-assembly.
Check for any dirt and foreign matter in the fuel pipe and around the fuel tube connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel pipe and fuel tube connector.
Do not use any tools to separate the fuel pipe and fuel tube connector.
Do not forcibly bend or twist the nylon tube.
Put the fuel pipe and fuel tube connector ends in plastic bags to prevent damage and contamination.
If the fuel pipe and fuel tube connector are stuck together, pinch the fuel pipe between your fingers and turn it carefully to free it. Then disconnect the fuel tube sub-assembly.
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE
DISCONNECT SUCTION HOSE
REMOVE ENGINE ROOM ECU COVER
DISCONNECT WIRE HARNESS (for LHD)
After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.
Engine room LH side:
Disengage the engine wire clamp.
Disconnect the engine wire from the engine room ECU box.
Engine room RH side:
Disengage the 4 clamps and separate the No. 1 center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.
Disengage the No. 2 engine wire clamp.
Remove the nut and disconnect the No. 2 engine wire from the positive (+) battery terminal.
Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.
Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.
Disengage the No. 4 engine wire clamp.
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.
Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.
Disengage the clamp.
Remove the bolt and disconnect the ground cable from the generator assembly.
DISCONNECT WIRE HARNESS (for RHD)
After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.
Engine room LH side:
Disengage the 4 clamps and separate the No. 1 center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.
Disengage the No. 2 engine wire clamp.
Remove the nut and disconnect the No. 2 engine wire from the positive (+) battery terminal.
Remove the No. 1 engine room relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.
Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.
Disengage the No. 4 engine wire clamp.
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.
Disengage the engine wire clamp.
Disconnect the engine wire from the engine room ECU box.
Engine room RH side:
Remove the bolt and disconnect the No. 3 engine wire from the vehicle body.
Disengage the clamp.
Remove the bolt and disconnect the ground cable from the generator assembly.
REMOVE POWER STEERING ECU ASSEMBLY
for LHD
for RHD
REMOVE BATTERY TRAY
for LHD:Click here
for RHD:Click here
SEPARATE NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY
for LHD:Click here
for RHD:Click here
REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
SEPARATE FRONT SKID CONTROL SENSOR WIRE
DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH
Remove the bolt and nut, and disconnect the front shock absorber assembly LH from the front suspension lower arm assembly LH.
Because the nut has its own stopper, do not turn the nut. Loosen the bolt with the nut secured.
DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH
Perform the same procedure as for the LH side.
SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH
SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH
Perform the same procedure as for the LH side.
REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY
SEPARATE TIE ROD ASSEMBLY LH
SEPARATE TIE ROD ASSEMBLY RH
Perform the same procedure as the LH side.
DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
DISCONNECT WIRE HARNESS (for LHD)
Disconnect the 3 power steering link assembly connectors.
For the connector with lock lever, pull up the lock lever to disengage the lock.
Disengage the 2 wire harness clamps from the power steering link assembly.
DISCONNECT WIRE HARNESS (for RHD)
Disconnect the 3 power steering link assembly connectors.
For the connector with lock lever, pull up the lock lever to disengage the lock.
Disconnect the 2 wire harness clamps from the power steering link assembly.
REMOVE ENGINE ASSEMBLY WITH TRANSMISSION
Remove the 8 nuts, 2 bolts and 2 oil cooler brackets.
Remove the 6 bolts and 2 No. 2 frame crossmember assemblies.
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.
Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally.
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 sub-assembly 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.
Remove the 4 bolts and separate the rear engine mounting member from the vehicle body.
*a | Nut |
Remove the 4 bolts and disconnect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH.
Remove the 8 bolts, 2 nuts, strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.
Operate the engine lifter and remove the engine assembly with transmission from the vehicle.
Make sure that the engine assembly with transmission is clear of all wiring and hoses.
INSTALL ENGINE HANGER
Install the 2 No. 1 engine hangers with the 2 bolts as shown in the illustration.
