ENGINE ASSEMBLY > REMOVAL

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CAUTION:

1. Do not disconnect any part of the fuel system until you have discharged the fuel system pressure.
   
2. Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce the risk of fuel spray on yourself or in the engine compartment.
   

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

   NOTICE:

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

2. 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 engine switch off.
   

   HINT:

   DTC P0171/P0172 (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.
   

CAUTION:

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

1. Remove the drain plug.
   

CAUTION:

Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

1. Remove the radiator cap and reservoir cap.
   

2. 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.

   
   
   
   
   
   

1. Remove the 7 clips and intake duct seal.
   

1. Remove the nut, 2 clips and side cover.
   

1. Remove the 3 clips and side cover.
   

1. Remove the 2 nuts and V-bank cover.
   

1. Using a clip remover, remove the 3 clips.
   

2. Remove the 10 screws and under cover.
   

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

1. Remove the 4 bolts and 4 nuts.
   

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

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

1. Put matchmarks on both flanges.
   

2. 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.

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

4. Insert SST in the transmission to prevent oil leakage.
   

   SST

   09325-40010  
   

   NOTICE:

   Be careful not to damage the oil seal.

1. Remove the bolt and air cleaner inlet.
   

1. Disconnect the ventilation hose from the cylinder head.
   

2. Disconnect the MAF meter connector.
   

3. Disconnect the clamp from the air cleaner.
   

4. Disconnect the VSV (for EVAP).
   

5. Loosen the hose clamp.
   

6. Remove the 3 bolts and air cleaner case.
   

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

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

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

1. Disconnect the inlet hose.
   

1. Disconnect the outlet hose.
   

1. Remove the fuel pipe clamp.
   

2. Pinch and pull the fuel tube's connector to disconnect it from the fuel main pipe.
   

   NOTICE:

   1. Check for foreign matter in the fuel tube around the fuel tube's connector. Clean it if necessary. Foreign matter can affect the O-ring's ability to seal the connector and fuel main pipe.
      
   2. Do not use any tools to separate the connector and pipe.
      
   3. Do not forcefully bend or twist the hose.
      
   4. Keep the connector and pipe free from foreign matter.
      
   5. If the connector and pipe are stuck together, pinch the connector and turn it carefully to disconnect it.
      
   
   
   6. Put the connector in a plastic bag to prevent damage and contamination.
      

1. Remove the 3 bolts and ECM cover.
   

1. Disconnect the ECM connectors.
   

2. Using a screwdriver, disconnect the connector holder.
   

3. Disconnect the 6 ECM connectors.
   

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

5. Remove the engine room No. 1 relay block cover.
   

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

7. Remove the bolt and disconnect the ground cable.
   

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

2. 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.
   

1. Disconnect the magnetic clutch connector.
   

2. Remove the 3 bolts and nut.
   

3. Using an E8 "torx" socket, remove the stud bolt and 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.

1. Remove the nut and disconnect the height control sensor link.
   

1. Remove the 4 bolts and protector.
   

SST

09628-00011  

HINT:

Perform the same procedure as for the LH side.

1. Remove the clip and the castle nut.
   

2. 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.
      

1. 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.
   

2. 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.

3. 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.
      

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

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

1. 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.
   

2. 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.

3. 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.
      

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

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

1. 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.

2. 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.
      

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

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

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

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

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

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

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

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

1. Set the shift lever to the neutral position.
   

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

1. Set the engine lifter.
   

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

3. Remove the 12 bolts shown in the illustration.
   

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

   NOTICE:

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

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

   Part No.: 

   No. 1 Engine hanger	12281 - 31070
   No. 2 Engine hanger	12282 - 31070
   Bolts	91671 - 10825

   Torque:

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

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

1. Remove the 9 bolts and automatic transmission assembly.
   

1. Using SST, hold the crankshaft.
   

   SST

   09213-70011   (09213-70020)
   09330-00021  
   

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

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

1. Fix the engine onto a engine stand with the bolts.
   

1. Remove the engine wire from the engine.
   

1. Remove the oil level gauge.
   

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

3. Remove the O-ring from the oil dipstick guide.
   

1. Disconnect the heated oxygen sensor connector.
   

2. Remove the 6 nuts, exhaust manifold and gasket.
   

1. 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.).

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

1. Disconnect the heated oxygen sensor connector.
   

2. Remove the 6 nuts, exhaust manifold and gasket.
   

1. 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.).

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

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

2. Disconnect the generator connector.
   

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

4. Remove the nut, bolt and generator bracket.
   

5. Remove the 2 bolts and generator.
   

1. Remove the bolt, plate and idler pulley.
   

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

1. Using SST, hold the water pump pulley.
   

   SST

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

2. Remove the 4 bolts and water pump pulley.
   

1. Remove the bolt, 2 nuts and injector driver.
   

1. Remove the 3 clips and engine cover.
   

1. Remove the bolt and water by-pass pipe.
   

1. Remove the bolt and water by-pass pipe.
   

1. Remove the 2 bolts and intake manifold stay.
   

2. Remove the 4 bolts and 2 surge tank stays.
   

3. 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.

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

   Maximum warpage:

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

   If the warpage is greater than the maximum, replace the surge tank.
   

1. Remove the 4 bolts, 2 nuts, intake manifold and gasket.
   

   HINT:

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

1. 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.
      

2. 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.
      

1. Remove the fuel pulsation damper and 2 gaskets, and disconnect the fuel main tube from the fuel pump.
   

1. Disconnect the fuel pipe hose.
   

2. Remove the 2 bolts and fuel pipe.
   

1. Remove the fuel pipe from the fuel delivery pipe.
   

   NOTICE:

   Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

1. Disconnect the fuel hose.
   

2. Remove the 2 nuts, fuel pump and fuel pump insulator.
   

1. Disconnect the 3 wire harness clamps.
   

2. Remove the 2 bolts and 2 nuts.
   

3. With the connectors still connected, disconnect the delivery pipe.
   

   NOTICE:

   1. Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).
      
   2. Be extremely careful not to touch or strike the tips of the injectors.
      
   3. Pull and remove the fuel pipe in a straight line without tilting it.
      

4. Disconnect the 3 connectors from the 3 injectors.
   

5. Remove the 3 injector vibration insulators from the cylinder head.
   

1. Disconnect the 2 wire harness clamps.
   

2. Remove the 2 bolts and 2 nuts.
   

3. With the connectors still connected, disconnect the No. 2 fuel delivery pipe.
   

   NOTICE:

   1. Be extremely careful not to touch or strike the tips of the injectors.
      
   2. Pull and remove the fuel pipe in a straight line without tilting it.
      

4. Disconnect the 3 connectors from the 3 injectors.
   

5. Remove the 3 injector vibration insulators from the cylinder head.
   

1. Remove the injectors from the delivery pipe.
   

   NOTICE:

   Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

2. Remove the nozzle holder clamp from the injector.
   

3. Remove the E-ring, O-ring, No. 1 backup ring, No. 2 backup ring and No. 3 backup ring from the injector.
   

1. Remove the 2 bolts and 2 sensors.
   

1. Remove the 4 bolts and mounting bracket.
   

1. Remove the 4 bolts and mounting bracket.
   

1. Remove the 6 bolts and 6 ignition coils.
   

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

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

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