Engine Assembly - Removal

1. Discharge fuel system pressure

2. Remove automatic transmission assembly (for 2wd)

3. Remove automatic transmission assembly (for 4wd)

4. Remove hood sub-assembly

5. Remove throttle body cover sub-assembly

6. Remove air cleaner hose assembly

7. Remove air cleaner assembly

8. Remove no. 1 engine under cover sub-assembly

9. Remove engine under cover assembly rear

10. Drain engine coolant

11. Drain engine oil

12. Remove radiator assembly

13. Remove fan shroud

14. Disconnect no. 2 fuel hose

15. Disconnect fuel hose

16. Disconnect fuel vapor feed hose assembly

17. Remove fan and generator v belt

18. Separate vane pump assembly

19. Separate compressor

20. Remove fan with fluid coupling

21. Remove transmission oil filler tube sub-assembly

22. Remove oil level gauge guide

23. Disconnect heater hose

24. Separate engine wire

25. Remove engine assembly

26. Remove engine wire

27. Remove intake manifold assembly

28. Remove no. 2 wiring harness heat insulator

29. Remove no. 2 engine wire

30. Remove no. 1 engine mounting bracket front rh

31. Remove no. 1 engine mounting bracket front lh

32. Remove generator assembly

33. Remove heater hose

34. Remove drive plate & ring gear sub-assembly

35. Remove oil cooler pipe

36. Remove pump bracket

37. Remove no. 3 timing belt cover sub-assembly lh

38. Remove no. 2 timing chain or belt cover

39. Remove no. 2 timing belt cover sub-assembly

40. Remove v-ribbed belt tensioner assembly

41. Remove fan bracket sub-assembly

42. Remove ignition coil assembly

43. Remove camshaft position sensor

44. Remove crankshaft position sensor

45. Remove vvt sensor

46. Remove water by-pass pipe sub-assembly

47. Remove no. 2 air switching valve

48. Remove water by-pass joint rr

49. Remove air pump assembly with bracket

50. Remove starter assembly

51. Remove knock sensor

52. Remove water inlet housing

53. Remove water by-pass joint fr

54. Remove exhaust manifold sub-assembly rh

55. Remove exhaust manifold sub-assembly lh

56. Remove oil cooler assembly

57. Remove ventilation valve sub-assembly

58. Replace partial engine assembly

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HINT:

(Click here)

HINT:

(Click here)

HINT:

(Click here)

1. Disconnect the windshield washer hose.

2. Disconnect the hood dampers.

3. Remove the 4 bolts and hood sub-assembly.

1. Remove the 2 nuts and throttle body cover sub-assembly.

1. Disconnect the vacuum hoses (for P/S idle up and for fuel pressure regulator) and ventilation hose.

1. Disconnect the intake air flow meter connector.

2. Disconnect the ground cable from the body.

3. Remove the air cleaner cap and air cleaner element.

4. Remove the 3 bolts and air cleaner assembly.

CAUTION:

To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

1. Remove the radiator cap.

2. Remove the service hole cover from the engine under cover No. 1.

3. Install a vinyl hose onto the drain on the radiator side.

4. Fix the vinyl hose with tape.

5. Loosen the 3 drain plugs on the engine and radiator, and drain the coolant.

6. Drain the coolant from the reservoir tank.

7. Tighten the 3 drain plugs.

   Torque:

   13 N*m{130 kgf*cm, 9 ft.*lbf} for the engine

8. Remove the vinyl hose from the radiator.

1. Remove the oil pan drain plug and drain the engine oil.

2. Clean the oil pan drain plug and install a new gasket and the drain plug.

   Torque:

   39 N*m{398 kgf*cm, 29 ft.*lbf}

HINT:

(Click here)

1. Disconnect the fasteners of the clamp and oil cooler hoses from the fan shroud in sequence.

2. Remove the fan shroud with fan.

1. Observe the following precautions when disconnecting the fuel tube connector:
   

   1. Remove the No. 2 fuel pipe clamp.

   2. Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.

   4. Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.

   6. When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time.

   7. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away.

   9. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.

1. Observe the following precautions when disconnecting the fuel tube connector:
   

   1. Remove the No. 1 fuel pipe clamp.

   2. Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.

   4. Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.

   6. When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time.

   7. Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away.

   9. Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.

1. Loosen the belt tension by turning the belt tensioner counterclockwise, and then remove the fan and generator V belt.

   HINT:

   The pulley bolt for the belt tensioner has left-hand thread.

1. Disconnect the vacuum hose.

2. Remove the nut, 2 bolts and vane pump assembly.

   HINT:

   Hang up the hose instead of detaching.

1. Disconnect the compressor connector.

2. Remove the nut, 3 bolts, compressor stay and compressor.

   HINT:

   Hang up the hoses instead of detaching.

