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ENGINE ASSEMBLY REMOVAL

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Click here

CAUTION / NOTICE / HINT

B0066AWC06
*1 thermostat (thermostat housing assembly) *2 oil cooler hose sub-assembly
*3 oil cooler assembly (for air cooled type) - -
Note:

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).

Tip:

Enter the following menus: Powertrain / Engine / Data List / Engine Oil Temperature.


  1. Powertrain > Engine > Data List
    Tester Display
    Engine Oil Temperature




Click here

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.

Click here

PROCEDURE


  1. Click here

    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. Click here

    REMOVE V-BANK COVER SUB-ASSEMBLY


    1. B006866

      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.

      Note:

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  3. Click here

    REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  4. Click here

    ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

    Click here

  5. Click here

    RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM



  6. Click here

    DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  7. Click here

    DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note:

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

    Click here

  8. Click here

    SECURE STEERING WHEEL

    Click here

  9. Click here

    REMOVE FRONT WHEELS

    Click here

  10. Click here

    REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. B0065T3

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

  11. Click here

    REMOVE REAR ENGINE UNDER COVER LH


    1. B0066YN

      Remove the screw and rear engine under cover LH.

  12. Click here

    REMOVE REAR ENGINE UNDER COVER RH

    Tip:

    Perform the same procedure as for the LH side.

  13. Click here

    SEPARATE FRONT FENDER LINER LH


    1. Remove the 2 screws and separate the front fender liner LH.

  14. Click here

    SEPARATE FRONT FENDER LINER RH


    1. Remove the 2 screws and separate the front fender liner RH.

  15. Click here

    REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY


    1. B006558

      Remove the 6 bolts, 4 nuts and front suspension member brace sub-assembly.

  16. Click here

    REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. B00654D

      Remove the 4 bolts and front lower suspension member protector.

  17. Click here

    REMOVE NO. 2 ENGINE UNDER COVER


    1. B0067LL

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

  18. Click here

    REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  19. Click here

    DRAIN ENGINE OIL

    Click here

  20. Click here

    DRAIN ENGINE COOLANT

    Click here

  21. Click here

    DRAIN AUTOMATIC TRANSMISSION FLUID

    Click here

  22. Click here

    REMOVE INLET NO. 1 AIR CLEANER

    Click here

  23. Click here

    DISCONNECT VENTILATION HOSE

    Click here

  24. Click here

    REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  25. Click here

    REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  26. Click here

    REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B0067T0

      Disengage the 2 clamps and disconnect the vacuum hose assembly.

    2. B00663K

      Disengage the clamp and disconnect the vacuum switching valve connector.

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

  27. Click here

    REMOVE RADIATOR RESERVE TANK ASSEMBLY

    Click here

  28. Click here

    DISCONNECT NO. 1 RADIATOR HOSE


    1. B0065H9

      Slide the clip and disconnect the No. 1 radiator hose from the front water by-pass joint.

  29. Click here

    DISCONNECT NO. 2 RADIATOR HOSE


    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

  30. Click here

    DISCONNECT NO. 2 OIL COOLER INLET HOSE


    1. B0066W2

      Slide the clip and disconnect the No. 2 oil cooler inlet hose from the oil cooler assembly.

  31. Click here

    DISCONNECT NO. 2 OIL COOLER OUTLET HOSE


    1. B0066U8

      Slide the clip and disconnect the No. 2 oil cooler outlet hose from the oil cooler assembly.

  32. Click here

    DISCONNECT OIL COOLER HOSE SUB-ASSEMBLY


    1. B00689J

      Remove the 2 bolts and disconnect the oil cooler hose sub-assembly.

    2. B0067JZ

      Remove the 2 O-rings from the oil cooler hose sub-assembly.

  33. Click here

    REMOVE FRONT SUSPENSION UPPER TO COWL BRACE LH


    1. B0065EO

      Remove the bolt, 3 nuts and front suspension upper to cowl brace LH.

  34. Click here

    REMOVE FRONT SUSPENSION UPPER TO COWL BRACE RH


    1. B0066E2

      Remove the bolt, 3 nuts and front suspension upper to cowl brace RH.

