Engine Assembly Removal

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.

Disconnect the fuel pump connector.

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

Start the engine. After the engine has stopped on its own, turn the engine switch off.

NOTICE:

DTC P0171/P0172 (system too lean) may be set.

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

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

Connect the fuel pump connector.

Remove the drain plug.

Remove the radiator cap and reservoir 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.

Add the automatic transmission fluid following the flow chart below.

When adding the maximum amount of fluid: [*1]

1. Lift up the vehicle.
   





2. Remove the 2 bolts and transmission case cover.
   





3. Remove the refill plug and overflow plug.
   





4. Add ATF through the refill hole until it drains out from the overflow hole.
   

   NOTICE:

   Be sure to use ATF WS.





5. Install a new gasket and the overflow plug.
   

   Torque:

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

6. Add proper amount of ATF through the refill hole.
   

   NOTICE:

   Refill amount differs depending on the related procedures indicated below.

   Related procedures	Refill amount
   Removal and installation of oil pan (Including the oil drain)	1.3 liters (1.4 US qts, 1.1 lmp.qts)
   Removal of transmission valve body assembly	3.3 liters (3.5 US qts, 2.9 lmp.qts)
   Removal of torque converter assembly	4.4 liters (4.7 US qts, 3.9 lmp.qts)





7. Install a new O-ring and the refill plug.
   

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

8. Lower the vehicle.
   





9. Using SST, create a short-circuit between terminals TC and CG of the DLC3.
   

   SST

   09843-18040
   

10. Start the engine.
    

    NOTICE:

    1. Be sure to place the key inside the cabin in order to start the engine.
       
    2. Turn the A/C off.
       

11. Slowly move the shift lever from the P to the S position, shift the gear from 1st to 6th and then return the shift lever to the P position.
    

12. Switch to the fluid temperature detection mode.
    

    1. Move the shift lever from the N to the D position, or from D to N, within 1.5 seconds.
       
    2. Continue this procedure for 6 seconds or more.
       

    Standard:

    Meter indicator light "D" comes on for 2 seconds and then goes off.
    

13. Return the shift lever to the P position and disconnect terminal TC after confirming the above condition.
    

14. Idle the engine to raise fluid temperature.
    





15. Lift up the vehicle immediately after meter indicator light "D" comes on.
    

    NOTICE:

    1. Add fluid only when the meter indicator light is on.
       
    2. Perform this procedure while the engine is idling.
       




16. Remove the overflow plug. If ATF overflows, proceed to [*2].
    If ATF does not overflow, proceed to [*3].
    

    HINT:

    "Overflow" indicates the condition under which ATF drains out from the overflow tube.

When fluid overflows: [*2]

NOTICE:

Capacity of the overflow tube is approximately 3 cc.

1. Install a new gasket and the overflow plug when the draining ATF has become a trickle.
   

   Torque:

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

   NOTICE:

   Be careful when handling the drained ATF as it will be hot.

2. Install a new O-ring and tighten the refill plug.
   

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}





3. Install the transmission case cover with the 2 bolts.
   

   Torque:

   5.4 N*m{55 kgf*cm, 48 in.*lbf}

4. Lower the vehicle.
   

5. Turn the engine switch off and remove the SST.
   

When fluid does not overflow:[*3]

1. Remove the refill plug.
   





2. Add ATF through the refill hole until it drains out from the overflow hole.
   





3. Install a new gasket and the overflow plug when the draining ATF has become a trickle.
   

   Torque:

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

4. Install a new O-ring and tighten the refill plug.
   

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}





5. Install the transmission case cover with the 2 bolts.
   

   Torque:

   5.4 N*m{55 kgf*cm, 48 in.*lbf}

6. Lower the vehicle.
   

7. Turn the engine switch off and remove the SST.
   

When adding a minimum amount of fluid: [*4]

1. Using SST, create a short-circuit between terminals TC and CG of the DLC3.
   

   SST

   09843-18040
   

2. Start the engine.
   

   NOTICE:

   1. Be sure to place the key inside the cabin in order to start the engine.
      
   2. Turn the A/C off.
      

3. Slowly move the shift lever from the P to the S position, shift the gear from 1st to 6th and then return the shift lever to the P position.
   