1. Remove the 4 nuts and fan with fluid coupling.

2. Remove the fan pulley.

1. Remove the bolt and transmission oil filler tube.

1. Remove the bolt and oil level gauge guide.

2. Remove the O-ring.

1. Remove the front door scuff plate RH (Click here).

2. Remove the cowl side trim board RH (Click here).

3. Remove the glove compartment door (Click here).

4. Disconnect each connector for the ECM, four-wheel- drive-control ECU (4WD only) and instrument panel wire before pulling out the engine wire into the engine room.

5. Disconnect the 3 ground cables from the body.

6. Disconnect the No. 2 engine wire from the battery terminals (positive and negative) and engine room relay block.

1. Attach the engine chain hoist to the engine hangers.

2. Remove the 4 nuts and 4 bolts.

3. Lift the engine out of the vehicle slowly and carefully.

   HINT:

   Make sure that the engine is kept clear of all wiring hoses and cables.

1. Disconnect the VSV connector.

2. Disconnect the solenoid connector.

1. Disconnect the 2 water by-pass hoses from the throttle body.

2. Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.

3. Remove the bolt and nut holding the engine wire protector from the intake manifold and cylinder head.

4. Remove the 2 bolts and ground cables from the RH and LH cylinder heads.

5. Remove the bolt and V-bank cover bracket from the intake manifold.

6. Disconnect the engine wire from the engine hanger and wire bracket.

7. Remove the bolt and wire bracket from the intake manifold.

8. Remove the 6 bolts, 4 nuts, intake manifold assembly and 2 gaskets.

1. Remove the 2 bolts and No. 2 wiring harness heat insulator.

1. Remove the bolt and separate the ground cable wire.

2. Remove the nut, 2 bolts and No. 2 engine wire.

1. Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front.

1. Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front.

1. Disconnect the generator connector.

2. Remove the terminal cap and nut, and disconnect the generator wire.

3. Disconnect the alternator wire clamp from the cord clip on the generator.

4. Remove the bolt, 2 nuts and generator.

1. Using SST, hold the crankshaft.

   SST

   09213-70011
   09330-00021
   

2. Remove the 8 bolts, front spacer, drive plate and rear spacer.

1. Disconnect the 3 hoses.

2. Remove the bolt, nut and oil cooler pipe.

1. Remove the 4 bolts and pump bracket.

1. Remove the grommet and separate the cam position sensor connector from the No. 3 timing belt cover sub-assembly LH.

2. Remove the 4 bolts and No. 3 timing belt cover sub-assembly LH.

1. Remove the nut, 3 bolts and No. 2 timing belt cover.

1. Remove the 2 bolts and No. 2 timing belt cover sub-assembly.

1. Remove the bolt, 2 nuts and V-ribbed belt tensioner.

1. Remove the 2 nuts, 2 bolts and fan bracket sub-assembly.

1. Remove the 8 bolts and 8 ignition coils.

1. Remove the bolt, stud bolt and camshaft position sensor.

1. Remove the bolt and crankshaft position sensor.

1. Remove the 2 bolts and VVT sensors.

1. Remove the wire clamp.

2. Remove the bolt and water by-pass.

3. Remove the O-ring from the water by-pass pipe sub-assembly.

1. Remove the 2 vacuum hoses from the No. 2 air switching valves.

2. Remove the 4 bolts, 2 gaskets and the 2 No. 2 air switching valves from the water by-pass joint rear.

1. Remove the 4 nuts and water by-pass joint.

2. Remove the 2 gaskets from the water by-pass joint.

1. Disconnect the No.2 air hose from the air switching valve.

2. Disconnect the air switching valve connector.

3. Disconnect the pressure sensor connector for the air injection system.

4. Remove the 4 bolts and air pump with bracket assembly.

1. Disconnect the No. 2 engine wire.

2. Remove the 2 bolts and starter assembly.

1. Disconnect the 2 knock sensor connectors.

2. Remove the 2 nuts and 2 knock sensors.

1. Remove the 2 bolts.

2. Remove the water inlet housing and O-ring from the engine.

1. Remove the 4 nuts, water by-pass joint and 2 gaskets.

1. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

2. Disconnect the oxygen sensor connector.

3. Remove the 8 nuts and exhaust manifold sub-assembly.

1. Remove the 4 bolts and No. 2 exhaust manifold heat insulator.

2. Disconnect the oxygen sensor connector.

3. Remove the 8 nuts and exhaust manifold sub-assembly.

1. Remove the 2 bolts and nut.

2. Remove the oil cooler assembly with bracket and gasket.

1. Remove the ventilation valve cover.

2. Remove the ventilation valve sub-assembly.