Engine Assembly Removal

Disconnect the fuel pump ECU connector (Click here).

Start the engine. After the engine stops, turn the engine switch off.

HINT:

DTC P0171/0174 (system too lean) may be stored.

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

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

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

NOTICE:

1. After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work (Click here).
   
2. When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).
   

Connect the fuel pump ECU connector (Click here).

Remove the 4 bolts and transmission oil cooler air duct.

Using a clip remover, remove the 4 clips and radiator side deflector RH.

Using a clip remover, remove the 4 clips and radiator side deflector LH.

Remove the 2 hood support bolts and disconnect the hood supports.

CAUTION:

Remove the hood support assembly while supporting the hood by hand.

Remove the 4 bolts and hood.

w/ KDSS:
Remove the 3 clips and front fender apron trim packing B.

w/o KDSS:
Remove the 4 clips and front fender apron trim packing B.

Remove the 4 clips and front fender apron trim packing D.

Remove the 3 clips and front fender apron trim packing A.

Remove the 4 clips and front fender apron trim packing C.

Remove the 10 bolts and No. 1 engine under cover sub-assembly.

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

Remove the 4 bolts and oil pan protector assembly.

Raise the front of the V-bank cover to detach the 3 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

Remove the oil filler cap.

Remove the 2 bolts and No. 2 engine under cover seal.

Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

Install a new gasket and the oil pan drain plug.

Torque:

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

Install the No. 2 engine under cover seal with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Loosen the radiator drain cock plug.

Remove the radiator cap and drain the coolant.

HINT:

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

Loosen the 2 cylinder block drain cock plugs and drain the coolant from the engine.

Tighten the 2 cylinder block drain cock plugs.

Torque:

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

Tighten the radiator drain cock plug by hand.

Remove the drain plug and gasket, and drain the ATF.

Install a new gasket and the drain plug.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Remove the bolt and loosen the nut.

Detach the hook of the battery clamp from the battery bracket, and then remove the battery clamp.

Remove the battery.

Disconnect the No. 2 PCV hose and No. 1 air hose.

Disconnect the mass air flow meter connector and detach the clamp.

Remove the 3 bolts and loosen the hose clamp, and then remove the air cleaner and hose.

Remove the No. 1 radiator hose.

Loosen the 4 nuts holding the fluid coupling fan.

Remove the fan and generator V belt (Click here).

Disconnect the reservoir hose from the upper radiator tank.

w/ Air Cooled Transmission Oil Cooler:
Detach the claw to open the flexible hose clamp.

Remove the 2 bolts and disconnect the oil cooler tube from the fan shroud.

Remove the 2 bolts holding the fan shroud.

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

NOTICE:

Be careful not to damage the radiator core.

Remove the fan pulley from the engine water pump.

Remove the No. 2 radiator hose.

Remove the 4 bolts and radiator.

Disconnect the No. 3 air injection system hose from the air tube sub-assembly.

Disconnect the 2 water by-pass hoses and remove the 2 bolts and No. 5 water by-pass pipe.

Detach the 2 wire harness clamps and PCV hose clamp.

Remove the 3 bolts and EGR valve bracket.

Disconnect the PCV hose from the PCV pipe of the cylinder head cover LH and RH.

Remove the bolt and PCV hose.

Disconnect the No. 2 air injection system hose from the air switching valve.

Disconnect the manifold absolute pressure sensor connector and detach the clamp.

Remove the 2 bolts and bracket.

Remove the bolt and air tube.

w/o Secondary Air Injection System:

1. Disconnect the manifold absolute pressure sensor connector and detach the clamp.
   

2. Remove the 2 bolts and bracket.
   

Disconnect the No. 4 water by-pass hose.

Disconnect the throttle position sensor and throttle control motor connector.

Disconnect the PCV valve hose.

Disconnect the purge VSV connector.

Disconnect the purge line hose from the purge VSV.

Disconnect the vacuum switching valve connector (for ACIS).

Remove the bolt.

Detach the 3 wire harness clamps from the 3 wire harness brackets.

Disconnect the fuel tube from the fuel delivery pipe (Click here).

Disconnect the fuel tube from the No. 2 fuel delivery pipe (Click here).

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

Text in Illustration

	Bolt
	Nut

Remove the engine oil level dipstick.

Detach the engine wire clamp.

Remove the bolt and engine oil level dipstick guide.

Remove the O-ring from the engine oil level dipstick guide.

Slide the clip and disconnect the suction hose from the vane pump.

Remove the union bolt and disconnect the pressure feed tube.

Remove the gasket.

