Engine Assembly Removal

Remove the 11 clips and intake duct seal.

Remove the 5 clips and side cover.

Remove the 2 clips and side cover.

Raise the V-bank cover to disengage the clip on the rear of the cover. Raise the cover again to disengage the 2 clips on the front of the cover and remove the cover.

NOTICE:

Attempting to disengage both front and rear clips at the same time may cause the cover to break.

Start up the engine.

Turn the A/C switch on.

Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

Stop the engine.

Using SST, let the refrigerant gas out.

SST

07110-58060(07117-58060,07117-58070,07117-58080,07117-58090,07117-78050,07117-88060,07117-88070,07117-88080)

Remove the 2 bolts and engine under cover air guide bracket.

Remove the bolt and engine under cover LH.

Remove the drain plug.

Install a new gasket and the drain plug.

Torque:

40 N*m{408 kgf*cm, 30 ft.*lbf}

Remove the radiator cap and reservoir tank cap.

Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs. Then drain the coolant.

HINT:

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

Remove the bolt, clip and inlet air cleaner.

Disconnect the MAF meter connector.

Disconnect the clamp from the air cleaner.

Disconnect the VSV hose.

Disconnect the 4 clamps.

Remove the hose clamp and air cleaner cap with air cleaner hose.

Remove the 2 bolts, clamp and air cleaner case.

Remove the clamp and disconnect the union to check valve hose.

Remove the clamp and disconnect the No. 2 fuel vapor feed hose.

Remove the clamp and disconnect the inlet radiator hose.

Remove the clamp and disconnect the outlet radiator hose.

Remove the clamp and disconnect the radiator reservoir tank hose.

Disconnect the inlet heater water hose.

Disconnect the outlet heater water hose.

Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor.

Remove the O-ring from the cooler refrigerant suction hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

Remove the bolt and disconnect the discharge hose from the compressor.

Remove the O-ring from the discharge hose sub-assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

Remove the 3 bolts and ECM cover.

NOTICE:

1. Remove all water from on and around the ECM cover.
   
2. Perform the inspection indoors to avoid rain.
   
3. Be sure to prevent water intrusion to the ECM (connectors and screw parts).
   

Disconnect the 6 ECM connectors.

Using a screwdriver, disconnect the connector holder.

Remove the engine room No. 1 relay block cover.

Remove the nut and disconnect the wire from the engine room No. 1 junction block.

Remove the nut and disconnect the battery positive (+) cable.

Disconnect the connector and remove the 4 clamps from body.

Remove the bolt, clamp and engine wire No. 3.

Remove the bolt and disconnect the ground cable.

Remove the clamp and disconnect the No. 3 fuel hose.

Remove the 4 bolts and suspension member protector.

Fix the steering wheel with the seat belt in order to prevent rotation.

HINT:

This operation is useful to prevent damage to the spiral cable.

Loosen bolt (A) and remove bolt (B), then slide the steering sliding yoke sub-assembly.

NOTICE:

1. Do not remove bolt (A).
   
2. Do not separate the steering sliding yoke sub-assembly from the power steering gear assembly.
   

Put matchmarks on the steering sliding yoke sub-assembly and the power steering gear assembly.

Separate the steering sliding yoke sub-assembly from the power steering gear assembly.

Remove the nut and disconnect the height control sensor link.

Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.

Remove the 2 bolts from the front lower ball joint.

Remove the 2 bolts and exhaust pipe No. 1 support bracket sub-assembly.

Remove the bolt (A) to disconnect the earth wire from the bracket.

Remove the 2 clamps to disconnect the wire harness from the bracket.

Disconnect the 2 connectors (C) and (D) from the power steering link assembly.

Release the lock of connector (E) and disconnect the connector from the power steering link assembly.

Remove the bolt (B) and the power steering earth wire from the power steering link assembly.

Set the shift lever to the neutral position.

Remove the nut, and separate the floor shift gear shifting rod sub-assembly.

Set the engine lifter.

Remove the 4 bolts, then separate the engine rear mounting member.

Remove the 12 bolts shown in the illustration.

Operate the engine lifter, then slowly remove the engine from the vehicle.

NOTICE:

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

Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts as shown in the illustration.

Torque:

33 N*m{336 kgf*cm, 24 ft.*lbf}

Attach an engine sling device and hang the engine with a chain block.

Disconnect the terminal 50 connector from the starter assembly.

Detach the terminal cap.

Remove the nut and disconnect the wire harness from terminal 30.

Remove the 2 bolts and starter.

Remove the oil level gauge.

Remove the bolt, then remove the No. 2 oil dipstick guide.

Remove the O-ring from the No. 2 oil dipstick guide.

Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.

Remove the O-ring from the No. 1 oil dipstick guide.

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:

0.7 mm (0.028 in.)

HINT:

The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:

0.7 mm (0.028 in.)

HINT:

The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).

Using SST, hold the crankshaft.

SST

09213-70011(09213-70020)
09330-00021

Remove the 8 bolts and the flywheel.

Using SST, hold the crankshaft.

SST

09213-70011(09213-70020)
09330-00021

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

Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.

Fix the engine onto a engine stand with the bolts.

While releasing the belt tension by turning the belt tensioner counterclockwise, and remove the V-ribbed belt from the belt tensioner.

While turning the belt tensioner counterclockwise, align with its holes, and then insert the 5 mm bi-hexagon wrench into the holes to fix the belt tensioner.

Remove the 3 clips and clamp, then remove the No. 2 engine cover.

Remove the 3 clips, then remove the No. 1 engine cover.

Remove the bolt, plate and idler pulley.

Remove the terminal cap.

Remove the nut (A) and disconnect the wire harness from terminal B.

Remove the bolt (B) and clamp bracket.

Disconnect the generator connector, and detach the 2 clamps.

Remove the nut, and disconnect the generator bracket.

Remove the 2 bolts and generator.

Remove the 2 bolts and 2 generator brackets.

Disconnect the magnetic clutch connector.

Remove the 3 bolts and nut.

Remove the compressor and magnetic clutch.

Disconnect the 2 clamps.

Remove the 4 bolts and mounting bracket.

Remove the 4 bolts and mounting bracket.

Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.)

Using SST, hold the water pump pulley.

SST

09960-10010(09962-01000,09963-00700)

Remove the 4 bolts and water pump pulley.

Remove the engine wire from the engine.

Remove the bolt, 2 nuts and injector driver.

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:

2.5 mm (0.098 in.)

Remove the bolt and No. 2 surge tank stay.

Remove the bolt, and disconnect 2 hoses and water hose joint.

Disconnect the connector for the SCV.

Disconnect the SCV position sensor connector.

Remove the 4 bolts, 4 nuts, intake manifold and gasket.

Surge tank side:

1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
   

   Maximum warpage:

   0.1 mm (0.003 in.)
   

   If the warpage is greater than the maximum, replace the intake manifold.
   

Cylinder head side:

1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
   

   Maximum warpage:

   0.1 mm (0.003 in.)
   

   If the warpage is greater than the maximum, replace the intake manifold.
   

Disconnect the 2 knock sensor connectors.

Remove the 2 bolts and 2 knock sensors.

Remove the 2 bolts and 2 radio setting condensers.

Remove the bolt and V-bank cover bracket.

Remove the 6 bolts and 6 ignition coils.

Remove the 4 bolts, then remove the oil level sensor and gasket.

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

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