ENGINE ASSEMBLY REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE

    CAUTION:


    • Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.

    • Even after discharging the fuel pressure, place a cloth or equivalent over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.


    1. Disconnect the cable from the negative (-) battery terminal.

      CAUTION:

      Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    2. A01E0YHE01

      Disconnect the fuel pump connector.

    3. Connect the cable to the negative (-) battery terminal.

    4. Start the engine. After the engine has stopped on its own, turn the ignition switch OFF.

      Tech Tips

      DTC P0171/25 (system too lean) may be set.

    5. Crank the engine again, then check that the engine does not start.

    6. Loosen the fuel tank cap, then discharge the pressure in the fuel tank completely.

    7. Connect the fuel pump connector.

  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

  3. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 4 bolts and under cover.

  4. DRAIN ENGINE COOLANT


    1. Remove the radiator cap.

    2. Loosen the cylinder block drain cock plug and radiator drain cock plug, and then drain the coolant.

      Tech Tips

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

      A01DZG1E01

  5. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug and drain the oil into a container.

  6. REMOVE INTAKE AIR CONNECTOR AND AIR CLEANER ASSEMBLY

    A01DYQWE01

    1. Disconnect the vacuum hose.

    2. Disconnect the No. 2 ventilation hose.

    3. Disconnect the MAF meter connector and wire harness clamps.

    4. Loosen the hose clamp and remove the 4 bolts, air cleaner and intake air connector assembly.

  7. REMOVE RADIATOR GRILLE


    1. A01DYIBE01
      Text in Illustration
      *1 Protective Tape

      Put protective tape around the radiator grille.

    2. Remove the 2 clips and 2 screws.

    3. A01DY0N

      Detach the 6 claws and remove the radiator grille.

  8. DISCONNECT RADIATOR INLET HOSE

  9. DISCONNECT RADIATOR OUTLET HOSE

  10. REMOVE DRIVE BELT


    1. A01DZJYE01

      Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the drive belt. Then remove the drive belt.

      Note

      When removing the drive belt, do not use the idle pulley's bolt.

      Tech Tips

      After removing the drive belt, move the tensioner upward to the maximum amount.

  11. REMOVE FAN SHROUD

    A01E1G2E01

    1. Disconnect the reservoir hose from the radiator tank upper.

    2. Loosen the 4 nuts holding the fluid coupling fan.

    3. Remove the driver belt Click here.

    4. Remove the 2 bolts holding the fan shroud.

    5. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

      Note

      Be careful not to damage the radiator core.

    6. Remove the fan pulley from the water pump.

  12. REMOVE FAN PULLEY

  13. REMOVE RADIATOR ASSEMBLY


    1. A01E2KT

      Disconnect the 2 airbag sensor front connectors.

    2. Using a clip remover, detach the 4 clamps from the radiator side as shown in the illustration.

      Tech Tips

      Tape the clip remover tip before use.

    3. A01DZ1ZE01

      Remove the 4 bolts and radiator.

  14. DISCONNECT HOSE

    A01DYDTE01

    1. Disconnect the vacuum hose (from brake master cylinder).

    2. For unleaded gasoline specification vehicle:

      Disconnect the purge line hose.

  15. DISCONNECT FUEL HOSE


    1. Disconnect the No. 2 fuel hose from the pressure regulator.

    2. A01DV2VE01

      Disconnect the No. 1 fuel hose from the pulsation damper.


      1. Detach the lock claw by lifting up the cover, as shown in the illustration.

      2. Check for foreign matter on the pipe and around the connector before disconnecting. Clean if necessary.

      3. A01E1NPE04

        If the connector and the pipe are stuck, pinch the connector, push and pull the pipe to disconnect them.

        Note

        Do not use any tools in this procedure.

      4. Check for foreign matter on the seal surface of the disconnected pipe. Clean if necessary.

      5. A01E1LIE05

        To protect the disconnected pipe and connector from damage and contamination, cover it with a plastic bag.

  16. DISCONNECT ENGINE WIRE

    A01E0LJ

    1. Disconnect the ECM connectors from the cabin.


      1. Remove the glove compartment door.

      2. Disconnect the 4 ECM connectors.

      3. 4WD:

        Disconnect the 4WD control ECU connector.

    2. Remove the bolt and clamp, and disconnect the ground wire.

    3. Remove the bolt and disconnect the ground wire from the frame.

    4. Pull out the engine wire from the cabin.

    5. A01DVS5E06

      Remove the engine room relay block cover (upper).