  35. Click here

    DISCONNECT HEATER WATER OUTLET HOSE


    1. B0067ZY

      Remove the water hose set.

    2. B00674L

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

  36. Click here

    DISCONNECT HEATER WATER INLET HOSE


    1. B0065ZZ

      Remove the water hose set.

    2. B0066BT

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

  37. Click here

    DISCONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. B0066UA

      Disengage the union to check valve hose from the clamp.

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

  38. Click here

    DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. B0067OK

      Disengage the union to check valve hose from the clamp.

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

  39. Click here

    DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B00674W

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).

  40. Click here

    DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. B006754

      Remove the fuel pipe clamp.

    2. B00660K

      Pinch the fuel tube connector and then pull off the No. 2 fuel tube sub-assembly.

      Note:
      • 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.

  41. Click here

    DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B0065Z7

      Remove the fuel pipe clamp.

    2. B00687Z

      Pinch the fuel tube connector and then pull off the fuel tube sub-assembly.

      Note:
      • 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.

  42. Click here

    DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  43. Click here

    DISCONNECT SUCTION HOSE

    Click here

  44. Click here

    REMOVE ENGINE ROOM ECU COVER

    Click here

  45. Click here

    DISCONNECT WIRE HARNESS (for LHD)

    Tip:

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


    1. Engine room LH side:


      1. B0066IZ

        Disengage the engine wire clamp.

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

        Click here

    2. Engine room RH side:


      1. B006827

        Disengage the 4 clamps and separate the No. 1 center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

      2. B0066IL

        Disengage 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. B0064ZJ

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

      6. B0065V4

        Disengage the No. 4 engine wire clamp.

      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. B00664A

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

    3. B0067WT

      Disengage the clamp.

    4. Remove the bolt and disconnect the ground cable from the generator assembly.

  46. Click here

    DISCONNECT WIRE HARNESS (for RHD)

    Tip:

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


    1. Engine room LH side:


      1. B006722

        Disengage the 4 clamps and separate the No. 1 center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

      2. B0066HM

        Disengage 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. B0065TX

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

      6. B0065LW

        Disengage the No. 4 engine wire clamp.

      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. B0066IZ

        Disengage the engine wire clamp.

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

        Click here

    2. Engine room RH side:


      1. B00664A

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

    3. B0067WT

      Disengage the clamp.

    4. Remove the bolt and disconnect the ground cable from the generator assembly.

  47. Click here

    REMOVE POWER STEERING ECU ASSEMBLY



  48. Click here

    REMOVE BATTERY TRAY

    for LHD:Click here

    for RHD:Click here

  49. Click here

    SEPARATE NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY

    for LHD:Click here

    for RHD:Click here

  50. Click here

    REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  51. Click here

    SEPARATE FRONT SKID CONTROL SENSOR WIRE

    Click here

  52. Click here

    DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. B0066DS

      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.

  53. Click here

    DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  54. Click here

    SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  55. Click here

    SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

  56. Click here

    REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  57. Click here

    SEPARATE TIE ROD ASSEMBLY LH

    Click here

  58. Click here

    SEPARATE TIE ROD ASSEMBLY RH

    Tip:

    Perform the same procedure as the LH side.

  59. Click here

    DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  60. Click here

    DISCONNECT WIRE HARNESS (for LHD)


    1. B006842

      Disconnect the 3 power steering link assembly connectors.

      Tip:

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

    2. Disengage the 2 wire harness clamps from the power steering link assembly.

  61. Click here

    DISCONNECT WIRE HARNESS (for RHD)


    1. B006710

      Disconnect the 3 power steering link assembly connectors.

      Tip:

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

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

  62. Click here

    REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. B0067LC

      Remove the 8 nuts, 2 bolts and 2 oil cooler brackets.

    2. B0066V0

      Remove the 6 bolts and 2 No. 2 frame crossmember assemblies.

    3. B006683C01
      B00667M 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, 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.

    4. B006668

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

    5. B00661DC02
      *a Nut

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

    6. Remove the 8 bolts, 2 nuts, strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.

    7. 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 and hoses.