4. Switch to the fluid temperature detection mode.
   

   1. Move the shift lever from the N to the D position, or from D to N, within 1.5 seconds.
      
   2. Continue this procedure for 6 seconds or more.
      

   Standard:

   Meter indicator light "D" comes on for 2 seconds and then goes off.
   

5. Return the shift lever to the P position and disconnect terminal TC after confirming the above condition.
   

6. Idle the engine to raise fluid temperature.
   





7. Lift up the vehicle immediately after meter indicator light "D" comes on.
   

   NOTICE:

   1. Add fluid only when the meter indicator light is on.
      
   2. Perform this procedure while the engine is idling.
      




8. Remove the overflow plug. If ATF overflows, proceed to [*5]. If ATF does not overflow, proceed to [*6].
   

   HINT:

   "Overflow" indicates the condition under which ATF drains out from the overflow tube.

When fluid overflows: [*5]

1. Install a new gasket and the overflow plug when the draining ATF has become a trickle.
   

   Torque:

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

   NOTICE:

   Be careful when handling the drained ATF as it will be hot.





2. Install the transmission case cover with the 2 bolts.
   

   Torque:

   5.4 N*m{55 kgf*cm, 48 in.*lbf}

3. Lower the vehicle.
   

4. Turn the engine switch off and remove the SST.
   

When fluid does not overflow: [*6]

1. Remove the refill plug.
   





2. Add ATF through the refill hole until it drains out from the overflow hole.
   





3. Install a new gasket and the overflow plug when the draining ATF has become a trickle.
   

   Torque:

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

4. Install a new O-ring and tighten the refill plug.
   

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}





5. Install the transmission case cover with the 2 bolts.
   

   Torque:

   5.4 N*m{55 kgf*cm, 48 in.*lbf}

6. Lower the vehicle.
   

7. Turn the engine switch off and remove the SST.
   

Remove the 7 clips and intake duct seal.

Remove the nut, 2 clips and side cover.

Remove the 3 clips and side cover.

Remove the 2 nuts and V-bank cover.

Using a clip remover, remove the 3 clips.

Remove the 10 screws and under cover.

Remove the 4 screws, 2 grommets, 2 spacers and under cover.

Remove the 4 bolts and 4 nuts.

Disconnect the exhaust pipe front ends from the exhaust manifold and remove the 2 gaskets.

Remove the 2 bolts, 2 compression springs, exhaust pipe and gasket.

Put matchmarks on both flanges.

Remove the 4 nuts, bolts and washers.

HINT:

If the flange connection is hard to separate, temporarily tighten one nut only and evenly tap the flange with a brass bar and hammer to separate the propeller shaft assembly from the differential companion flange.

Remove the 2 bolts, 2 center support bearing washers and center support bearing.

Insert SST in the transmission to prevent oil leakage.

SST

09325-40010

NOTICE:

Be careful not to damage the oil seal.

Remove the bolt and air cleaner inlet.

Disconnect the ventilation hose from the cylinder head.

Disconnect the MAF meter connector.

Disconnect the clamp from the air cleaner.

Disconnect the VSV (for EVAP).

Loosen the hose clamp.

Remove the 3 bolts and air cleaner case.

Disconnect the hose from the water inlet with thermostat and radiator tank upper.

Disconnect the hose from the water inlet and radiator tank lower.

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

Disconnect the inlet hose.

Disconnect the outlet hose.

Remove the fuel pipe clamp.

Pinch and pull the fuel hose's connector to disconnect it from the fuel pipe.

NOTICE:

1. Check for foreign matter in the fuel hose and around the fuel hose's connector. Clean if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel pipe.
   
2. Do not use any tools to separate the connector and fuel pipe.
   
3. Do not forcefully bend or twist the hose.
   
4. Keep the connector and pipe free from foreign matter.
   


5. Put the connector in a plastic bag to prevent damage and contamination.
   
6. If the connector and fuel pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
   

Remove the 3 bolts and engine room ECM cover.

Disconnect the ECM connectors.

Using a screwdriver, disconnect the connector holder.

Disconnect the 6 ECM connectors.

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

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 bolt and disconnect the ground cable.

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 V-ribbed belt tensioner.

Disconnect the magnetic clutch connector.