    6. Remove the engine room relay block cover (side).


      1. Using a screwdriver, detach the 4 claws and remove the relay block cover.

        Tech Tips

        Tape the screwdriver tip before use.

    7. Remove the nut and disconnect the cable from the engine room junction block.

    8. Disconnect the 2 engine room junction block connectors and disconnect the wire clamp.

    9. Remove the bolt and disconnect the wire clamp from the front engine mounting bracket LH.

    10. For unleaded gasoline specification vehicle:

      Remove the bolt and disconnect the clamp.

  17. DISCONNECT VANE PUMP

    A01E1X6E01

    1. Disconnect the oil pressure switch connector.

    2. Remove the 2 bolts and disconnect the vane pump from the engine.

    3. Support the vane pump securely.

  18. REMOVE OIL DIPSTICK


    1. Remove the bolt, dipstick guide and O-ring.

      Tech Tips

      Cover the dipstick guide hole to prevent foreign matter from entering it.

  19. REMOVE OIL DIPSTICK GUIDE

  20. DISCONNECT COOLER COMPRESSOR FROM ENGINE (w/ Air Conditioning System)


    1. Disconnect the compressor connector.

    2. A01E33NE01

      Remove the 2 bolts and disconnect the suction hose from the engine.

    3. A01DYVKE02

      Remove the 4 bolts and disconnect the compressor from the engine.

    4. Support the cooler compressor securely.

  21. REMOVE HOOD ASSEMBLY

    A01E0MJE01

    1. Disconnect the washer nozzle hose.

    2. Remove the 4 bolts and hood.

      Note

      Be careful not to damage the vehicle.

  22. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (R150F / R151F)


    1. Remove the manual transmission unit assembly Click here.

  23. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (R150 / R151)


    1. Remove the manual transmission unit assembly Click here.

  24. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (A343F)


    1. Remove the automatic transmission assembly Click here.

  25. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (A343E)


    1. Remove the automatic transmission assembly Click here.

  26. REMOVE CLUTCH COVER (for Manual Transmission)


    1. A01DVT8E01

      Place matchmarks on the clutch cover and flywheel.

    2. Loosen each set bolt one turn at a time until spring tension is released.

    3. Remove the 6 set bolts and pull off the clutch cover.

      Note

      Do not drop the clutch disc.

  27. REMOVE CLUTCH DISC (for Manual Transmission)

    Note

    Keep the lining part of the clutch disc, pressure plate and surface of the flywheel away from oil and foreign matter.

  28. REMOVE FLYWHEEL (for Manual Transmission)


    1. A01DW34E01

      Fix the crankshaft in place with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01E251E01

      Remove the 10 bolts and flywheel.

  29. REMOVE DRIVE PLATE (for Automatic Transmission)


    1. A01DW34E01

      Fix the crankshaft in place with SST.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01DZXHE01

      Remove the 10 bolts, rear spacer, drive plate and front spacer.

  30. REMOVE REAR END PLATE


    1. Remove the bolt and rear end plate.

  31. REMOVE ENGINE ASSEMBLY


    1. A01DZG5E01

      Install the 2 engine hangers as shown in the illustration.

      Item Part No.
      Engine hanger 12281-0C010
      Bolt 90105-T0129
      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

    2. Attach the engine sling device to the engine hangers.

    3. A01DW3LE01

      Remove the 4 bolts and 4 nuts and chain block holding the engine mounting bracket and frame.

    4. A01DY4BE01

      Lift the engine out of the vehicle slowly and carefully.

      Note

      Make sure to disconnect all the wires, hoses and cables from the engine. Keep the disconnected wires, hoses and cables off of the engine.

  32. INSTALL ENGINE TO ENGINE STAND


    1. Place the engine assembly onto the stand.

  33. REMOVE IGNITION COIL


    1. Disconnect the 4 ignition coil connectors and remove the 4 bolts and 4 ignition coils.

  34. REMOVE SPARK PLUG

  35. REMOVE VENTILATION PIPE


    1. Remove the bolt and ventilation pipe.

  36. REMOVE GENERATOR


    1. A01DZY1E03

      Remove the nut, bolt and generator wire.