Remove the 2 bolts and vane pump.

Remove the 3 bolts, nut and stud bolt, and then disconnect the cooler compressor.

HINT:

It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

Remove the 2 bolts and insulator.

Disconnect the heated oxygen sensor connector.

Using SST, remove the heated oxygen sensor from the front No. 2 exhaust pipe.

SST

09224-00010

Detach the clamp and disconnect the heated oxygen sensor connector.

Using SST, remove the heated oxygen sensor from the front exhaust pipe.

SST

09224-00010

Remove the bolt and exhaust tailpipe clamp.

Remove the 2 exhaust pipe supports, gasket and tailpipe.

Remove the 4 bolts and disconnect the center exhaust pipe.

Remove the 3 exhaust pipe supports, 2 gaskets and center exhaust pipe.

Remove the 2 nuts and front No. 2 exhaust pipe.

Remove the gasket.

Remove the 2 nuts and front exhaust pipe.

Remove the gasket.

Remove the 3 bolts and No. 2 manifold stay.

Remove the 3 bolts and manifold stay.

Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

w/ Secondary Air Injection System:
Remove the 9 nuts, exhaust manifold and 2 gaskets.

w/o Secondary Air Injection System:
Remove the 7 nuts, exhaust manifold and gasket.

Remove the 3 bolts and heat insulator.

Disconnect the air fuel ratio sensor connector and detach the wire harness clamp.

w/ Secondary Air Injection System:
Remove the 9 nuts, exhaust manifold and 2 gaskets.

w/o Secondary Air Injection System:
Remove the 7 nuts, exhaust manifold and 2 gaskets.

Remove the 3 bolts and starter cover.

Disconnect the starter connector.

Remove the nut and disconnect the starter wire.

Remove the 2 bolts and starter.

Remove the flywheel housing side cover.

Remove the fuel pipe clamp from the fuel tube connector.

Disconnect the fuel hose and fuel tube sub-assembly (Click here).

Disconnect the clamp and ECM connector.

HINT:

Refer to the following procedures to disconnect the ECM connector (Click here).

Disconnect the 4 connectors and 2 clamps from the connector holder block.

Remove the bolt and disconnect the ground wire.

Remove the nut and disconnect the wire and 2 clips from the engine room junction block.

Disconnect the 2 connectors and 2 clips from the engine room junction block.

w/ Secondary Air Injection System:
Disconnect the 2 air injection control driver connectors.

Remove the bolt, disconnect the clamp and ground wire.

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

Disconnect the 2 connectors and 2 clips from the engine room junction block.

w/ Secondary Air Injection System:
Disconnect the connector and clamp.

w/ Winch:
Detach the wire harness clamp, remove the nut and disconnect the ground wire from the wire harness clamp bracket.

Disconnect the 2 transmission oil cooler hoses from the oil cooler tube unions.

Remove the 2 bolts and disconnect the oil cooler tube.

Turn the crankshaft to gain access to the 6 bolts and remove the bolts while holding the crankshaft pulley setting bolt with a wrench.

w/ Rear Heater:
Disconnect the 6 water hoses.

Remove the 2 bolts and No. 1 water by-pass pipe.

w/o Rear Heater:
Disconnect the 4 water hoses.

Remove the 2 bolts and No. 1 water by-pass pipe.

Disconnect the hose.

Remove the 2 bolts and No. 1 water by-pass pipe.

Remove the 2 bolts and engine mounting heat insulator.

Remove the 4 bolts and rear engine No. 1 mounting insulator from the transmission.

Using SST, hold the crankshaft.

SST

09213-70011(09213-70020)
09330-00021

Remove the 10 bolts, the rear drive plate spacer, the drive plate and ring gear, and the crankshaft angle sensor rotor.

Install 2 engine hangers with 2 bolts as shown in the illustration.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

HINT:

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

NOTICE:

When hanging the engine, make sure to hang the engine with the angle of the sling device at 50° or less. Otherwise, the engine or engine hangers may be damaged.

Remove the 2 nuts and 4 bolts from the front engine mounting insulator LH and RH.

Lift the engine out of the vehicle carefully.

NOTICE:

1. Make sure the engine is clear of all wiring, hoses and cables.
   
2. With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
   
3. Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
   

Remove the front engine mounting insulator LH and RH.

Place the engine onto a workbench.

Install the engine to an engine stand with bolts.

Remove the 2 bolts and 2 engine hangers.

Remove the nut and mounting insulator.

Remove the nut and mounting insulator.

Remove the bolt and No. 2 front engine mounting bracket LH.