  63. Click here

    INSTALL ENGINE HANGER


    1. B0066PO

      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
      Tip:
      No. 1 Engine Hanger 12081-38040
      Bolt 90119-14120
    2. B0065EQC02
      *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.

      Note:

      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.

  64. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK

    Click here

  65. Click here

    REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  66. Click here

    REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH


    1. B0065VZ

      Disengage the 2 clamps and remove the engine under cover sub-assembly LH from the front suspension crossmember sub-assembly.

  67. Click here

    REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH


    1. B0066RG

      Disengage the 2 clamps and remove the engine under cover sub-assembly RH from the front suspension crossmember sub-assembly.

  68. Click here

    REMOVE ENGINE MOUNTING DAMPER


    1. B0065DX

      Remove the 2 bolts and 2 engine mounting dampers.

  69. Click here

    REMOVE NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY (w/ Differential Pressure Sensor)

    Click here

  70. Click here

    REMOVE NO. 1 VACUUM TRANSMITTING HOSE ASSEMBLY (w/ Differential Pressure Sensor)

    Click here

  71. Click here

    DISCONNECT NO. 1 VACUUM PIPE (w/ Differential Pressure Sensor)


    1. B00660G

      Remove the bolt and disconnect the No. 1 vacuum pipe from the exhaust manifold sub-assembly RH.

    2. Using a 14 mm union nut wrench, disconnect the No. 1 vacuum pipe from the exhaust manifold sub-assembly RH.

    3. B00674A

      Remove the nut and disconnect the No. 1 pipe.

  72. Click here

    DISCONNECT NO. 2 VACUUM PIPE (w/ Differential Pressure Sensor)


    1. B0066XT

      Remove the bolt and disconnect the No. 2 vacuum pipe from the exhaust manifold sub-assembly LH.

    2. Using a 14 mm union nut wrench, disconnect the No. 2 vacuum pipe from the exhaust manifold sub-assembly LH.

    3. B0067IS

      Remove the nut and disconnect the No. 2 pipe.

  73. Click here

    REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY (w/ Differential Pressure Sensor)


  74. Click here

    REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  75. Click here

    REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  76. Click here

    REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  77. Click here

    REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  78. Click here

    REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  79. Click here

    REMOVE V-RIBBED BELT

    Click here

  80. Click here

    DISCONNECT WIRE HARNESS

    Click here

  81. Click here

    REMOVE OIL COOLER TUBE


    1. B0066DQ

      Disengage the clamp from the oil cooler tube.

    2. Remove the 3 bolts and oil cooler tube.

  82. Click here

    REMOVE COMPRESSOR ASSEMBLY WITH PULLEY


    1. B0067YV

      Remove the 2 bolts and 2 nuts.

  83. Click here

    REMOVE GENERATOR ASSEMBLY

    Click here

  84. Click here

    REMOVE STARTER ASSEMBLY

    Click here

  85. Click here

    REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  86. Click here

    REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  87. Click here

    REMOVE REAR ENGINE MOUNTING MEMBER

    Tip:

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


    1. B0067L9

      Remove the 4 nuts and rear engine mounting member from the rear engine mounting insulator.

  88. Click here

    REMOVE REAR ENGINE MOUNTING INSULATOR

    Tip:

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


    1. B0067WE

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

  89. Click here

    REMOVE REAR ENGINE MOUNTING HEAT INSULATOR


    1. B006679

      Remove the 4 nuts and rear engine mounting heat insulator from the rear engine mounting insulator.

  90. Click here

    REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  91. Click here

    REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B0067GB

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

  92. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tip:

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


    1. B0066M3

      Remove the 2 engine mounting spacers.

    2. B0067BE

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

  93. Click here

    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 2 bolts and 2 No. 1 engine hangers.

  94. Click here

    INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. B0067BK

      Using a precision straightedge and feeler gauge.

      Check the surface which contacts the cylinder head LH for warpage.

      Maximum Warpage
      0.50 mm (0.0197 in.)

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

  95. Click here

    INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. B0067JS

      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.