    2. Disconnect the generator connector.

    3. Remove the 2 bolts and generator.

  37. REMOVE ENGINE WIRE


    1. Disconnect the oil pressure sensor connector.

    2. Disconnect the noise filter connector.

    3. Disconnect the camshaft position sensor connector.

    4. Disconnect the 4 injector connectors.

    5. Disconnect the crankshaft position sensor connector.

    6. Disconnect the OCV connector.

    7. Disconnect the throttle body connector.

    8. Disconnect the ECT sensor connector.

    9. Disconnect the knock sensor connector.

    10. Disconnect the wire harness from the clamps.

    11. Remove the 2 bolts and wire harness from the engine.

  38. REMOVE THROTTLE BODY


    1. Disconnect the throttle position sensor and control motor connector.

    2. Disconnect the 2 water by-pass hoses.

    3. A01DYN1E01

      Remove the 2 bolts, 2 nuts and throttle body.

    4. Remove the gasket.

  39. REMOVE FUEL DELIVERY PIPE

    CAUTION:

    Be careful not to drop the injectors when removing the delivery pipe.


    1. A01DYZ7E01

      Disconnect the 4 clamps and wire harness from the delivery pipe.

    2. Disconnect the vacuum hose.

    3. A01DYDWE01

      Disconnect the 4 injector connectors.

    4. Remove the 2 bolts and delivery pipe together with the 4 injectors.

    5. A01DWU3E01

      Using 2 screwdrivers, pry out the 4 spacers from the cylinder head.

      Tech Tips

      Tape the screwdriver tips before use.

  40. REMOVE INJECTOR


    1. A01DZZFE01

      Pull out the 4 injectors from the delivery pipe.

  41. REMOVE INTAKE MANIFOLD


    1. A01DVQ2E01

      Disconnect the crankshaft position sensor from the clamp.

    2. Remove the 5 bolts, 2 nuts, intake manifold and gasket.

  42. REMOVE EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)


    1. A01DXB3E01

      Remove the 5 bolts and heat insulator.

  43. REMOVE EXHAUST MANIFOLD HEAT INSULATOR (w/ Secondary Air Injection System)


    1. A01E2CUE01

      Remove the 5 bolts and heat insulator.

  44. REMOVE AIR SWITCHING VALVE (w/ Secondary Air Injection System)


    1. A01DYQEE01

      Remove the 4 nuts, intake pipe insulator and 2 gaskets.

    2. A01E0IZE01

      Remove the 2 nuts and air switching valve.

  45. REMOVE EXHAUST MANIFOLD (w/o Secondary Air Injection System)


    1. A01DYT5E01

      Remove the 6 nuts, exhaust manifold and gasket.

  46. REMOVE EXHAUST MANIFOLD (w/ Secondary Air Injection System)


    1. A01DVZOE01

      Remove the 8 nuts, exhaust manifold and gasket.

  47. REMOVE IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. A01DXLA

      Loosen the bolt, and then remove the idle pulley assembly.

      Tech Tips

      The bolt in the illustration cannot be removed from the idle pulley assembly.

  48. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A01DUZFE02

      Remove the 5 bolts and No. 1 compressor mounting bracket.

  49. REMOVE DRIVE BELT TENSIONER


    1. A01DWSYE01

      Remove the 3 bolts and belt tensioner.

  50. REMOVE WATER INLET


    1. Remove the bolt, 2 nuts, water inlet and gasket.

  51. REMOVE THERMOSTAT


    1. Remove the thermostat and gasket.

  52. REMOVE NO. 1 IDLER PULLEY


    1. A01E053E01

      Remove the bolt, pulley plate, idler pulley and spacer.

  53. REMOVE OIL PRESSURE SWITCH


    1. Using a 24 mm deep socket wrench, remove the oil pressure switch.

  54. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A01DV1DE01

      Remove the 2 nuts, water by-pass pipe and gasket.

  55. REMOVE KNOCK SENSOR


    1. Remove the bolt and sensor.

  56. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. Using a 19 mm deep socket wrench, remove the sensor.

  57. REMOVE CAMSHAFT POSITION SENSOR


    1. A01DVCKE01

      Remove the bolt, sensor and O-ring.

  58. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01DXF5E04

      Disconnect the sensor connector.

    2. Disconnect the connector from the connector bracket.

    3. Detach the harness clamp.

    4. Remove the bolt and sensor.

  59. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE


    1. A01DY85E01

      Remove the bolt, oil control valve and O-ring.

  60. REMOVE FRONT ENGINE MOUNTING BRACKET RH


    1. A01DYK8E01

      Remove the 4 bolts and mounting bracket.

  61. REMOVE FRONT ENGINE MOUNTING BRACKET LH


    1. A01DZJZE01

      Remove the 4 bolts and mounting bracket.