43 N*m | 438 kgf*cm | 32 ft.*lbf |
No. 1 Engine Hanger | 12081-38040 |
Bolt | 90119-14120 |
*a | No. 1 Engine Hanger |
*b | Engine Assembly |
*c | 50° or Less |
Attach an engine sling device and hang the engine assembly with transmission with a chain block.
When hanging the engine assembly, make sure to hang it with the chains at an angle of 50° or less. Otherwise, the engine assembly or engine hangers may be damaged.
REMOVE ENGINE OIL LEVEL DIPSTICK
REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE
REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH
Disengage the 2 clamps and remove the engine under cover sub-assembly LH from the front suspension crossmember sub-assembly.
REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH
Disengage the 2 clamps and remove the engine under cover sub-assembly RH from the front suspension crossmember sub-assembly.
REMOVE ENGINE MOUNTING DAMPER
Remove the 2 bolts and 2 engine mounting dampers.
REMOVE NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY (w/ Differential Pressure Sensor)
REMOVE NO. 1 VACUUM TRANSMITTING HOSE ASSEMBLY (w/ Differential Pressure Sensor)
DISCONNECT NO. 1 VACUUM PIPE (w/ Differential Pressure Sensor)
Remove the bolt and disconnect the No. 1 vacuum pipe from the exhaust manifold sub-assembly RH.
Using a 14 mm union nut wrench, disconnect the No. 1 vacuum pipe from the exhaust manifold sub-assembly RH.
Remove the nut and disconnect the No. 1 pipe.
DISCONNECT NO. 2 VACUUM PIPE (w/ Differential Pressure Sensor)
Remove the bolt and disconnect the No. 2 vacuum pipe from the exhaust manifold sub-assembly LH.
Using a 14 mm union nut wrench, disconnect the No. 2 vacuum pipe from the exhaust manifold sub-assembly LH.
Remove the nut and disconnect the No. 2 pipe.
REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (w/ Differential Pressure Sensor)
for Bank 1:
for Bank 2:
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
REMOVE V-RIBBED BELT
DISCONNECT WIRE HARNESS
REMOVE OIL COOLER TUBE
Disengage the clamp from the oil cooler tube.
Remove the 3 bolts and oil cooler tube.
REMOVE COMPRESSOR ASSEMBLY WITH PULLEY
Remove the 2 bolts and 2 nuts.
REMOVE GENERATOR ASSEMBLY
REMOVE STARTER ASSEMBLY
REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT
REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
REMOVE REAR ENGINE MOUNTING MEMBER
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Remove the 4 nuts and rear engine mounting member from the rear engine mounting insulator.
REMOVE REAR ENGINE MOUNTING INSULATOR
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Remove the 4 bolts and rear engine mounting insulator from the automatic transmission assembly.
REMOVE REAR ENGINE MOUNTING HEAT INSULATOR
Remove the 4 nuts and rear engine mounting heat insulator from the rear engine mounting insulator.
REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Remove the 2 nuts and front suspension crossmember sub-assembly from the engine assembly.
REMOVE FRONT ENGINE MOUNTING INSULATOR
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
Remove the 2 engine mounting spacers.
Remove the 2 nuts and 2 front engine mounting insulators from the front suspension crossmember sub-assembly.
INSTALL ENGINE TO ENGINE STAND
Install the engine assembly to an engine stand.
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.
Remove the 2 bolts and 2 No. 1 engine hangers.
INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
Using a precision straightedge and feeler gauge.
Check the surface which contacts the cylinder head LH for warpage.
Maximum Warpage |
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0.50 mm (0.0197 in.) |
If the warpage is more than the maximum, replace the exhaust manifold sub-assembly LH.
INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
Using a precision straightedge and feeler gauge.
Check the surface which contacts the cylinder head sub-assembly for warpage.
Maximum Warpage |
---|
0.50 mm (0.0197 in.) |
If the warpage is more than the maximum, replace the exhaust manifold sub-assembly RH.