Remove the 3 bolts and nut.

Using an E8 "torx" socket, remove the stud bolt and with pulley 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 nut and disconnect the height control sensor link.

Remove the 4 bolts and protector.

Remove the clip and the castle nut.

Using SST, separate the tie rod end LH from the steering knuckle.

SST

09628-00011

NOTICE:

1. Hang SST with a string, etc. to prevent it from falling.
   
2. Do not damage the front disc brake dust cover.
   
3. Do not damage the ball joint dust cover.
   
4. Do not damage the steering knuckle.
   

Support the front suspension lower arm with a jack. Be sure to place a wooden block between the jack and the front suspension lower arm to avoid damage.

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

NOTICE:

Do not remove the nut.

Loosen the lock nut of the front shock absorber.

NOTICE:

1. Do not remove the lock nut.
   
2. Loosen the lock nut only when disassembling the front shock absorber with coil spring.
   

Remove the 3 nuts from the upper side of the front suspension support.

Slowly lower the jack. Remove the bolt and nut from the lower side to remove the front shock absorber with coil spring.

Support the front suspension lower arm with a jack. Be sure to place a wooden block between the jack and the front suspension lower arm to avoid damage.

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

NOTICE:

Do not remove the nut.

Loosen the lock nut of the front shock absorber.

NOTICE:

1. Do not remove the lock nut.
   
2. Loosen the lock nut only when disassembling the front shock absorber with coil spring.
   

Remove the 3 nuts from the upper side of the front suspension support.

Slowly lower the jack. Remove the bolt and nut from the lower side to remove the front shock absorber with coil spring.

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 intermediate shaft assembly No.2.

HINT:

1. Do not remove bolt (A).
   
2. Do not disconnect the steering intermediate shaft assembly No.2 from the power steering link assembly.
   

Put matchmarks on the steering intermediate shaft assembly No.2 and the power steering link assembly.

Separate the intermediate shaft assembly No.2 from the power steering link assembly.

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

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

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

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

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

Remove the 2 bolts, 2 washers, 2 nuts, and the power steering link assembly from the front suspension cross member.

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 the engine is clear of all wiring and hoses.

Install the 2 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.

Remove the 9 bolts and automatic transmission assembly.

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 remove the front suspension crossmember sub-assembly from the engine.

Fix the engine onto a engine stand with the bolts.

Remove the engine wire from the engine.

Remove the oil dipstick.

Remove the 2 bolts, then remove the No. 1 and No. 2 oil dipstick guide.

Remove the O-ring from the oil level gauge guide.

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

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

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 surface contacting the cylinder head for warpage.

Maximum warpage:

0.7 mm (0.028 in.)

HINT:

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

Detach the clamp, and remove the bolt from the generator.

Disconnect the generator connector.

Detach the rubber cap, and then remove the nut and battery cable.

Remove the nut, bolt and generator bracket.

Remove the 2 bolts and generator.

Remove the bolt, plate and idler pulley.

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 3 clips and engine cover.

Remove the bolt and water by-pass pipe.

Remove the bolt and water by-pass pipe.

Remove the 2 bolts and intake manifold stay.

Remove the 4 bolts and 2 surge tank stays.

Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.

HINT:

Cover the intake manifold port to prevent foreign matter from entering it.

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

Maximum warpage:

Specified Condition	Condition
When installed	0.3 mm (0.011 in.)
When not installed	2.5 mm (0.098 in.)

Remove the holder.

Pull out the fuel pressure pulsation damper from the fuel delivery pipe.

Remove the bolt and disconnect the No. 1 fuel hose from the cylinder head cover.

Disconnect the 6 fuel injector connectors.

Remove the 5 bolts and the fuel delivery pipe together with the 6 fuel injectors.

NOTICE:

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

Pull out the 6 fuel injectors from the delivery pipe.

Remove the 6 insulators and 6 O-rings from the 6 fuel injectors.

Remove the 6 bolts, 4 nuts, intake manifold and gasket.

HINT:

Cover the cylinder head intake port to prevent foreign matter from entering it.

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.
   

Remove the 2 bolts and 2 sensors.

Remove the 4 bolts and mounting bracket.

Remove the 4 bolts and mounting 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.